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SEN06606-03
MOTOR GRADER
GD535 -5 SERIAL NUMBERS
1001
and up
Notice of revision
Notice of revision 3rd revision The affected pages are indicated by the use of the following marks. It is requested that necessary actions must be taken to these pages according to the list below.
2018/02 Mark
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q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q
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GD535-5 (03)
00 Index and foreword
GD535-5
00-1
Table of contents
Table of contents
00 Index and foreword
1
00 Index and foreword Table of contents ......................................................................................................................................... 00-2 Acronyms .................................................................................................................................................. 00-12 Foreword and general information ............................................................................................................ 00-17 Safety notice .......................................................................................................................................... 00-17 How to read the shop manual ................................................................................................................ 00-22 Explanation of terms for maintenance standard .................................................................................... 00-24 Handling of electric equipment and hydraulic components.................................................................... 00-26 Handling of connectors newly used for engines .................................................................................... 00-35 How to read electric wire code............................................................................................................... 00-38 Precautions when carrying out work ...................................................................................................... 00-41 Method of disassembling and connecting push-pull type coupler.......................................................... 00-44 Standard tightening torque table ............................................................................................................ 00-47 Conversion table .................................................................................................................................... 00-51 01 Specification Acronyms ................................................................................................................................................. 01-2-1 Specifications .............................................................................................................................................. 01-3 Specification drawing (Canopy specification)........................................................................................... 01-3 Specification drawing (Cab specification) ............................................................................................. 01-3-1 Specifications (Canopy specification) ...................................................................................................... 01-4 Specifications (Cab specification) ......................................................................................................... 01-9-1 Weight table ........................................................................................................................................... 01-10 Table of fuel, coolant, and lubricants...................................................................................................... 01-11 10 Structure and function Acronyms ................................................................................................................................................. 10-3-1 Engine and cooling system ......................................................................................................................... 10-4 Cooling system ........................................................................................................................................ 10-4 Fan drive .................................................................................................................................................. 10-6 Power train system ..................................................................................................................................... 10-7 Power train system drawing..................................................................................................................... 10-7 Power train piping drawing....................................................................................................................... 10-8 Transmission control ................................................................................................................................ 10-9 Torque converter .................................................................................................................................... 10-10 Transmission.......................................................................................................................................... 10-14 Transmission control valve..................................................................................................................... 10-33 ECMV..................................................................................................................................................... 10-35 Main relief valve and torque converter relief valve................................................................................. 10-42 Front axle ............................................................................................................................................... 10-44 Rear axle................................................................................................................................................ 10-47 Differential (Non-differential specification) ............................................................................................. 10-48 Differential (Differential lock specification) ............................................................................................. 10-50 Differential lock solenoid valve............................................................................................................... 10-53 Final drive .............................................................................................................................................. 10-54 Tandem drive ......................................................................................................................................... 10-56 Steering system ........................................................................................................................................ 10-59 Steering piping drawing.......................................................................................................................... 10-59 Priority valve .......................................................................................................................................... 10-60 Steering valve ........................................................................................................................................ 10-65 Brake system ............................................................................................................................................ 10-73 Hydraulic piping drawing of brake system ............................................................................................. 10-73 Brake valve ............................................................................................................................................ 10-74 Brake circuit accumulator....................................................................................................................... 10-79 Brake circuit accumulator charge valve ................................................................................................. 10-80 Wheel brake........................................................................................................................................... 10-86
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00 Index and foreword
Table of contents
Parking brake solenoid valve and lifter lock pin solenoid valve ............................................................. 10-87 Parking brake......................................................................................................................................... 10-88 Undercarriage and frame .......................................................................................................................... 10-89 Frame..................................................................................................................................................... 10-89 Tire......................................................................................................................................................... 10-90 Hydraulic system....................................................................................................................................... 10-92 Hydraulic system.................................................................................................................................... 10-92 Hydraulic piping drawing of work equipment ......................................................................................... 10-94 Work equipment control ......................................................................................................................... 10-96 Hydraulic tank ........................................................................................................................................ 10-97 Work equipment pump and steering pump ............................................................................................ 10-98 Power train pump................................................................................................................................... 10-99 Power train pump and differential lock pump....................................................................................... 10-100 Brake pump.......................................................................................................................................... 10-101 Control valve ........................................................................................................................................ 10-102 Functions and valve operations ........................................................................................................... 10-104 Hydraulic cylinder................................................................................................................................. 10-105 Swivel joint ........................................................................................................................................... 10-106 Pilot check valve .................................................................................................................................. 10-107 Work equipment system ..........................................................................................................................10-110 Circle and drawbar................................................................................................................................10-110 Blade.....................................................................................................................................................10-112 Lifter ......................................................................................................................................................10-114 Circle rotation motor..............................................................................................................................10-116 Circle rotation gear................................................................................................................................10-118 Cab and its attachments ......................................................................................................................... 10-120 ROPS canopy ...................................................................................................................................... 10-120 ROPS cab ............................................................................................................................................ 10-121 Electrical system ..................................................................................................................................... 10-122 Machine monitor .................................................................................................................................. 10-122 Automatic gear shift control system ..................................................................................................... 10-133 Transmission controller ........................................................................................................................ 10-140 Engine controller .................................................................................................................................. 10-143 KOMTRAX system............................................................................................................................... 10-146 KOMTRAX terminal ............................................................................................................................. 10-147 Engine starting circuit........................................................................................................................... 10-149 Engine stop circuit................................................................................................................................ 10-151 Preheating circuit ................................................................................................................................. 10-152 Sensors................................................................................................................................................ 10-153 Engine power mode selector circuit ..................................................................................................... 10-162 20 Standard value table Acronyms .................................................................................................................................................... 20-3 Standard value table ................................................................................................................................... 20-8 Standard value table for engine ............................................................................................................... 20-8 Standard value table for machine .......................................................................................................... 20-10 30 Testing and adjusting Acronyms .................................................................................................................................................... 30-4 Tools for testing, adjusting, and troubleshooting......................................................................................... 30-9 Tools for testing, adjusting, and troubleshooting...................................................................................... 30-9 Engine and cooling system ....................................................................................................................... 30-16 Testing engine speed ............................................................................................................................. 30-16 Testing boost pressure........................................................................................................................... 30-18 Testing exhaust gas temperature........................................................................................................... 30-20 Testing exhaust gas color ...................................................................................................................... 30-22 Adjusting valve clearance ...................................................................................................................... 30-24 Testing compression pressure ............................................................................................................... 30-26 Testing blowby pressure ........................................................................................................................ 30-29
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00 Index and foreword
Testing engine oil pressure .................................................................................................................... 30-30 Handling fuel system devices ................................................................................................................ 30-31 Releasing remaining pressure from fuel system.................................................................................... 30-32 Testing fuel pressure.............................................................................................................................. 30-33 Bleeding air from fuel circuit................................................................................................................... 30-34 Testing fuel circuit for leakage................................................................................................................ 30-35 Handling cylinder cutout mode operation............................................................................................... 30-36 Handling no-injection cranking operation............................................................................................... 30-37 Handling voltage circuit of engine controller .......................................................................................... 30-38 Testing muffler (main body) and stacked muffler for looseness and damage ........................................ 30-39 Testing muffler function .......................................................................................................................... 30-40 Testing installed condition of cylinder heads and manifolds .................................................................. 30-41 Testing of engine piping for damage and looseness.............................................................................. 30-42 Testing fuel discharge, return rate, and leakage .................................................................................... 30-43 Checking and replacing alternator belt .................................................................................................. 30-47 Checking and replacing auto-tensioner .............................................................................................. 30-47-2 Power train ................................................................................................................................................ 30-48 Testing power train oil pressure ............................................................................................................. 30-48 Adjusting transmission speed sensor .................................................................................................... 30-62 Retrieval of disabled machine due to transmission valve failure ........................................................... 30-65 Flushing procedure for torque converter and transmission circuits........................................................ 30-68 Testing and adjusting toe-in ................................................................................................................... 30-70 Testing and adjusting differential lock oil pressure (differential lock specification)................................. 30-72 Steering system ........................................................................................................................................ 30-74 Testing and adjusting steering oil pressure............................................................................................ 30-74 Testing oil leakage of steering cylinder .................................................................................................. 30-75 Bleeding air from steering circuit............................................................................................................ 30-76 Brake system ............................................................................................................................................ 30-77 Releasing remaining pressure from brake circuit................................................................................... 30-77 Testing and adjusting brake oil pressure................................................................................................ 30-78 Bleeding air from brake circuit ............................................................................................................... 30-81 Testing wear of wheel brake disc ........................................................................................................... 30-82 Testing and adjusting parking brake pad................................................................................................ 30-83 Releasing parking brake manually ......................................................................................................... 30-86 Charging brake accumulator with gas.................................................................................................... 30-87 Hydraulic system....................................................................................................................................... 30-89 Testing work equipment oil pressure...................................................................................................... 30-89 Testing lifter lock pin circuit pressure ..................................................................................................... 30-91 Testing oil leakage of work equipment cylinder...................................................................................... 30-93 Bleeding air from work equipment circuit ............................................................................................... 30-96 Work equipment ........................................................................................................................................ 30-97 Adjusting drawbar ball joint clearance ................................................................................................... 30-97 Testing and adjusting circle guide clearance ......................................................................................... 30-98 Testing and adjusting slip clutch type circle drive ................................................................................ 30-100 Electrical system ..................................................................................................................................... 30-102 Procedure for testing diodes ................................................................................................................ 30-102 Special functions of machine monitor .................................................................................................. 30-104 Handling high-voltage circuit of engine controller ................................................................................ 30-151 KOMTRAX terminal start-up procedure ............................................................................................... 30-152 Preparatory work for troubleshooting of electrical system failure......................................................... 30-156 Pm Clinic ................................................................................................................................................. 30-158 Pm Clinic.............................................................................................................................................. 30-158 40 Troubleshooting Acronyms .................................................................................................................................................... 40-8 Information related to troubleshooting ...................................................................................................... 40-13 Points to remember when troubleshooting ............................................................................................ 40-13 How to proceed in troubleshooting ........................................................................................................ 40-14 Checks before troubleshooting .............................................................................................................. 40-15
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Inspection procedure before troubleshooting......................................................................................... 40-17 Troubleshooting procedure .................................................................................................................... 40-32 Failure code list...................................................................................................................................... 40-34 Symptoms and troubleshooting numbers .............................................................................................. 40-42 Information described in troubleshooting table ...................................................................................... 40-45 Diagnosis of open harness in pressure sensor system ......................................................................... 40-47 Connector list and layout ....................................................................................................................... 40-49 Connector pin layout .............................................................................................................................. 40-67 T-box and T-adapter list ....................................................................................................................... 40-103 Locations of fuses ................................................................................................................................ 40-108 Troubleshooting by failure code (display of code)....................................................................................40-111 Failure code [1500L0] Double Engagement of T/M Clutches ...............................................................40-111 Failure code [15G0MW] Failure of R-Clutch System ............................................................................40-112 Failure code [15H0MW] Failure of Clutch System (FH)........................................................................40-113 Failure code [15J0MW] Failure of Clutch System (FL) .........................................................................40-114 Failure code [15K0MW] Failure of Clutch System (1st) ........................................................................40-115 Failure code [15L0MW] Failure of Clutch System (2nd) .......................................................................40-116 Failure code [15M0MW] Failure of Clutch System (3rd) .......................................................................40-117 Failure code [15N0MW] Failure of Clutch System (4th)........................................................................40-118 Failure code [15SBL1] Release Trouble of ECMV (R)..........................................................................40-119 Failure code [15SBMA] Malfunction of ECMV (R) ............................................................................... 40-121 Failure code [15SCL1] Release Trouble of ECMV (FH) ...................................................................... 40-123 Failure code [15SCMA] Malfunction of ECMV (FH)............................................................................. 40-125 Failure code [15SDL1] Release Trouble of ECMV (FL) ....................................................................... 40-127 Failure code [15SDMA] Malfunction of ECMV (FL) ............................................................................. 40-129 Failure code [15SEL1] Release Trouble of ECMV (1st) ...................................................................... 40-131 Failure code [15SEMA] Malfunction of ECMV (1st) ............................................................................. 40-133 Failure code [15SFL1] Release Trouble of ECMV (2nd) ..................................................................... 40-135 Failure code [15SFMA] Malfunction of ECMV (2nd) ............................................................................ 40-137 Failure code [15SGL1] Release Trouble of ECMV (3rd)...................................................................... 40-139 Failure code [15SGMA] Malfunction of ECMV (3rd) ............................................................................ 40-141 Failure code [15SHL1] Release Trouble of ECMV (4th) ...................................................................... 40-143 Failure code [15SHMA] Malfunction of ECMV (4th)............................................................................. 40-145 Failure code [15SJMA] Malfunction of ECMV (L/U)............................................................................. 40-147 Failure code [15U0NT] Overload of Inching Clutch ............................................................................. 40-148 Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ........................................................... 40-149 Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear)............................................................ 40-151 Failure code [989L00] Engine Controller Lock Caution 1 .................................................................... 40-153 Failure code [989M00] Engine Controller Lock Caution 2 ................................................................... 40-154 Failure code [989N00] Engine Controller Lock Caution 3.................................................................... 40-155 Failure code [AB00KE] Charge Voltage Low ....................................................................................... 40-156 Failure code [AB00KY] Hot Short of Alternator R Terminal.................................................................. 40-157 Failure code [B@BAZG] Derating in speed due to engine oil pressure drop....................................... 40-158 Failure code [B@BCNS] Engine Overheat .......................................................................................... 40-159 Failure code [B@CENS] T/C Oil Temp. Overheat ............................................................................... 40-160 Failure code [B@CKNS] DIFF Oil Temp. Overheat ............................................................................. 40-161 Failure code [B@HANS] HYD Oil Temp. Overheat.............................................................................. 40-163 Failure code [CA111] Engine NE, controller internal error ................................................................... 40-165 Failure code [CA115] Engine NE, Bkup speed sensor error................................................................ 40-166 Failure code [CA122] Charge pressure sensor high error ................................................................... 40-167 Failure code [CA123] Charge pressure sensor low error..................................................................... 40-169 Failure code [CA131] Throttle sensor high error.................................................................................. 40-171 Failure code [CA132] Throttle sensor low error ................................................................................... 40-173 Failure code [CA144] Coolant sensor high error.................................................................................. 40-176 Failure code [CA145] Coolant sensor low error ................................................................................... 40-178 Failure code [CA153] Charge temperature sensor high error.............................................................. 40-180 Failure code [CA154] Charge temperature sensor low error ............................................................... 40-182 Failure code [CA155] Speed derating error by high charge temperature ............................................ 40-184 Failure code [CA187] Sensor power supply 2 low error....................................................................... 40-185
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00 Index and foreword
Failure code [CA221] Atmospheric pressure sensor high error ........................................................... 40-187 Failure code [CA222] Atmospheric pressure sensor low error ............................................................ 40-189 Failure code [CA227] Sensor power supply 2 high error ..................................................................... 40-191 Failure code [CA234] Engine overspeed ............................................................................................. 40-192 Failure code [CA238] Ne speed sensor power supply error ................................................................ 40-193 Failure code [CA271] IMV short-circuit error........................................................................................ 40-194 Failure code [CA272] IMV open circuit ................................................................................................ 40-196 Failure code [CA322] Injector #1 (L/B #1) open/short.......................................................................... 40-198 Failure code [CA323] Injector #5 (L/B #5) open/short.......................................................................... 40-200 Failure code [CA324] Injector #3 (L/B #3) open/short.......................................................................... 40-202 Failure code [CA325] Injector #6 (L/B #6) open/short.......................................................................... 40-204 Failure code [CA331] Injector #2 (L/B #2) open/short.......................................................................... 40-206 Failure code [CA332] Injector #4 (L/B #4) open/short.......................................................................... 40-208 Failure code [CA342] Data compatibility error in engine controller ...................................................... 40-210 Failure code [CA351] Injector drive circuit error................................................................................... 40-211 Failure code [CA352] Sensor power supply 1 low error....................................................................... 40-212 Failure code [CA386] Sensor power supply 1 high error ..................................................................... 40-214 Failure code [CA428] Water-in-fuel sensor high error.......................................................................... 40-215 Failure code [CA429] Water-in-fuel sensor low error ........................................................................... 40-217 Failure code [CA431] Idle validation switch error................................................................................. 40-219 Failure code [CA432] Idle validation action error ................................................................................. 40-222 Failure code [CA435] Engine oil pressure switch error ........................................................................ 40-225 Failure code [CA441] Power supply voltage low error ......................................................................... 40-226 Failure code [CA442] Power supply voltage high error........................................................................ 40-228 Failure code [CA449] Common rail pressure high error 2 ................................................................... 40-229 Failure code [CA451] Common rail pressure sensor high error........................................................... 40-230 Failure code [CA452] Common rail pressure sensor low error ............................................................ 40-232 Failure code [CA488] Torque derating error by high charge temperature............................................ 40-234 Failure code [CA553] Common rail pressure high error 1 ................................................................... 40-235 Failure code [CA559] Supply pump pressure low error 1 .................................................................... 40-236 Failure code [CA689] Engine Ne speed sensor error .......................................................................... 40-238 Failure code [CA731] Engine Bkup speed sensor phase error............................................................ 40-240 Failure code [CA757] All continuous data lost error............................................................................. 40-242 Failure code [CA778] Engine Bkup speed sensor error....................................................................... 40-243 Failure code [CA1633] KOMNET (CAN communication) error ............................................................ 40-247 Failure code [CA2185] Throttle sensor power supply high error.......................................................... 40-250 Failure code [CA2186] Throttle sensor power supply low error ........................................................... 40-252 Failure code [CA2249] Supply pump pressure low error 2 .................................................................. 40-254 Failure code [CA2311] Abnormality in IMV (IMA) solenoid .................................................................. 40-255 Failure code [CA2555] Intake heater relay open circuit ....................................................................... 40-256 Failure code [CA2556] Intake heater relay short circuit ....................................................................... 40-258 Failure code [D160KA] Disconnection of Backup Light Relay ............................................................. 40-260 Failure code [D160KB] Ground Fault of Backup Light Relay............................................................... 40-262 Failure code [D160KY] Hot Short of Back Lamp Relay Output............................................................ 40-264 Failure code [D19JKZ] Personal Code Relay Abnormality .................................................................. 40-266 Failure code [D19KKZ] Failure of Diff Control Relay............................................................................ 40-268 Failure code [D1EHKA] Disconnection of Engine Start Relay ............................................................. 40-270 Failure code [D1EHKB] Ground Fault of Engine Start Relay ............................................................... 40-271 Failure code [D1EHKY] Hot Short of Engine Start Relay ..................................................................... 40-272 Failure code [D1FBKB] Ground Fault of Sol. Self-Holding Relay ........................................................ 40-273 Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 ......................................................................... 40-275 Failure code [D8AQKR] CAN2 Discon (KOMTRAX)............................................................................ 40-276 Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON)................................................... 40-278 Failure code [DAF0MB] Monitor ROM Abnormality ............................................................................. 40-279 Failure code [DAF0MC] Monitor Error ................................................................................................. 40-280 Failure code [DAF3KK] Controller Power Source Low (MON)............................................................. 40-281 Failure code [DAQ0KK] Controller Power Source Low (T/M) .............................................................. 40-283 Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) .................................................... 40-285 Failure code [DAQ0MC] T/M Con Error ............................................................................................... 40-286
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00 Index and foreword
Table of contents
Failure code [DAQ1KA] Disconnection of Key SW ACC ..................................................................... 40-287 Failure code [DAQ2KK] Solenoid Power Source Low (T/M)................................................................ 40-289 Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) ........................................................ 40-291 Failure code [DAQQKR] CAN2 Discon (Transmission Con)................................................................ 40-292 Failure code [DAQRMA] Inconsistency of Option Selection (T/M)....................................................... 40-293 Failure code [DB2QKR] CAN2 Discon (Engine Con)........................................................................... 40-294 Failure code [DD1PKB] Abnormality of RPM Switch ........................................................................... 40-298 Failure code [DD1QKB] Abnormality of RPM Set Mode Switch .......................................................... 40-300 Failure code [DDB6L4] Parking brake signal error .............................................................................. 40-302 Failure code [DDTHKA] Disconnection of Fill Switch (FH) .................................................................. 40-304 Failure code [DDTJKA] Disconnection of Fill Switch (FL).................................................................... 40-305 Failure code [DDTKKA] Disconnection of Fill Switch (1st)................................................................... 40-306 Failure code [DDTLKA] Disconnection of Fill Switch (2nd).................................................................. 40-307 Failure code [DDTMKA] Disconnection of Fill Switch (3rd).................................................................. 40-308 Failure code [DDTNKA] Disconnection of Fill Switch (R)..................................................................... 40-309 Failure code [DDTPKA] Disconnection of Fill Switch (4th) .................................................................. 40-310 Failure code [DF10KA] Disconnection of Shift Lever Input...................................................................40-311 Failure code [DF10L4] Gear Speed/Travel Direction Signal Error ....................................................... 40-315 Failure code [DGF1KX] Out of Range of T/M Oil Temp. Sensor.......................................................... 40-318 Failure code [DGH2KB] Ground Fault of Hydraulic Oil Temp. S.......................................................... 40-320 Failure code [DGT1KX] Out of Range of T/C Oil Temp. Sensor .......................................................... 40-322 Failure code [DGT7KB] Ground Fault of Diff Oil Temp. S.(C).............................................................. 40-324 Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor .................................................. 40-325 Failure code [DHT5L6] Failure of T/C Oil Press Sensor ...................................................................... 40-327 Failure code [DJF1KA] Disconnection of Fuel Level Sensor ............................................................... 40-329 Failure code [DK70KX] Out of Range of Inching Potentio. .................................................................. 40-331 Failure code [DKD0KX] Out of Range of Articulated Angle Sensor..................................................... 40-333 Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor ..................................................... 40-335 Failure code [DLF1LC] Failure of T/M Input Speed Sensor ................................................................. 40-337 Failure code [DLF2KA] Disconnection of T/M Inter. Speed Sensor ..................................................... 40-339 Failure code [DLF2LC] Failure of T/M Intermediate Speed Sensor ..................................................... 40-341 Failure code [DLM3KA] Rad Fan Spd Sen Opn/Shrt Cir ..................................................................... 40-343 Failure code [DLM3LC] Rad Fan Spd Sen Sig Error ........................................................................... 40-345 Failure code [DLM3MB] Rad Fan Spd Sen Error................................................................................. 40-346 Failure code [DLT3KA] Disconnection of T/M output Speed Sensor ................................................... 40-347 Failure code [DW4BKA] Disconnection of Parking Brake Valve .......................................................... 40-349 Failure code [DW4BKB] Ground Fault of Parking Brake Valve............................................................ 40-351 Failure code [DW4BKY] Hot Short of Parking Brake Solenoid ............................................................ 40-353 Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup)................................................... 40-355 Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) .................................................... 40-357 Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) .......................................................... 40-358 Failure code [DXH2KA] Disconnection of ECMV Solenoid (High) ....................................................... 40-360 Failure code [DXH2KB] Ground Fault of ECMV Solenoid (High)......................................................... 40-362 Failure code [DXH2KY] Hot Short of ECMV Solenoid (High) .............................................................. 40-364 Failure code [DXH3KA] Disconnection of ECMV Solenoid (Low)........................................................ 40-366 Failure code [DXH3KB] Ground Fault of ECMV Solenoid (Low) ......................................................... 40-368 Failure code [DXH3KY] Hot Short of ECMV Solenoid (Low) ............................................................... 40-370 Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st).......................................................... 40-372 Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) ........................................................... 40-374 Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st) ................................................................. 40-376 Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd) ........................................................ 40-378 Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) .......................................................... 40-380 Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd)................................................................ 40-382 Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) ......................................................... 40-384 Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd)........................................................... 40-386 Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd)................................................................. 40-388 Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse) ................................................. 40-390 Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse)................................................... 40-392 Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse) ........................................................ 40-394
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Table of contents
00 Index and foreword
Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th) ......................................................... 40-396 Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th) .......................................................... 40-398 Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th) ................................................................ 40-400 Troubleshooting of electrical system (E-mode)....................................................................................... 40-402 E-1 Engine does not start (Starting motor does not rotate).................................................................. 40-402 E-2 Manual preheating system does not work ..................................................................................... 40-406 E-3 When starting switch is turned ON, machine monitor displays nothing......................................... 40-412 E-4 LCD panel backlight of machine monitor fails (goes out or flickers).............................................. 40-415 E-5 LCD display failure of machine monitor......................................................................................... 40-416 E-6 The switch of machine monitor switch panel does not work.......................................................... 40-417 E-7 Two-switch operation of switch panel on machine monitor does not function. .............................. 40-418 E-8 Machine monitor buzzer does not sound. ..................................................................................... 40-419 E-9 Some gauges or caution lamps of machine monitor do not work normally. .................................. 40-420 E-10 Speedometer or engine speed display is abnormal. ................................................................... 40-421 E-11 Engine coolant temperature is displayed abnormally. ................................................................. 40-422 E-12 Articulated meter display is abnormal. ........................................................................................ 40-424 E-13 Torque converter oil temperature is displayed abnormally. ......................................................... 40-426 E-14 Fuel gauge is displayed abnormally. ........................................................................................... 40-428 E-15 Centralized warning lamps do not light or do not go out. ............................................................ 40-430 E-16 Alarm buzzer does not sound or does not stop sounding. .......................................................... 40-431 E-17 Transmission mode cannot be switched. .................................................................................... 40-433 E-18 Engine mode cannot be switched. .............................................................................................. 40-435 E-19 Differential gear lock function does not operate or is not canceled (for differential gear lock model). ... ............................................................................................................................................................. 40-437 E-20 Cannot be locked or canceled by the lifter lock pin. .................................................................... 40-439 E-21 Horn does not sound or does not stop sounding......................................................................... 40-441 E-22 Backup alarm does not sound or does not stop sounding. ......................................................... 40-443 E-23 Headlamps, clearance lamps, and tail lamps do not light up or go out. ...................................... 40-446 E-24 Working lamps do not light up or go out. ..................................................................................... 40-454 E-25 Turn indicator light or emergency flashing light does not flash.................................................... 40-459 E-26 Stop lamp does not light up or does not go out. .......................................................................... 40-468 E-27 Backup lamp does not light up or does not go out ...................................................................... 40-470 E-28 All wipers do not operate............................................................................................................. 40-472 E-29 Front wiper does not operate ...................................................................................................... 40-474 E-30 Rear wiper does not operate ....................................................................................................... 40-478 E-31 Left and right door wiper does not operate.................................................................................. 40-481 E-32 Left door wiper does not operate................................................................................................. 40-484 E-33 Right door wiper does not operate .............................................................................................. 40-486 E-34 Front or door washer does not operate ....................................................................................... 40-488 E-35 Rear washer does not operate .................................................................................................... 40-490 E-36 KOMTRAX system does not operate normally. ........................................................................... 40-492 Troubleshooting of hydraulic and mechanical system (H-mode) ............................................................ 40-494 How to use troubleshooting table......................................................................................................... 40-494 H-1 Engine speed drops significantly or engine stalls.......................................................................... 40-500 H-2 Machine does not move off. .......................................................................................................... 40-501 H-3 Gear speed does not shift. ............................................................................................................ 40-502 H-4 Travel speed or power is low......................................................................................................... 40-503 H-5 Torque converter lockup does not operate or is not canceled....................................................... 40-506 H-6 Machine starts or gear speed shifts with long time lag.................................................................. 40-507 H-7 Torque converter oil temperature is high....................................................................................... 40-510 H-8 Differential gear lock function does not operate or is not canceled............................................... 40-513 H-9 Steering speed or power is insufficient.......................................................................................... 40-514 H-10 Steering wheel does not move .................................................................................................... 40-515 H-11 Wheel brakes do not work or are weak ....................................................................................... 40-516 H-12 Wheel brakes are not released or drag....................................................................................... 40-517 H-13 Parking brake does not work or it is weak................................................................................... 40-518 H-14 Parking brake (including emergency release system) is not released or drags .......................... 40-519 H-15 All work equipment operates slowly or lacks power .................................................................... 40-520 H-16 Work equipment does not operate. ............................................................................................. 40-521
00-8
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Table of contents
H-17 Unusual noise is heard from around hydraulic pump.................................................................. 40-522 H-18 Blade lift speed or power is low................................................................................................... 40-523 H-19 Hydraulic drift of lifted blade is large. .......................................................................................... 40-524 H-20 Drawbar side shift speed or power is low.................................................................................... 40-525 H-21 Blade side shift speed or power is low. ....................................................................................... 40-526 H-22 Power tilt speed or power is low.................................................................................................. 40-527 H-23 Articulate speed or power is low.................................................................................................. 40-528 H-24 Leaning speed or power is insufficient. ....................................................................................... 40-529 H-25 Hydraulic drift (tilting) of leaning is large. .................................................................................... 40-530 H-26 Blade does not rotate. ................................................................................................................. 40-531 H-27 Lifter lock pin is not locked or is not canceled............................................................................. 40-532 Troubleshooting of engine (S-mode)....................................................................................................... 40-533 How to read matrix............................................................................................................................... 40-533 S-1 Engine startability is poor. ............................................................................................................. 40-536 S-2 Engine does not start. ................................................................................................................... 40-537 S-3 Engine does not pick-up smoothly................................................................................................. 40-540 S-4 Engine stops during operation....................................................................................................... 40-541 S-5 Engine runs rough or is unstable................................................................................................... 40-542 S-6 Engine lacks power. ...................................................................................................................... 40-543 S-7 Exhaust smoke is black (Incomplete combustion) ........................................................................ 40-544 S-8 Large oil consumption (or blue exhaust gas) ................................................................................ 40-545 S-9 Oil becomes contaminated early. .................................................................................................. 40-546 S-10 Fuel consumption is excessive.................................................................................................... 40-547 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) .......................................... 40-548 S-12 Oil pressure drops. ...................................................................................................................... 40-549 S-13 Oil amount increases (due to water or fuel mixing). .................................................................... 40-550 S-14 Coolant temperature rises too high (overheating). ...................................................................... 40-551 S-15 Unusual noise is heard................................................................................................................ 40-552 S-16 Vibration is excessive.................................................................................................................. 40-553 50 Disassembly and assembly Acronyms .................................................................................................................................................... 50-3 Related information on disassembly and assembly.................................................................................... 50-8 How to read this manual .......................................................................................................................... 50-8 Coating materials list.............................................................................................................................. 50-10 Special tool list ....................................................................................................................................... 50-14 Sketches of special tools ....................................................................................................................... 50-22 Engine and cooling system ....................................................................................................................... 50-49 Removal and installation of supply pump assembly .............................................................................. 50-49 Removal and installation of injector assembly ....................................................................................... 50-53 Removal and installation of cylinder head assembly ............................................................................. 50-62 Removal and installation of air conditioner compressor belt............................................................... 50-78-1 Removal and installation of alternator belt............................................................................................. 50-79 Removal and installation of engine front oil seal.................................................................................... 50-81 Removal and installation of engine rear oil seal .................................................................................... 50-83 Removal and installation of radiator assembly (Canopy specification).................................................. 50-86 Removal and installation of radiator assembly (Cab specification)..................................................... 50-89-1 Removal and installation of aftercooler assembly (Canopy specification) ............................................. 50-90 Removal and installation of aftercooler assembly (Cab specification) ................................................ 50-93-1 Removal and installation of power train oil cooler assembly (Canopy specification)............................. 50-94 Removal and installation of power train oil cooler assembly (Cab specification)................................ 50-98-1 Removal and installation of fuel tank assembly ..................................................................................... 50-99 Removal and installation of engine hood assembly............................................................................. 50-104 Removal and installation of air conditioner compressor assembly ................................................... 50-105-1 Power train.............................................................................................................................................. 50-106 Removal and installation of engine, transmission, and torque converter assembly (Canopy specification)... ............................................................................................................................................................. 50-106 Removal and installation of engine, transmission, and torque converter assembly (Cab specification)......... ..............................................................................................................................................................50-112
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00 Index and foreword
Disconnection and connection of engine, transmission, and torque converter assembly.................... 50-113 Disassembly and assembly of torque converter assembly .................................................................. 50-115 Disassembly and assembly of transmission assembly ........................................................................ 50-126 Removal and installation of tandem drive and final drive assembly..................................................... 50-161 Disassembly and assembly of tandem drive assembly........................................................................ 50-164 Disassembly and assembly of differential assembly............................................................................ 50-170 Disassembly and assembly of final drive assembly ............................................................................. 50-183 Steering system ...................................................................................................................................... 50-192 Removal and installation of Orbitrol valve assembly (Canopy specification) ....................................... 50-192 Removal and installation of Orbitrol valve assembly (Cab specification).......................................... 50-196-1 Brake system .......................................................................................................................................... 50-197 Disassembly and assembly of wheel brake assembly......................................................................... 50-197 Undercarriage and frame ........................................................................................................................ 50-205 Removal and installation of center hinge pin ....................................................................................... 50-205 Hydraulic system..................................................................................................................................... 50-215 Removal and installation of hydraulic tank, battery, and frame assembly............................................ 50-215 Removal and installation of hydraulic tank assembly........................................................................... 50-223 Removal and installation of control valve assembly............................................................................. 50-227 Disassembly and assembly of hydraulic cylinder assembly ................................................................ 50-232 Work equipment ...................................................................................................................................... 50-236 Removal and installation of blade assembly ........................................................................................ 50-236 Removal and installation of circle drawbar assembly .......................................................................... 50-237 Removal and installation of circle rotation gear assembly ................................................................... 50-239 Disassembly and assembly of circle rotation gear assembly............................................................... 50-241 Canopy, cab and attachments................................................................................................................. 50-246 Removal and installation of canopy assembly (Canopy specification)................................................. 50-246 Removal and installation of operator's cab assembly (Cab specification) ........................................ 50-250-1 Removal and installation of operator cab glass (adhered glass) (Cab specification)...................... 50-250-10 Removal and installation of floor frame assembly (Canopy specification) ........................................... 50-251 Removal and installation of floor frame assembly (Cab specification).............................................. 50-253-1 Removal and installation of canopy and floor frame assembly (Canopy specification) ....................... 50-254 Removal and installation of operator's cab and floor frame assembly (Canopy specification) ......... 50-256-1 Removal and installation of air conditioner unit assembly ................................................................ 50-256-8 Removal and installation operator's seat ........................................................................................ 50-256-14 Removal and installation seat belt .................................................................................................. 50-256-15 Electrical system ..................................................................................................................................... 50-257 Removal and installation of engine controller assembly ...................................................................... 50-257 Removal and installation of machine monitor assembly ...................................................................... 50-259 Removal and installation of transmission controller assembly (Canopy specification) ........................ 50-260 Removal and installation of transmission controller assembly (Cab specification) ........................... 50-260-1 Removal and installation of KOMTRAX terminal assembly (Canopy specification)............................. 50-261 Removal and installation of KOMTRAX terminal assembly (Cab specification) .................................. 50-262 60 Maintenance standard Acronyms ................................................................................................................................................. 60-2-1 Engine and cooling system ......................................................................................................................... 60-3 Engine mount and transmission mount.................................................................................................... 60-3 Cooling system ........................................................................................................................................ 60-4 Power train system ..................................................................................................................................... 60-6 Torque converter ...................................................................................................................................... 60-6 Transmission............................................................................................................................................ 60-8 Main relief valve and torque converter relief valve................................................................................. 60-17 Front axle ............................................................................................................................................... 60-18 Rear axle................................................................................................................................................ 60-20 Differential (Non-differential specification) ............................................................................................. 60-21 Differential (Differential lock specification) ............................................................................................. 60-22 Final drive .............................................................................................................................................. 60-24 Differential lock solenoid valve............................................................................................................... 60-25 Tandem drive ......................................................................................................................................... 60-26
00-10
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Table of contents
Steering system ........................................................................................................................................ 60-27 Steering cylinder .................................................................................................................................... 60-27 Brake system ............................................................................................................................................ 60-28 Wheel brake........................................................................................................................................... 60-28 Parking brake......................................................................................................................................... 60-29 Undercarriage and frame .......................................................................................................................... 60-30 Frame and center hinge pin ................................................................................................................... 60-30 Hydraulic system....................................................................................................................................... 60-31 Hydraulic tank ........................................................................................................................................ 60-31 Work equipment pump and steering pump ............................................................................................ 60-32 Power train pump................................................................................................................................... 60-33 Power train pump and differential lock pump......................................................................................... 60-34 Parking brake solenoid valve and lifter lock pin solenoid valve ............................................................. 60-35 Leaning cylinder..................................................................................................................................... 60-36 Articulate cylinder................................................................................................................................... 60-37 Blade lift cylinder.................................................................................................................................... 60-38 Drawbar shift cylinder ............................................................................................................................ 60-39 Blade side shift cylinder ......................................................................................................................... 60-40 Power tilt cylinder................................................................................................................................... 60-41 Scarifier cylinder .................................................................................................................................... 60-42 Work equipment........................................................................................................................................ 60-43 Circle and drawbar................................................................................................................................. 60-43 Blade...................................................................................................................................................... 60-45 Lifter ....................................................................................................................................................... 60-47 Circle rotation gear................................................................................................................................. 60-48 80 Appendix Acronyms .................................................................................................................................................... 80-3 Air conditioner system................................................................................................................................. 80-8 Precautions for refrigerant ....................................................................................................................... 80-8 Air conditioner component ....................................................................................................................... 80-9 Specifications of air conditioner ............................................................................................................. 80-12 Configuration and function of refrigeration cycle.................................................................................... 80-13 Outline of refrigeration cycle .................................................................................................................. 80-14 Component parts of air conditioner system............................................................................................... 80-16 Air conditioner unit ................................................................................................................................. 80-16 Component parts of air conditioner unit ................................................................................................. 80-19 Compressor ........................................................................................................................................... 80-21 Condenser ............................................................................................................................................. 80-22 Receiver drier......................................................................................................................................... 80-23 Explanation of procedure for testing and troubleshooting of air conditioner .......................................... 80-24 Circuit diagram and arrangement of connector pins for air conditioner ................................................. 80-26 Air conditioner system diagram.............................................................................................................. 80-28 Input and output signals of air conditioner control panel........................................................................ 80-29 Installation locations of air conditioner parts and arrangement of connectors ....................................... 80-32 Testing air leakage (duct).......................................................................................................................... 80-37 Method for testing air leakage (duct) ..................................................................................................... 80-37 Testing air conditioner using self-diagnosis function.............................................................................. 80-39 Check temperature control function .......................................................................................................... 80-40 Method for checking temperature control function................................................................................. 80-40 Testing fresh/recirc air changeover ........................................................................................................... 80-41 Method for testing fresh/recirc air changeover....................................................................................... 80-41 Test evaporator temperature sensor ......................................................................................................... 80-42 Method for checking evaporator temperature sensor ............................................................................ 80-42 Test relays................................................................................................................................................. 80-43 Method for testing relays........................................................................................................................ 80-43 Check blower AMP ................................................................................................................................... 80-44 Method for checking blower AMP .......................................................................................................... 80-44 Air conditioner troubleshooting chart 1 .................................................................................................. 80-46
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00 Index and foreword
Air conditioner troubleshooting chart 2 .................................................................................................. 80-48 Information described in troubleshooting table ...................................................................................... 80-51 A-1 Troubleshooting for power supply system (air conditioner does not operate) ................................. 80-52 A-2 Troubleshooting for compressor and refrigerant system (air is not cooled) .................................... 80-54 A-3 Troubleshooting for blower motor system (no air comes out or air flow is abnormal) ..................... 80-57 A-4 Troubleshooting for temperature control function............................................................................ 80-60 A-5 Troubleshooting for fresh/recirc air changeover .............................................................................. 80-63 A-6 Troubleshooting for hot water cut valve........................................................................................... 80-66 Troubleshooting using gauge pressure.................................................................................................. 80-68 Connection of service tool......................................................................................................................... 80-70 Method for connecting service tool ........................................................................................................ 80-71 Precautions for disconnecting and connecting hoses and tubes in air conditioner pipings ................... 80-72 Handle compressor oil .............................................................................................................................. 80-74 90 Diagrams and drawings Acronyms ................................................................................................................................................. 90-2-1 Hydraulic diagrams and drawings ............................................................................................................... 90-3 Symbols used in hydraulic circuit diagrams ............................................................................................. 90-3 Hydraulic circuit diagram.......................................................................................................................... 90-5 Power train hydraulic circuit diagram ....................................................................................................... 90-9 Electrical diagrams and drawings ............................................................................................................. 90-11 Symbols used in electric circuit diagrams .............................................................................................. 90-11 Chassis electric circuit diagram ............................................................................................................. 90-15 Floor electric circuit diagram (Canopy specification) ............................................................................. 90-25 Floor electric circuit diagram (Cab specification) ................................................................................... 90-37 Index ................................................................................................................................................................ 1
00-11-1
GD535-5 (03)
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Table of contents
00-11-2
Acronyms
00 Index and foreword
Acronyms q q q q
1
The abbreviations of unknown parts, equipment and functions have been extracted from the Shop Manual, and their official names and details are defined in this Acronyms. Abbreviations that are commonly used in society might not be described. Special and rarely used abbreviations are described in the supplementary explanation in the text. The acronyms consist of two parts: the list of abbreviations that are used in the text, and the list of abbreviations that are used in circuit diagrams.
Abbreviations that are used in the text Abbreviations
Official name
Application (Applicable models (*1) and equipment) Traveling, brake
ABS
Antilock Brake System
AISS
Automatic Idling Setting Engine System
AJSS
Advanced Joystick Steering System
ARAC
Automatic Retarder Accelerator Control
(HD series, HM series)
Steering (WA series) Traveling, brake (HD series, HM series) Traveling, brake
ARSC
Automatic Retarder Speed Control
ASR
Automatic Spin Regulator
ATT
Attachment
BCV
Brake Cooling oil control Valve
CAN
(HD series, HM series) Traveling, brake (HD series, HM series) Work equipment
Explanation With this function, when the tires skid (wheels stop rotating), the brakes are released, and when the wheels start to rotate, the brakes are applied again. This function automatically sets the idle speed. A lever is used to perform the steering operations instead of a steering wheel. Moreover, it shifts gear and changes direction (FORWARD or REVERSE). When the accelerator pedal is released while the machine is traveling downhill, this function automatically applies the retarder with a constant braking force. When the accelerator pedal is released while the machine is traveling downhill, this function automatically applies the retarder to ensure that the machine speed does not accelerate above the speed set by the operator. When the tires spin on soft ground surfaces, this function automatically uses the optimum braking force to drive both wheels. The function or parts which are attached to the standard model and used
(HD series)
When the retarder is not being used, this valve bypasses part of the brake cooling oil to reduce the load on the hydraulic pump.
Controller Area Network
Communication, electronic control
One of communication standards that is used in the network on the machine
CDR
Crankcase Depression Regulator
Engine
A regulator valve which is installed to KCCV ventilator. It is written as CDR valve and it is not used independently.
CLSS
Closed-center Load Sensing System
Hydraulic system
This system can simultaneously actuate multiple actuators regardless of the load (provides better combined operation than OLSS).
Engine
Engine controller electronically controls supply pump, common rail, and injector. This function maintains optimum fuel injection amount and fuel injection timing.
Electronic control
Electronic control device that receives signals from each sensor of the machine and that specifies the optimum operation to the actuators. (Same as ECU)
CRI
Common Rail Injection
ECM
Electronic Control Module
00-12
Brake
1
GD535-5 (03)
00 Index and foreword
Abbreviations
Acronyms
Official name
ECMV
Electronic Control Modulation Valve
ECSS
Electronically Controlled Suspension System
Application (Applicable models (*1) and equipment) Transmission (D series, HD series, WA series and others) Traveling (WA series)
Explanation Proportional solenoid valve that reduces the connection shock by gradually increasing the hydraulic pressure to engage the clutch. This system ensures smooth high-speed travel by absorbing vibration of machine during travel with hydraulic spring effect of accumulator.
ECU
Electronic Control Unit
Electronic control
Electronic control device that receives signals from each sensor of the machine and that specifies the optimum operation to the actuators. (Same as ECM)
EGR
Exhaust Gas Recirculation
Engine
This function recirculates part of exhaust gas to the combustion chamber in order to reduce combustion temperature and control the emission of NOx.
Equipment Management Monitoring System
Machine monitor
This system allows data (filter, oil replacement interval, malfunctions on machine, failure code, and failure history) from each sensor on the machine to be checked on the monitor.
EPC
Electromagnetic Proportional Control
Hydraulic system
Electromagnetic proportional control This mechanism allows actuators to be operated in proportion to the current supplied.
FOPS
Falling Object Protective Structure
Operator's cab, canopy
Forward-Neutral-Rever se
Operation
Forward-Neutral-Reverse
Communication
Global positioning system The satellite positioning system to determine the current position on the earth
EMMS
F-N-R
GPS
Global Positioning System
GNSS
Global Navigation Satellite System
This structure protects the operator's head from falling objects. (Falling Object Protective Structure) This performance is standardized as ISO 3449.
(KOMTRAX, KOMTRAX Plus) Communication (KOMTRAX, KOMTRAX Plus) Steering
Global navigation satellite system A general term for positioning system using satellites such as GPS, GALILEO, etc. This function uses a combination of hydraulic motor and bevel shaft to control difference in travel speed of right and left tracks. Accordingly machine can turn without using steering clutch.
HSS
Hydrostatic Steering System
HST
Hydro Static Transmission
ICT
Information and Communication Technology
Communication, electronic control
A general term for the engineering and its socially applied technology of information processing and communication.
IMA
Inlet Metering Actuator
Engine
Valve that adjusts fuel intake amount at inlet port of pump in order to control fuel discharged volume of supply pump. (Same as IMV)
IMU
Inertial Measurement Unit
Engine
This is a device to detect the angle (or angular velocity) and acceleration of the 3 axes that control motions.
IMV
Inlet Metering Valve
Engine
Valve adjusting fuel intake amount at inlet port of pump in order to control fuel discharged volume of supply pump. (Same as IMA)
GD535-5 (01)
(D series) Transmission (D series, WA series)
This function uses a combination of hydraulic pump and hydraulic motor to shift the speed range steplessly without using gears.
00-13
Acronyms
Abbreviations
00 Index and foreword
Official name
Application (Applicable models (*1) and equipment)
KCCV
KOMATSU Closed Crankcase Ventilation
Engine
KCSF
KOMATSU Catalyzed Soot Filter
Engine
KDOC
KOMATSU Diesel Oxidation Catalyst
Engine
KDPF
KOMATSU Diesel Particulate Filter
Explanation The mechanism for oil separation from gas in order to re-burn the blow-by gas and for oil return to the intake system. It is mainly composed of filters. The filter to capture the soot from exhaust gas. It is built in the KDPF. The catalyst for exhaust gas purification.
Engine
It may be built in the KDPF or combined with the muffler. This component is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it. It is used instead of the conventional muffler.
Traveling, brake
This function recovers the drive force of the wheels by braking automatically with the optimum force and at the same time activates the inter-axle differential lock when the wheels idle while the machine travels on the soft ground road.
KOMATSU Traction Control System
(HM series)
LCD
Liquid Crystal Display
Machine monitor
The liquid crystal display panel. Image display device such as a monitor which assembles in the liquid crystal element.
LED
Light Emitting Diode
Electronic components
Light emitting diode It refers to semiconductor element that emits light when the voltage is applied in forward direction.
LIN
Local Interconnect Network
Communication, electronic control
One of communication standards that is used in the network on the machine
LS
Load Sensing
Hydraulic system
Function that detects differential pressure of pump and controls discharged volume corresponding to load.
KTCS
Low Voltage Differential Communication, electronic Signaling control
One of communication standards that is used in the network on the machine
MAF
Mass Air Flow
Engine
The intake airflow rate of the engine. It is not used alone, but used in combination with sensors. The intake airflow sensor may be called the MAF sensor.
MMS
Multimedia Messaging Service
Communication
The service to allow transmission and reception of short messages such as characters, voice and images between mobile phones.
Normally Closed
Electric system, hydraulic system
The characteristics of an electric or hydraulic circuit that is normally closed when the system is not operating, and that is normally opened when the system is operating.
Normally Open
Electric system, hydraulic system
The characteristics of an electric or hydraulic circuit that is normally opened when the system is not operating, and that is normally closed when the system is operating.
Open-center Load Sensing System
Hydraulic system
The hydraulic system that can simultaneously operate multiple actuators regardless of the load.
Pressure Compensation
Hydraulic system
The function to compensate for the hydraulic pressure.
LVDS
NC
NO
OLSS PC
00-14
GD535-5 (01)
00 Index and foreword
Abbreviations
Acronyms
Official name
Application (Applicable models (*1) and equipment)
Explanation
Steering Palm Command Control System (D series)
The function to make the controller analyze the lever, pedal, and dial data instantaneously, and to allow the electronic control of engine, transmission and others appropriately.
PCV
Pre-stroke Control Valve
Engine
This valve is installed at inlet port of pump and it adjusts fuel intake amount in order to control fuel discharged volume of supply pump.
PPC
Proportional Pressure Control
Hydraulic system
Used for controlling proportional pressure. This system moves actuators in proportion to the hydraulic pressure.
PPM
Piston Pump and Motor
PTO
Power Take Off
Power transmission
Power take-off mechanism
PTP
Power Tilt and power Pitch dozer
Work equipment (D series)
This function performs hydraulic control of the tilt and pitch of the bulldozer blade.
Operator's cab, canopy
The structure to protect the operator (fastened with seat belt) if the machine falls. (Roll-over protective structure for operator)
PCCS
ROPS
Roll-Over Protective Structure
Hydraulic system (D series, PC series, others)
Piston hydraulic pump and motor.
This performance is standardized as ISO 3471.
Selective Catalytic Reduction
Urea SCR system
The exhaust gas purification device, that uses urea water and converts the nitrogen oxides (NOx) into harmless nitrogen and water (by reduction reaction). It may be called part of the exhaust gas purifying catalyst or the related device name.
Le Systeme International d’ Unites
Unit
Abbreviated for the "International System of Units". It is the universal unit system and "A single unit for a single quantity" is the basic principle applied.
SOL
Solenoid
Electrical system
It refers to an actuator consisting of a solenoid and an iron core that is moved by the magnetic force when the solenoid is energized.
TWV
2-Way Valve
Hydraulic system
Solenoid valve that switches over direction of flow.
VGT
Variable Geometry Turbocharger
Engine
Turbocharger having the variable geometry of exhaust passage
SCR
SI
*1: Applicable model codes D: Bulldozer HD: Dump truck HM: Articulated dump truck PC: Hydraulic excavator WA: Wheel loader
GD535-5 (03)
00-15
Acronyms
00 Index and foreword
Abbreviations used in circuit diagrams Abbreviations Air Conditioner
A/D
Analogue-to-Digital
A/M
Air Mix damper
ACC
Accessory
ADD
Additional
AUX
Auxiliary
BR
Battery Relay
CW
Clockwise
CCW
Counter Clockwise
ECU
Electronic Control Unit
ECM
Electronic Control Module
ENG
Engine External Ground
F.G.
Frame Ground
GND
Ground
IMA
Inlet Metering Actuator
NC
No Connection
S/T STRG
Steering
SIG
Signal
SOL
Solenoid
STD
Standard
OPT OP PRESS SPEC SW TEMP
00-16
Official name
A/C
EXGND
1
Option Pressure Specification Switch Temperature
T/C
Torque Converter
T/M
Transmission
GD535-5 (01)
00 Index and foreword
Safety notice
Foreword and general information
1
Safety notice
1 (Rev. 2009/9)
Important safety notice Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. 1. General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work. 1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual. 2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc. 4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning tag in the operator's compartment. 5) Only qualified workers must carry out work and operation which require license or qualification. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones. Before starting work, thoroughly check the tools, machine, forklift, service car, etc. 7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work. 8) Before starting work, warm up your body thoroughly to start work under good condition.
GD535-5 (01)
9) Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places. Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signals Prohibition of operation and handling by unli5 censed workers 6 Safety check before starting work Wearing protective goggles(for cleaning or grind7 ing work) Wearing shielding goggles and protectors(for 8 welding work) 9 Good physical condition and preparation Precautions against work which you are not used 10 to or you are used to too much
00-17
Safety notice
2. Preparation work 1) Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning tag on them. 3) When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work. 4) Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. 3. Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug,loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative (-) terminal first. 5) When raising a heavy component (heavier than 25kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 6) When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover.
00-18
00 Index and foreword
7) When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires. 8) When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. 9) As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. 10)Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated. 11)When installing high pressure hoses and tubes, make sure that they are not twisted. Damaged hoses and tubes are dangerous, so be extremely careful when installing hoses and tubes for high pressure circuits. In addition, check that connections of them are correct. 12)When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speeds, be particularly careful to check that they are installed correctly. 13)When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 14)When measuring hydraulic pressure, check that the measuring tools are correctly installed. 15)Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. 16)If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
GD535-5 (01)
00 Index and foreword
4. Precautions for sling work and making signals 1) Only one appointed worker must make signals and co-workers must communicate with each other frequently. The appointed signaler must make specified signals clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The signaler must always stand in front of the load and guide the operator safely. q Do not stand under the load. q Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with 1 wire rope alone. It may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 7) Limit the hanging angle to 60 °, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8kN {1,000kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6kN {2,000kg} of total weight can be suspended. This weight is reduced to 9.8kN {1,000kg} when the 2 ropes make a hanging angle of 120 °. If the 2 ropes sling a 19.6kN {2,000kg } load at a lifting angle of 150 ° , each of them is subjected to a force as large as 39.2kN {4,000kg}.
GD535-5 (01)
Safety notice
8) When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10)Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.
11)Do not use twisted or kinked wire ropes. 12)When lifting a load, observe the following. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.
00-19
Safety notice
If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. q Do not lift up the load at an angle. 13)When lowering a load, observe the following. q When lowering a load, stop it temporarily at 30cm above the floor, and then lower it slowly. q Check that the load is stable, and then remove the sling. q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place. q
5. Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. 6. Precautions for using overhead hoist crane kWhen raising a heavy part (heavier than 25), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 is indicated after the mark of 4. 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, ground fault circuit interrupter, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signals for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load at an angle. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the crane is moving longitudinally or laterally. 7) Do not drag a sling. 8) When lifting a load, stop it just after it leaves the ground and check safety, and then lift it up. 9) Consider the travel route in advance and lift up a load to a safe height. 10)Place the control switch on a position where it will not be an obstacle to work and passage. 11)After operating the hoist, do not swing the control switch. 12)Remember the position of the main switch so that you can turn off the power immediately in an emergency.
00-20
00 Index and foreword
13)If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the ground fault circuit interrupter, check that the devices related to that switch are not in operation state. 14)If you find an obstacle around the hoist, stop the operation. 15)After finishing the work, stop the hoist at the specified position and raise the hook to at least 2mabove the floor. Do not leave the sling installed to the hook. 7. Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below. Wire ropes (Standard "Z" twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal diameter Allowable load of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4
a The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).
GD535-5 (01)
00 Index and foreword
Safety notice
8. Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1) Disconnection k For the environment, the air conditioner of this machine uses the refrigerant (air conditioner gas: R134a) which has fewer factors of the depletion of the ozone layer. However, it does not mean that you may discharge the refrigerant into the atmosphere as it is. Be sure to recover the refrigerant when disconnecting the refrigerant gas circuit and then reuse it. a Ask professional traders for collecting and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant gas gets in your eyes or contacts your skin, you may lose your sight and your skin may be frozen. Accordingly, put on safety glasses, safety gloves and safety clothes when recovering or adding the refrigerant. Refrigerant gas must be recovered and added by a qualified person. 2) Connection 1] When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter them. 2] When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints. 3] Check that each O-ring (1) is not damaged or deteriorated. 4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8, VALEO THERMAL SYSTEMS: ZXL100PG (equivalent to PAG46)) to its O-rings (1). a Example of O-ring (Fitted to every joint of hoses and tubes)
a For tightening torque, see the precautions for installation in each section of "Disassembly and assembly".
GD535-5 (01)
00-21
How to read the shop manual
00 Index and foreword
How to read the shop manual q q q
Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors. Materials and specifications are subject to change without notice. Shop manuals are divided into the "Chassis volume" and "Engine volume". For the engine unit, see the engine volume of the engine model mounted on the machine.
Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections. 00. Index and foreword This section contains table of contents, and safety and basic information. If any revision of the shop manual is made, the LIST OF REVISED PAGES will be added. 01. Specification This section explains the specifications of the machine. 10. Structure, function and maintenance standard 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. 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. 30. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgment criteria for testing and adjusting are explained in Testing and adjusting. 40. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The "S mode" of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. 60. Maintenance standard This section gives maintenance standard values of each component. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. 80. Appendix The section explains the equipment which can not be included in the other sections. This section explains the structure, function, testing, adjusting, and troubleshooting fo the equipment. 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume) q Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. q Engine volume This section explains the method of remanufacturing and repairing engine and replacing parts.
00-22
GD535-5 (01)
00 Index and foreword
How to read the shop manual
Revision and distribution
Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol
Item
k
Safety
a
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing work.
4
Weight
Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
3
Remarks
Special safety precautions are necessary when performing work.
Tightening torque Places that require special attention for tightening torque during assembly.
2
Coat
5
Oil, coolant
6
Drain
Places to be coated with adhesives, etc. during assembly.
Places where oil, etc. must be added, and capacity.
Places where oil, etc. must be drained, and quantity to be drained.
Units
In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
GD535-5 (01)
00-23
Explanation of terms for maintenance standard
00 Index and foreword
Explanation of terms for maintenance standard The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the machine maintenance work. The following terms are used to explain the criteria. 1. Standard size and tolerance q To be accurate, the finishing size of parts is a little different from one to another. q To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated. q The above size set temporarily is called the "standard size" and the range of difference from the standard size is called the "tolerance". q The tolerance with the symbols of + or - is indicated on the right side of the standard size. Example: Standard size
Tolerance -0.022 -0.126
120
a The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (-0.022/-0.126) q
q
Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of size of rotating shaft and hole and relationship drawing of them Example: Standard size 60
00-24
Tolerance Shaft -0.030 -0.076
Hole +0.046 0
GD535-5 (01)
00 Index and foreword
2. Standard clearance and standard value q The clearance made when new parts are assembled is called the "standard clearance", which is indicated by the range from the minimum clearance to the maximum clearance. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q A value of performance and function of new products or equivalent is called the "standard value", which is indicated by a range or a target value. q When some parts are repaired, the value of performance/function is set to the standard value. 3. Standard interference q When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that of the mating shaft, the difference between those diameters is called the "interference". q The range (A - B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the "standard interference". q After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range.
Explanation of terms for maintenance standard
5. Clearance limit q Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the "clearance limit". q If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired. 6. Interference limit q The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the "interference limit". q The interference limit shows the repair limit of the part of smaller tolerance. q If the interference between the parts exceeds the interference limit, they must be replaced or repaired.
4. Repair limit and allowable value or allowable dimension q The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the "repair limit". q If a part is worn to the repair limit, it must be replaced or repaired. q The performance and function of a product lowers while it is used. A value which the product can be used without causing a problem is called the "allowable value" or "allowable dimension". q If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement.
GD535-5 (01)
00-25
Handling of electric equipment and hydraulic components
00 Index and foreword
Handling of electric equipment and hydraulic components To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct "operation", "maintenance and inspection", "troubleshooting", and "repairs" must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on "Handling electric equipment" and "Handling hydraulic components" (particularly gear oil and hydraulic oil). Points to remember when handling electric equipment 1. Handling wiring harnesses and connectors Wiring harnesses consist of wires connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wires. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. 2. Main failures occurring in wiring harness 1) Defective contact of connectors (defective contact between male and female connectors) Problems with defective contact are likely to occur because the male connector is not properly fitted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connector about 10 times. 2) Defective crimping or soldering of connectors The pins of the male and female connectors are connected to wires by crimping or soldering. If excessive force is applied to the wire, the joint is separated to cause defective contact or the wire is broken.
00-26
GD535-5 (01)
00 Index and foreword
Handling of electric equipment and hydraulic components
3) Disconnections in wiring If the harness is pulled to disconnect, or components are lifted with a crane with the harness still connected, or a heavy object hits the harness, the crimping of the connector may separate, or the soldering may be damaged, or the harness may be broken.
4) High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. Accordingly, take care not to splash water over the connector. The connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it. 5) Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface of the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with electric contact cleaner. a When wiping the joint portion of the connector, be careful not to apply excessive force or deform the pins. a If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.
GD535-5 (01)
00-27
Handling of electric equipment and hydraulic components
00 Index and foreword
3. Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull with one hand. 2] When removing from clips q Both of the connector and clip have stoppers, which are engaged with each other when the connector is installed.
When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. a If the connector is twisted up and down or to the left or right, the housing may break.
q
3] Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
00-28
GD535-5 (01)
00 Index and foreword
Handling of electric equipment and hydraulic components
2) Connecting connectors 1] Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. Check that there is no damage or breakage to the outside of the connector. a If there is any damage or breakage, replace the connector. a If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the connector and harness with a dryer, but be careful not to make them too hot as this will cause short circuits. 2] Fix the connector securely. Position the connector correctly, and then fit them securely. For connectors with the lock stopper, push in the connector until the stopper clicks into position. 3] Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a If the connector cannot be corrected easily, remove the clamp and adjust the position. q If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
GD535-5 (01)
00-29
Handling of electric equipment and hydraulic components
3) DT connector (DT 8-pole, 12-pole) Disconnection (Left of figure) While pressing both locks (a) and (b), pull out female connector (2). Connection (Right of figure) 1] Push in female connector (2) horizontally until the lock clicks. Arrow: 1) 2] Since locks (a) and (b) may not be set completely, push in female connector (2) while moving it up and down until the locks are set normally. Arrow: 1), 2), 3) a Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely. (1): Male connector (2): Female connector (a),(b): Locks
00-30
00 Index and foreword
q
Disconnection
q
Connection (Example of incomplete setting of ((a))
GD535-5 (01)
00 Index and foreword
Handling of electric equipment and hydraulic components
4) Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 1] Disconnect the connector and wipe off the water with a dry cloth. a If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from the compressed air before blowing with air. 2] Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. a Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.
3] Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a After completely drying the connector, blow it with electric contact cleaner and reassemble.
GD535-5 (01)
00-31
Handling of electric equipment and hydraulic components
00 Index and foreword
4. Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the controller. 2) Do not place objects on top of the controller. 3) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 4) During rainy weather, do not leave the controller in a place where it is exposed to rain. 5) Do not place the controller on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). 6) Precautions when carrying out arc welding When carrying out arc welding on the machine body, disconnect all wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.
5. Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connecting connectors. 2) Before carrying out troubleshooting, check all the related connectors for half fit. a Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. a If the power is turned ON with the connectors still disconnected, unnecessary abnormality warning will be issued. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), wag the related wiring harnesses and connectors several times and check that there is no change in the reading of the tester. a If there is any change, there is probably defective contact in that circuit.
00-32
GD535-5 (01)
00 Index and foreword
Handling of electric equipment and hydraulic components
Points to remember when handling hydraulic components With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic components, it is necessary to be particularly careful. 1. Be careful of the operating environment Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust. 2. Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic components in the field, there is danger of dust entering the components. It is also difficult to check the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic components should be carried out in a specially prepared dustproof workshop, and the performance should be checked with special test equipment.
3. Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out onto the ground, but collect it and ask the customer to dispose of it, or take it back with you for disposal.
4. Do not let any dirt or dust get in during refilling operations Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.
GD535-5 (01)
00-33
Handling of electric equipment and hydraulic components
00 Index and foreword
5. Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil. 6. Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.
7. Cleaning operations After repairing the hydraulic components (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning components is used to remove the ultra fine (about 3 m) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.
00-34
GD535-5 (01)
00 Index and foreword
Handling of connectors newly used for engines
Handling of connectors newly used for engines a Mainly, following engines are object for following connectors. q 95E-5 q 107E-1 q 114E-3 q 125E-5 q 140E-5 q 170E-5 q 12V140E-3 Slide lock type (FRAMATOME-3,FRAMATOME-2) q
95-170,12V140 engines q Various pressure sensors and NE speed sensor Examples) Intake air pressure sensor in intake manifold: PIM (125,170,12V140 engines) Oil pressure sensor: POIL (125,170,12V140 engines) Oil pressure switch (95,107,114 engines) Ne speed sensor of flywheel housing: NE (95-170,12V140 engines) Ambient pressure sensor: PAMB (125,170,12V140 engines)
Pull lock type (PACKARD-2) q 95-170,12V140 engines q Various temperature sensors Examples) Intake air temperature sensor in intake manifold: TIM Fuel temperature sensor: TFUEL Oil temperature sensor: TOIL Coolant temperature sensor: TWTR, etc. Disconnect Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward.
Disconnect 1) Slide lock L1 to the right. 2) While pressing lock L2, pull out connector(1) toward you. a Even if lock L2 is pressed, connector(1) cannot be pulled out toward you, if part A does not float. In this case, float part A with a small screwdriver while press lock L2 , and then pull out connector(1) toward you.
Connect Insert the connector straight until it "clicks".
Connect Insert the connector straight until it "clicks".
GD535-5 (01)
00-35
Handling of connectors newly used for engines
Push lock type (1) q 95, 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03)
00 Index and foreword
While pressing up lock (C)of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.
Disconnect While pressing lock (C), pull out connector (3) in the direction of the arrow. q
114 engine
Connect Insert the connector straight until it "clicks".
q
107 engine
Push lock type (2) q 107, 114 engines Example) Intake air pressure/temperature sensor in intake manifold(SUMITOMO-04) Disconnect While pressing lock (D), pull out connector (4) in the direction of the arrow.
a If the lock is on the underside, use flat-head screwdriver[1]since you cannot insert your fingers. Connect Insert the connector straight until it "clicks".
00-36
GD535-5 (01)
00 Index and foreword
Push lock type (3) q 95, 125 - 170, 12V140 engines Disconnect While pressing lock (E) of the connector, pull out connector (5) in the direction of the arrow. Example) Fuel pressure sensor in common rail: PFUEL etc. (AMP-3)
Handling of connectors newly used for engines
Turn-housing type (Round green connector) q
140 engine Example) Intake air pressure sensor in intake manifold. (CANNON-04): PIM etc.
Disconnect 1) Turn housing (H1) in the direction of the arrow. a When connector is unlocked, housing (H1)becomes heavy to turn. 2) Pull out housing (H1)in the direction of the arrow. a Housing (H1)is left on the wiring harness side.
Example) Injection pressure control valve of fuel supply pump: PCV (SUMITOMO-2)
Connect 1) Insert the connector to the end, while setting its groove. 2) Turn housing (H1)in the direction of the arrow until it "clicks".
Examples) Speed sensor of fuel supply pump: G (SUMITOMO-3) a Pull the connector straight up.
Connect Insert the connector straight until it "clicks".
GD535-5 (01)
00-37
How to read electric wire code
00 Index and foreword
How to read electric wire code a The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting. In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram. Example: AEX
0.85
L
---
Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85 Indicates color of wire by color code. Color codes are shown in Table 3. Indicates size of wire by nominal No. Size (Nominal No.) is shown in Table 2. Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. (Since the use of AV and AVS wires depends on size (nominal No.), their symbols are not indicated on the diagram.)
1. Type, symbol, and material AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness and outside diameter and different from AV and AVS in material of the cover. (Table 1) Type Low-voltage wire for automobile Thin-cover low-voltage wire for automobile Heat-resistant low-voltage wire for automobile
00-38
Symbol
Material Conductor
Annealed copper for electric appliance
Insulator
Soft polyvinyl chloride
Conductor
Annealed copper for electric appliance
Insulator
Soft polyvinyl chloride
AV
AVS
Conductor AEX Insulator
Using temperature range (°C)
Example of use
General wiring (nominal No. 5 and above.) -30 to +60 General wiring (nominal No. 3 and below.)
Annealed copper for electric General wiring in extremely cold disappliance -50 to +110 trict, wiring at high ambient temperature Heat-resistant crosslinked place polyethylene
GD535-5 (01)
00 Index and foreword
How to read electric wire code
2. Dimensions (Table 2) Nominal No.
0.5f
(0.5)
Number of strands/Diame- 20/0.18 ter of strand
Cov-er D
Conductor
Sectional area (mm2)
(0.85)
1.25f
(1.25)
2f
2
3f
3
5
7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
0.51
0.56
0.76
0.88
1.27
1.29
1.96
2.09
3.08
3.30
5.23
d (approx.)
1.0
1.2
1.5
1.9
1.9
2.3
2.4
3.0
AVS
Standard
2.0
2.2
2.5
2.9
2.9
3.5
3.6
—
AV
Standard
—
—
—
—
—
—
—
4.6
AEX
Standard
2.0
2.2
2.7
3.0
3.1
—
3.8
4.6
Nominal No.
8
15
20
30
40
Number of strands/Diameter of strand
50/0.45
84/0.45
41/0.80
70/0.80
85/0.80
Sectional area (mm2)
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
d (approx.)
3.7
4.8
6.0
8.0
8.6
9.8
10.4
12.0
13.6
AVS
Standard
—
—
—
—
—
—
—
—
—
AV
Standard
5.5
7.0
8.2
10.8
11.4
13.0
13.6
16.0
17.6
AEX
Standard
5.3
7.0
8.2
10.8
11.4
13.0
13.6
16.0
17.6
Conductor
Cov-er D
0.75f
50
60
85
100
108/0.80 127/0.80 169/0.80 217/0.80
"f" of nominal No. denotes "flexible".
GD535-5 (01)
00-39
How to read electric wire code
00 Index and foreword
3. Color codes table (Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR
Color of wire Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red
Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW
Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow & Green Yellow & Blue Yellow & Red Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking. Example: "GW" means that the background is Green and marking is White. 4. Types of circuits and color codes (Table 4) Type of wire
AEX
Charge
R
WG
—
—
—
—
R
—
Ground
B
—
—
—
—
—
B
—
Start
R
—
—
—
—
—
R
—
Light
RW
RB
RY
RG
RL
—
D
—
Instrument
Y
YR
YB
YG
YL
YW
Y
Gr
Signal
G
GW
GR
GY
GB
GL
G
Br
L
LW
LR
LY
LB
—
L
—
Br
BrW
BrR
BrY
BrB
—
—
—
Lg
LgR
LgY
LgB
LgW
—
—
—
O
—
—
—
—
—
—
—
Gr
—
—
—
—
—
—
—
P
—
—
—
—
—
—
—
Sb
—
—
—
—
—
—
—
Dg
—
—
—
—
—
—
—
Ch
—
—
—
—
—
—
—
Type of circuit
Others
00-40
AVS or AV
GD535-5 (01)
00 Index and foreword
Precautions when carrying out work
Precautions when carrying out work When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the work. 1. Precautions when carrying out removal work q If the coolant contains antifreeze, dispose of it correctly. q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering. q When draining oil, prepare a container of adequate size to catch the oil. q Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. q To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. q Check the number and thickness of the shims, and keep in a safe place. q When raising component, be sure to use lifting equipment of ample strength. q When using forcing screws to remove any component, tighten the forcing screws uniformly in turn. q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations. 1) Face seal type hoses and tubes Nominal number 02 03 04 05 06 10 12
Plug (nut end)
Sleeve nut (elbow end)
07376 - 70210 07376 - 70315 07376 - 70422 07376 - 70522 07376 - 70628 07376-71034 07376-71234
02789-20210 02789-20315 02789-20422 02789-20522 02789-20628 07221-21034 07221-21234
2) Split flange type hoses and tubes Nominal number 04 05
Flange (hose end)
Sleeve head (tube end)
Split flange
07379 - 00400 07379 - 00500
07378 - 10400 07378 - 10500
07371 - 30400 07371 - 30500
3) If the part is not under hydraulic pressure, the following corks can be used. Nominal number 06 08 10 12 14 16 18 20 22 24 27
GD535-5 (01)
Part No. 07049 - 00608 07049 - 00811 07049 - 01012 07049 - 01215 07049 - 01418 07049 - 01620 07049 - 01822 07049 - 02025 07049 - 02228 07049 - 02430 07049 - 02734
D 6 8 10 12 14 16 18 20 22 24 27
Dimensions d 5 6.5 8.5 10 11.5 13.5 15 17 18.5 20 22.5
L 8 11 12 15 18 20 22 25 28 30 34
00-41
Precautions when carrying out work
00 Index and foreword
2. Precautions when carrying out installation work q Tighten all bolts and nuts (sleeve nuts) to the specified torque (KES) . q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. q Bend the cotter pins and lock plates securely. q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 – 3 drops of adhesive. q When coating with liquid gasket, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with liquid gasket. q Clean all parts, and correct any damage, dents, burrs, or rust. q Coat rotating parts and sliding parts with engine oil. q When press fitting parts, coat the surface with molybdenum disulfide lubricant (LM-P). q After fitting snap rings, check that the snap ring is fitted securely in the ring groove. q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. q When installing split flanges, fasten uniformly in turn to prevent excessive tightening on one side. a When operating the hydraulic cylinders for the first time after reassembling cylinders, hydraulic pumps and other hydraulic component removed for repair, always bleed the air as follows: 1] Start the engine and run at low idle. 2] Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cylinder 100 mm from the end of its stroke. 3] Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke. 4] After doing this, run the engine at normal speed. a When using the machine for the first time after repair or long storage, follow the same procedure. 3. Precautions when completing work 1) Refilling with coolant, oil and grease q If the coolant has been drained, close the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system . Then check the coolant level again. q If the hydraulic component has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. q If the piping or hydraulic component have been removed, always bleed the air from the system after reassembling the parts. a For details, see Testing and adjusting, "Bleeding air". q Add the specified amount of grease (molybdenum disulfide grease) to the work equipment parts. 2) Checking cylinder head and manifolds for looseness Check the cylinder head and intake and exhaust manifold for looseness. If any part is loose, retighten it. q For the tightening torque, see "Disassembly and assembly" . 3) Checking engine piping for damage and looseness Intake and exhaust system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and exhaust gas leakage. If any part is loose or damaged, retighten or repair it. Cooling system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leakage. If any part is loose or damaged, retighten or repair it. Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loose or damaged, retighten or repair it.
00-42
GD535-5 (01)
00 Index and foreword
Precautions when carrying out work
4) Checking muffler, exhaust pipe and their mounts for damage and looseness 1] Visually check the muffler, exhaust pipe and their mounts for a crack and damage. If any part is damaged, replace it. 2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounts for looseness. If any part is loose, retighten it. 5) Checking muffler function Check the muffler for abnormal sound and sound different from that of a new muffler. If any abnormal sound is heard, repair the muffler, referring to "Troubleshooting" and "Disassembly and assembly".
GD535-5 (01)
00-43
Method of disassembling and connecting push-pull type coupler
00 Index and foreword
Method of disassembling and connecting push-pull type coupler k k
Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil container.
Type 1 1. Disconnection 1) Hold adapter (1) and push hose joint (2) into mating adapter (3) . (Fig. 1) a The adapter can be pushed in approximately 3.5 mm. a Do not hold rubber cap portion (4). 2) With hose joint (2) pushed into adapter (3), press rubber cap portion (4) against adapter (3) until it clicks. (Fig. 2) 3) Hold hose adapter (1) or hose (5) and pull it out. (Fig. 3) a Since some hydraulic oil flows out, prepare an oil container.
2. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (Fig. 4) a Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (Fig. 5) a When the hose is pulled back, the rubber cap portion moves toward the hose approximately 3.5 mm. This does not indicate abnormality, however.
00-44
GD535-5 (01)
00 Index and foreword
Method of disassembling and connecting push-pull type coupler
Type 2 1. Disconnection 1) Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6) 2) While holding the condition of Step 1), turn lever (8) to the right (clockwise). (Fig. 7) 3) While holding the condition of Steps 1) and 2), pull out whole body (7) to disconnect it. (Fig. 8)
2. Connection q Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
GD535-5 (01)
00-45
Method of disassembling and connecting push-pull type coupler
00 Index and foreword
Type 3 1. Disconnection 1) Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10) 2) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 11) 3) While holding the condition of Steps 1) and 2), pull out whole body (9) to disconnect it. (Fig. 12)
2. Connection q Hold the tightening portion and push body (9) straight until the sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)
00-46
GD535-5 (01)
00 Index and foreword
Standard tightening torque table
Standard tightening torque table 1. Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. a The following table applies to the bolts in Fig. A. Thread diame- Width across ter of bolt flats mm mm 6 10 8 13 10 17 12 19 14 22 16 24 18 27 20 30 22 32 24 36 27 41 30 46 33 50 36 55 39 60
Tightening torque Nm 11.8 – 14.7 27 – 34 59 – 74 98 – 123 157 –196 245 – 309 343 – 427 490 – 608 662 – 829 824 – 1,030 1,180 – 1,470 1,520 – 1,910 1,960 – 2,450 2,450 – 3,040 2,890 – 3,630
kgm 1.2 – 1.5 2.8 – 3.5 6.0 – 7.5 10.0 – 12.5 16 – 20 25 – 31.5 35 – 43.5 50 – 62 67.5 – 84.5 84 – 105 120 – 150 155 – 195 200 – 250 250 – 310 295 – 370
a The following table applies to the bolts in Fig. B. Thread diame- Width across ter of bolt flats mm mm 6 10 8 12 10 14 12 17
Tightening torque Nm 5.9 – 9.8 13.7 – 23.5 34.3 – 46.1 74.5 – 90.2
a Fig. A
kgm 0.6 – 1.0 1.4 – 2.4 3.5 – 4.7 7.6 – 9.2
a Fig. B
Remarks: The widths across flats by thread diameter of flanged bolts (marked with "*") in Fig. A are the ones indicated in the table for bolts shown in Fig. B. (Values of tightening torques shown in the table for Fig. A are applied.)
GD535-5 (01)
00-47
Standard tightening torque table
00 Index and foreword
2. Table of tightening torques for split flanged bolts a Unless there are special instructions, tighten split flanged bolts to the torque below. Thread diame- Width across ter of bolt flats mm mm 10 14 12 17 16 22
Tightening torque Nm 59 – 74 98 – 123 235 – 285
kgm 6.0 – 7.5 10.0 – 12.5 23.5 – 29.5
3. Table of tightening torques for O-ring boss piping joints a Unless there are special instructions, tighten O-ring boss piping joints to the torque below. Nominal No. 02 03,04 05,06 10,12 14
Thread diame- Width across ter flats mm mm 14 Varies 20 depending on 24 type of con33 nector. 42
Tightening torque Nm {kgm} Range 35 – 63 {3.5 – 6.5} 84 – 132 {8.5 – 13.5} 128 – 186 {13.0 – 19.0} 363 – 480 {37.0 – 49.0} 746 – 1,010 {76.0 – 103}
Target 44 {4.5} 103 {10.5} 157 {16.0} 422 {43.0} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs a Unless there are special instructions, tighten O-ring boss plugs to the torque below. Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52
00-48
Thread diame- Width across ter flats mm mm 8 14 10 17 12 19 14 22 16 24 18 27 20 30 24 32 30 32 33 – 36 36 42 – 52 –
Tightening torque Nm {kgm} Range 5.88 – 8.82 {0.6 – 0.9} 9.8 – 12.74 {1.0 – 1.3} 14.7 – 19.6 {1.5 – 2.0} 19.6 – 24.5 {2.0 – 2.5} 24.5 – 34.3 {2.5 – 3.5} 34.3 – 44.1 {3.5 – 4.5} 44.1 – 53.9 {4.5 – 5.5} 58.8 – 78.4 {6.0 – 8.0} 93.1 – 122.5 { 9.5 – 12.5} 107.8 – 147.0 {11.0 – 15.0} 127.4 – 176.4 {13.0 – 18.0} 181.3 – 240.1 {18.5 – 24.5} 274.4 – 367.5 {28.0 – 37.5}
Target 7.35 {0.75} 11.27 {1.15} 17.64 {1.8} 22.54 {2.3} 29.4 {3.0} 39.2 {4.0} 49.0 {5.0} 68.6 {7.0} 107.8 {11.0} 127.4 {13.0} 151.9 {15.5} 210.7 {21.5} 323.4 {33.0}
GD535-5 (01)
00 Index and foreword
Standard tightening torque table
5. Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below. a Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque (Nm {kgm}) Nominal No. of hose
Width across flats
02
19
03 04 05 06 (10) (12) (14)
22 24 27 32 36 41 46 55
Taper seal
Range
Target
Thread size (mm)
34 – 54 {3.5 – 5.5} 34 – 63 {3.5 – 6.5} 54 – 93 {5.5 – 9.5} 59 – 98 {6.0 – 10.0} 84 – 132 {8.5 – 13.5} 128 – 186 {13.0 – 19.0} 177 – 245 {18.0 – 25.0} 177 – 245 {18.0 – 25.0} 197 – 294 {20.0 – 30.0} 246 – 343 {25.0 – 35.0}
44 {4.5} 44 {4.5} 74 {7.5} 78 {8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}
– 14 – 18 22 24 30 33 36 42
Face seal Nominal No. Thread diame–Number of ter (mm) (Referthreads, type of ence) thread 9/16 – 18UNF 14.3 – – 11/16 – 16UN 17.5 – – 13/16 – 16UN 20.6 1 – 14UNS 25.4 1-3/16 – 12UN 30.2 – – – – – –
6. Table of tightening torques for face seal joints a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be used for engines etc. to the torque shown in the following table. a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil (wetted). Outer diame- Width across ter of pipe flats (mm) (mm) 8 10 12 15 (16) 22 (20)
19 22 24 (27) 30 (32) 36
Tightening torque (Nm {kgm}) Range
Target
14 – 16 {1.4 – 1.6} 24 – 27 {2.4 – 2.7} 43 – 47 {4.4 – 4.8} 60 – 68 {6.1 – 6.8} 90 – 95 {9.2 – 9.7}
15 {1.5} 25.5 {2.6} 45 {4.6} 64 {6.5} 92.5 {9.4}
Face seal Nominal No. –Num- Thread diameter ber of threads, type (mm) of thread (Reference) 9/16 – 18UN 14.3 11/16 – 16UN 17.5 13/16 – 16UN 20.6 1 – 14UN 25.4 1 – 3/16 – 12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are slso used, depending on the specification.
GD535-5 (01)
00-49
Standard tightening torque table
00 Index and foreword
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts) a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114 engine series to the torque below. Tightening torque Bolts and nuts
Thread size mm 6 8 10 12 14
Nm 10 ± 2 24 ± 4 43 ± 6 77 ± 12 –
kgm 1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22 –
8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints) a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine series to the torque below. Thread size mm 6 8 10 12 14
Tightening torque Nm 8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5
kgm 0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws) a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine series to the torque below. Material Thread size (inch) 1/16 1/8 1/4 3/8 1/2 3/4
00-50
Tightening torque In cast iron or steel In aluminum Nm kgm Nm kgm 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
GD535-5 (01)
00 Index and foreword
Conversion table
Conversion table Method of using the conversion table The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below. Example: Method of using the conversion table to convert from millimeters to inches 1. Convert 55 mm into inches. 1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A). 2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). 3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 550 mm into inches. 1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the left) to convert it to 55 mm. 2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. 3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches. Millimeters to inches
(A)
GD535-5 (01)
(B)
0 10 20 30 40
0 0 0.394 0.787 1.181 1.575
1 0.039 0.433 0.827 1.220 1.614
2 0.079 0.472 0.866 1.260 1.654
3 0.118 0.512 0.906 1.299 1.693
4 0.157 0.551 0.945 1.339 1.732
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.017 2.441 2.835 3.228 3.622
2.087 2.480 2.847 3.268 3.661
2.126 2.520 2.913 3.307 3.701
5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740
6 0.236 0.630 1.024 1.417 1.811
7 0.276 0.669 1.063 1.457 1.850
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929 2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
00-51
Conversion table
00 Index and foreword
Millimeters to inches 0 10 20 30 40
0 0 0.394 0.787 1.181 1.575
1 0.039 0.433 0.827 1.220 1.614
2 0.079 0.472 0.866 1.260 1.654
3 0.118 0.512 0.906 1.299 1.693
4 0.157 0.551 0.945 1.339 1.732
5 0.197 0.591 0.984 1.378 1.772
5 0.236 0.630 1.024 1.417 1.811
7 0.276 0.669 1.063 1.457 1.850
1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.017 2.441 2.835 3.228 3.622
2.087 2.480 2.847 3.268 3.661
2.126 2.520 2.913 3.307 3.701
2.165 2.559 2.953 3.346 3.740
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
2.283 2.677 3.071 3.465 3.858
0 10 20 30 40
0 0 22.05 44.09 66.14 88.18
1 2.20 24.25 46.30 68.34 90.39
2 4.41 26.46 48.50 70.55 92.59
3 6.61 28.66 50.71 72.75 94.80
4 8.82 30.86 51.91 74.96 97.00
5 11.02 33.07 55.12 77.16 99.21
6 13.23 35.27 57.32 79.37 101.41
7 15.43 37.48 59.53 81.57 103.62
1 kg = 2.2046 lb 8 9 17.64 19.84 39.68 41.89 61.73 63.93 83.78 85.98 105.82 108.03
50 60 70 80 90
110.23 132.28 154.32 176.37 198.42
112.44 134.48 156.53 178.57 200.62
114.64 136.69 158.73 180.78 202.83
116.85 138.89 160.94 182.98 205.03
119.05 141.10 163.14 185.19 207.24
121.25 143.30 165.35 187.39 209.44
123.46 145.51 167.55 189.60 211.64
125.66 147.71 169.76 191.80 213.85
127.87 149.91 171.96 194.01 216.05
0 10 20 30 40
0 0 2.642 5.283 7.925 10.567
1 0.264 2.906 5.548 8.189 10.831
2 0.528 3.170 5.812 8.454 11.095
3 0.793 3.434 6.076 8.718 11.359
4 1.057 3.698 6.340 8.982 11.624
5 1.321 3.963 6.604 9.246 11.888
6 1.585 4.227 6.869 9.510 12.152
7 1.849 4.491 7.133 9.774 12.416
1l= 0.2642 U.S.Gal 8 9 2.113 2.378 4.755 5.019 7.397 7.661 10.039 10.303 12.680 12.944
50 60 70 80 90
13.209 15.850 18.492 21.134 23.775
13.473 16.115 18.756 21.398 24.040
13.737 16.379 19.020 21.662 24.304
14.001 16.643 19.285 21.926 24.568
14.265 16.907 19.549 22.190 24.832
14.529 17.171 19.813 22.455 25.096
14.795 17.435 20.077 22.719 25.361
15.058 17.700 20.341 22.983 25.625
15.322 17.964 20.605 23.247 25.889
2.323 2.717 3.110 3.504 3.898
Kilogram to pound
130.07 152.12 174.17 196.21 218.26
Liters to U.S. Gallons
00-52
15.586 18.228 20.870 23.511 26.153
GD535-5 (01)
00 Index and foreword
Conversion table
Liters to U.K. Gallons 1l = 0.21997 U.K.Gal 8 9 1.760 1.980 3.950 4.179 6.159 6.379 8.359 8.579 10.559 10.778
0 10 20 30 40
0 0 2.200 4.399 6.599 8.799
1 0.220 2.420 4.619 6.819 9.019
2 0.440 2.640 4.839 7.039 9.239
3 0.660 2.860 5.059 7.259 9.459
4 0.880 3.080 5.279 7.479 9.679
5 1.100 3.300 5.499 7.699 9.899
6 1.320 3.520 5.719 7.919 10.119
7 1.540 3.740 5.939 8.139 10.339
50 60 70 80 90
10.998 13.198 15.398 17.598 19.797
11.281 13.418 15.618 17.818 20.017
11.438 13.638 15.838 18.037 20.237
11.658 13.858 16.058 18.257 20.457
11.878 14.078 16.278 18.477 20.677
12.098 14.298 16.498 18.697 20.897
12.318 14.518 16.718 18.917 21.117
12.528 14.738 16.938 19.137 21.337
0 10 20 30 40
0 0 72.3 144.7 217.0 289.3
1 7.2 79.6 151.9 224.2 296.6
2 14.5 86.8 159.1 231.5 303.8
3 21.7 94.0 166.4 238.7 311.0
4 28.9 101.3 173.6 245.9 318.3
5 36.2 108.5 180.8 253.2 325.5
6 43.4 115.7 188.1 260.4 332.7
7 50.6 123.0 195.3 267.6 340.0
1 kgm = 7.233 ft.lb 8 9 57.9 65.1 130.2 137.4 202.5 209.8 274.9 282.1 347.2 354.4
50 60 70 80 90
361.7 434.0 506.3 578.6 651.0
368.9 441.2 513.5 585.9 658.2
376.1 448.5 520.8 593.1 665.4
383.4 455.7 528.0 600.3 672.7
390.6 462.9 535.2 607.6 679.9
397.8 470.2 542.5 614.8 687.1
405.1 477.4 549.7 622.0 694.4
412.3 484.6 556.9 629.3 701.6
419.5 491.8 564.2 636.5 708.8
426.8 499.1 571.4 643.7 716.1
100 110 120 130 140
723.3 795.6 868.0 940.3 1012.6
730.5 802.9 875.2 947.5 1019.9
737.8 810.1 882.4 954.8 1027.1
745.0 817.3 889.7 962.0 1034.3
752.2 824.6 896.9 969.2 1041.5
759.5 831.8 904.1 976.5 1048.8
766.7 839.0 911.4 983.7 1056.0
773.9 846.3 918.6 990.9 1063.2
781.2 853.5 925.8 998.2 1070.5
788.4 860.7 933.1 1005.4 1077.7
150 160 170 180 190
1084.9 1157.3 1129.6 1301.9 1374.3
1092.2 1164.5 1236.8 1309.2 1381.5
1099.4 1171.7 1244.1 1316.4 1388.7
1106.6 1179.0 1251.3 1323.6 1396.0
1113.9 1186.2 1258.5 1330.9 1403.2
1121.1 1193.4 1265.8 1338.1 1410.4
1128.3 1200.7 1273.0 1345.3 1417.7
1135.6 1207.9 1280.1 1352.6 1424.9
1142.8 1215.1 1287.5 1359.8 1432.1
1150.0 1222.4 1294.7 1367.0 1439.4
12.758 14.958 17.158 19.357 21.557
12.978 15.178 17.378 19.577 21.777
kgm to ft.lb
GD535-5 (01)
00-53
Conversion table
00 Index and foreword
kg/cm2 to lb/in2
0 10 20 30 40
0 0 142.2 284.5 426.7 568.9
1 14.2 156.5 298.7 440.9 583.2
2 28.4 170.7 312.9 455.1 597.4
3 42.7 184.9 327.1 469.4 611.6
4 56.9 199.1 341.4 483.6 625.8
5 71.1 213.4 355.6 497.8 640.1
6 85.3 227.6 369.8 512.0 654.3
1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9
50 60 70 80 90
711.2 853.4 995.6 1,138 1,280
725.4 867.6 1,010 1,152 1,294
739.6 881.8 1,024 1,166 1,309
753.8 896.1 1,038 1,181 1,323
768.1 910.3 1,053 1,195 1,337
782.3 924.5 1,067 1,209 1,351
796.5 938.7 1,081 1,223 1,365
810.7 953.0 1,095 1,237 1,380
825.0 967.2 1,109 1,252 1,394
839.2 981.4 1,124 1,266 1,408
100 110 120 130 140
1,422 1,565 1,707 1,849 1,991
1,437 1,579 1,721 1,863 2,005
1,451 1,593 1,735 1,877 2,020
1,465 1,607 1,749 1,892 2,034
1,479 1,621 1,764 1,906 2,048
1,493 1,636 1,778 1,920 2,062
1,508 1,650 1,792 1,934 2,077
1,522 1,664 1,806 1,949 2,091
1,536 1,678 1,821 1,963 2,105
1,550 1,693 1,835 1,977 2,119
150 160 170 180 190
2,134 2,276 2,418 2,560 2,702
2,148 2,290 2,432 2,574 2,717
2,162 2,304 2,446 2,589 2,731
2,176 2,318 2,460 2,603 2,745
2,190 2,333 2,475 2,617 2,759
2,205 2,347 2,489 2,631 2,773
2,219 2,361 2,503 2,646 2,788
2,233 2,375 2,518 2,660 2,802
2,247 2,389 2,532 2,674 2,816
2,262 2,404 2,546 2,688 2,830
200 210 220 230 240
2,845 2,987 3,129 3,271 3,414
2,859 3,001 3,143 3,286 3,428
2,873 3,015 3,158 3,300 3,442
2,887 3,030 3,172 3,314 3,456
2,901 3,044 3,186 3,328 3,470
2,916 3,058 3,200 3,343 3,485
2,930 3,072 3,214 3,357 3,499
2,944 3,086 3,229 3,371 3,513
2,958 3,101 3,243 3,385 3,527
2,973 3,115 3,257 3,399 3,542
00-54
GD535-5 (01)
00 Index and foreword
Conversion table
Temperature Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. °C –40.4 –37.2 –34.4 –31.7 –28.9
°F 114.8 116.6 118.4 120.2 122.0
°C 27.2 27.8 28.3 28.9 29.4
1°C = 33.8°F °F 81 177.8 82 179.6 83 181.4 84 183.2 85 185.0
54 55
123.8 125.6 127.4 129.2 131.0
30.0 30.6 31.1 31.7 32.2
86 87 88 89 90
186.8 188.6 190.4 192.2 194.0
13.3 13.9 14.4 15.0 15.6
56 57 58 59 60
132.8 134.6 136.4 138.2 140.0
32.8 33.3 33.9 34.4 35.0
91 92 93 94 95
195.8 197.6 199.4 201.2 203.0
78.8 80.6 82.4 84.2 86.0
16.1 16.7 17.2 17.8 18.3
61 62 63 64 65
141.8 143.6 145.4 147.2 149.0
35.6 36.1 36.7 37.2 37.8
96 97 98 99 100
204.8 206.6 208.4 210.2 212.0
31 32 33 34 35
87.8 89.6 91.4 93.2 95.0
18.9 19.4 20.0 20.6 21.1
66 68 69 69 70
150.8 152.6 154.4 156.2 158.0
40.6 43.3 46.1 48.9 51.7
105 110 115 120 125
221.0 230.0 239.0 248.0 257.0
2.2 2.8 3.3 3.9 4.4
36 37 38 39 40
96.8 98.6 100.4 102.2 104.0
21.7 22.2 22.8 23.3 23.9
71 72 73 74 75
159.8 161.6 163.4 165.2 167.0
54.4 57.2 60.0 62.7 65.6
130 135 140 145 150
266.0 275.0 284.0 293.0 302.0
5.0 5.6 6.1 6.7 7.2
41 42 43 44 45
105.8 107.6 109.4 111.2 113.0
24.4 25.0 25.6 26.1 26.7
76 77 78 79 80
168.8 170.6 172.4 174.2 176.0
68.3 71.1 73.9 76.7 79.4
155 160 165 170 175
311.0 320.0 329.0 338.0 347.0
–40 –35 –30 –25 –20
°F –40.0 –31.0 –22.0 –13.0 –4.0
°C –11.7 –11.1 –10.6 –10.0 –9.4
11 12 13 14 15
°F 51.8 53.6 55.4 57.2 59.0
°C 7.8 8.3 8.9 9.4 10.0
–28.3 –27.8 –27.2 –26.7 –26.1
–19 –18 –17 –16 –15
–2.2 –0.4 1.4 3.2 5.0
–8.9 –8.3 –7.8 –7.2 –6.7
16 47 18 19 20
60.8 62.6 64.4 66.2 68.0
10.6 11.1 11.7 12.2 12.8
51 52
–25.6 –25.0 –24.4 –23.9 –23.3
–14 –13 –12 –11 –10
6.8 8.6 10.4 12.2 14.0
–6.1 –5.6 –5.0 –4.4 –3.9
21 22 23 24 25
69.8 71.6 73.4 75.2 77.0
–22.8 –22.2 –21.7 –21.1 –20.6
–9 –8 –7 –6 –5
15.8 17.6 19.4 21.2 23.0
–3.3 –2.8 –2.2 –1.7 –1.1
26 27 28 29 30
–20.0 –19.4 –18.9 –18.3 –17.8
–4 –3 –2 –1 0
24.8 26.6 28.4 30.2 32.0
–0.6 0 0.6 1.1 1.7
–17.2 –16.7 –16.1 –15.6 –15.0
1 2 3 4 5
33.8 35.6 37.4 39.2 41.0
–14.4 –13.9 –13.3 –12.8 –12.2
6 7 8 9 10
42.8 44.6 46.4 48.2 50.0
GD535-5 (01)
46 47 48 49 50
00-55
Conversion table
00-56
00 Index and foreword
GD535-5 (01)
01 Specification
GD535-5
01-1
Contents
01 Specification
Contents
1
Acronyms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Specifications- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Specification drawing (Canopy specification) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Specification drawing (Cab specification) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Specifications (Canopy specification) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Specifications (Cab specification) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Weight table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Table of fuel, coolant, and lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
01-2
01-2-1 01-3 01-3 01-3-1 01-4 01-9-1 01-10 01-11
GD535-5 (03)
01 Specification
Acronyms
Acronyms q q q q
1
The abbreviations of unknown parts, equipment and functions have been extracted from the Shop Manual, and their official names and details are defined in this Acronyms. Abbreviations that are commonly used in society might not be described. Special and rarely used abbreviations are described in the supplementary explanation in the text. The acronyms consist of two parts: the list of abbreviations that are used in the text, and the list of abbreviations that are used in circuit diagrams.
Abbreviations that are used in the text Abbreviations
Official name
Application (Applicable models (*1) and equipment) Traveling, brake
ABS
Antilock Brake System
AISS
Automatic Idling Setting Engine System
AJSS
Advanced Joystick Steering System
ARAC
Automatic Retarder Accelerator Control
(HD series, HM series)
Steering (WA series) Traveling, brake (HD series, HM series) Traveling, brake
ARSC
Automatic Retarder Speed Control
ASR
Automatic Spin Regulator
ATT
Attachment
BCV
Brake Cooling oil control Valve
CAN
(HD series, HM series) Traveling, brake (HD series, HM series) Work equipment
Explanation With this function, when the tires skid (wheels stop rotating), the brakes are released, and when the wheels start to rotate, the brakes are applied again. This function automatically sets the idle speed. A lever is used to perform the steering operations instead of a steering wheel. Moreover, it shifts gear and changes direction (FORWARD or REVERSE). When the accelerator pedal is released while the machine is traveling downhill, this function automatically applies the retarder with a constant braking force. When the accelerator pedal is released while the machine is traveling downhill, this function automatically applies the retarder to ensure that the machine speed does not accelerate above the speed set by the operator. When the tires spin on soft ground surfaces, this function automatically uses the optimum braking force to drive both wheels. The function or parts which are attached to the standard model and used
(HD series)
When the retarder is not being used, this valve bypasses part of the brake cooling oil to reduce the load on the hydraulic pump.
Controller Area Network
Communication, electronic control
One of communication standards that is used in the network on the machine
CDR
Crankcase Depression Regulator
Engine
A regulator valve which is installed to KCCV ventilator. It is written as CDR valve and it is not used independently.
CLSS
Closed-center Load Sensing System
Hydraulic system
This system can simultaneously actuate multiple actuators regardless of the load (provides better combined operation than OLSS).
Engine
Engine controller electronically controls supply pump, common rail, and injector. This function maintains optimum fuel injection amount and fuel injection timing.
Electronic control
Electronic control device that receives signals from each sensor of the machine and that specifies the optimum operation to the actuators. (Same as ECU)
CRI
Common Rail Injection
ECM
Electronic Control Module
GD535-5 (03)
Brake
1
01-2-1
Acronyms
Abbreviations
01 Specification
Official name
ECMV
Electronic Control Modulation Valve
ECSS
Electronically Controlled Suspension System
Application (Applicable models (*1) and equipment) Transmission (D series, HD series, WA series and others) Traveling (WA series)
Explanation Proportional solenoid valve that reduces the connection shock by gradually increasing the hydraulic pressure to engage the clutch. This system ensures smooth high-speed travel by absorbing vibration of machine during travel with hydraulic spring effect of accumulator.
ECU
Electronic Control Unit
Electronic control
Electronic control device that receives signals from each sensor of the machine and that specifies the optimum operation to the actuators. (Same as ECM)
EGR
Exhaust Gas Recirculation
Engine
This function recirculates part of exhaust gas to the combustion chamber in order to reduce combustion temperature and control the emission of NOx.
Equipment Management Monitoring System
Machine monitor
This system allows data (filter, oil replacement interval, malfunctions on machine, failure code, and failure history) from each sensor on the machine to be checked on the monitor.
EPC
Electromagnetic Proportional Control
Hydraulic system
Electromagnetic proportional control This mechanism allows actuators to be operated in proportion to the current supplied.
FOPS
Falling Object Protective Structure
Operator's cab, canopy
F-N-R
Forward-NeutralReverse
Operation
Forward-Neutral-Reverse
Communication
GPS
Global Positioning System
Global positioning system The satellite positioning system to determine the current position on the earth
GNSS
Global Navigation Satellite System
EMMS
This structure protects the operator's head from falling objects. (Falling Object Protective Structure) This performance is standardized as ISO 3449.
(KOMTRAX, KOMTRAX Plus) Communication (KOMTRAX, KOMTRAX Plus) Steering
Global navigation satellite system A general term for positioning system using satellites such as GPS, GALILEO, etc. This function uses a combination of hydraulic motor and bevel shaft to control difference in travel speed of right and left tracks. Accordingly machine can turn without using steering clutch.
HSS
Hydrostatic Steering System
HST
Hydro Static Transmission
ICT
Information and Communication Technology
Communication, electronic control
A general term for the engineering and its socially applied technology of information processing and communication.
IMA
Inlet Metering Actuator
Engine
Valve that adjusts fuel intake amount at inlet port of pump in order to control fuel discharged volume of supply pump. (Same as IMV)
IMU
Inertial Measurement Unit
Engine
This is a device to detect the angle (or angular velocity) and acceleration of the 3 axes that control motions.
IMV
Inlet Metering Valve
Engine
Valve adjusting fuel intake amount at inlet port of pump in order to control fuel discharged volume of supply pump. (Same as IMA)
01-2-2
(D series) Transmission (D series, WA series)
This function uses a combination of hydraulic pump and hydraulic motor to shift the speed range steplessly without using gears.
GD535-5 (01)
01 Specification
Abbreviations
Acronyms
Official name
Application (Applicable models (*1) and equipment)
KCCV
KOMATSU Closed Crankcase Ventilation
Engine
KCSF
KOMATSU Catalyzed Soot Filter
Engine
KDOC
KOMATSU Diesel Oxidation Catalyst
Engine
KDPF
KOMATSU Diesel Particulate Filter
Explanation The mechanism for oil separation from gas in order to re-burn the blow-by gas and for oil return to the intake system. It is mainly composed of filters. The filter to capture the soot from exhaust gas. It is built in the KDPF. The catalyst for exhaust gas purification.
Engine
It may be built in the KDPF or combined with the muffler. This component is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it. It is used instead of the conventional muffler.
Traveling, brake
This function recovers the drive force of the wheels by braking automatically with the optimum force and at the same time activates the inter-axle differential lock when the wheels idle while the machine travels on the soft ground road.
KOMATSU Traction Control System
(HM series)
LCD
Liquid Crystal Display
Machine monitor
The liquid crystal display panel. Image display device such as a monitor which assembles in the liquid crystal element.
LED
Light Emitting Diode
Electronic components
Light emitting diode It refers to semiconductor element that emits light when the voltage is applied in forward direction.
LIN
Local Interconnect Network
Communication, electronic control
One of communication standards that is used in the network on the machine
LS
Load Sensing
Hydraulic system
Function that detects differential pressure of pump and controls discharged volume corresponding to load.
KTCS
Low Voltage Differential Communication, electronic Signaling control
One of communication standards that is used in the network on the machine
MAF
Mass Air Flow
Engine
The intake airflow rate of the engine. It is not used alone, but used in combination with sensors. The intake airflow sensor may be called the MAF sensor.
MMS
Multimedia Messaging Service
Communication
The service to allow transmission and reception of short messages such as characters, voice and images between mobile phones.
Normally Closed
Electric system, hydraulic system
The characteristics of an electric or hydraulic circuit that is normally closed when the system is not operating, and that is normally opened when the system is operating.
Normally Open
Electric system, hydraulic system
The characteristics of an electric or hydraulic circuit that is normally opened when the system is not operating, and that is normally closed when the system is operating.
Open-center Load Sensing System
Hydraulic system
The hydraulic system that can simultaneously operate multiple actuators regardless of the load.
Pressure Compensation
Hydraulic system
The function to compensate for the hydraulic pressure.
LVDS
NC
NO
OLSS PC
GD535-5 (01)
01-2-3
Acronyms
Abbreviations
01 Specification
Official name
Application (Applicable models (*1) and equipment)
Explanation
Steering Palm Command Control System (D series)
The function to make the controller analyze the lever, pedal, and dial data instantaneously, and to allow the electronic control of engine, transmission and others appropriately.
PCV
Pre-stroke Control Valve
Engine
This valve is installed at inlet port of pump and it adjusts fuel intake amount in order to control fuel discharged volume of supply pump.
PPC
Proportional Pressure Control
Hydraulic system
Used for controlling proportional pressure. This system moves actuators in proportion to the hydraulic pressure.
PPM
Piston Pump and Motor
PTO
Power Take Off
Power transmission
Power take-off mechanism
PTP
Power Tilt and power Pitch dozer
Work equipment (D series)
This function performs hydraulic control of the tilt and pitch of the bulldozer blade.
Operator's cab, canopy
The structure to protect the operator (fastened with seat belt) if the machine falls. (Roll-over protective structure for operator)
PCCS
ROPS
Roll-Over Protective Structure
Hydraulic system (D series, PC series, others)
Piston hydraulic pump and motor.
This performance is standardized as ISO 3471.
Selective Catalytic Reduction
Urea SCR system
The exhaust gas purification device, that uses urea water and converts the nitrogen oxides (NOx) into harmless nitrogen and water (by reduction reaction). It may be called part of the exhaust gas purifying catalyst or the related device name.
Le Systeme International d’ Unites
Unit
Abbreviated for the "International System of Units". It is the universal unit system and "A single unit for a single quantity" is the basic principle applied.
SOL
Solenoid
Electrical system
It refers to an actuator consisting of a solenoid and an iron core that is moved by the magnetic force when the solenoid is energized.
TWV
2-Way Valve
Hydraulic system
Solenoid valve that switches over direction of flow.
VGT
Variable Geometry Turbocharger
Engine
Turbocharger having the variable geometry of exhaust passage
SCR
SI
*1: Applicable model codes D: Bulldozer HD: Dump truck HM: Articulated dump truck PC: Hydraulic excavator WA: Wheel loader
01-2-4
GD535-5 (03)
01 Specification
Acronyms
Abbreviations used in circuit diagrams Abbreviations
Official name
A/C
Air Conditioner
A/D
Analogue-to-Digital
A/M
Air Mix damper
ACC
Accessory
ADD
Additional
AUX
Auxiliary
BR
Battery Relay
CW
Clockwise
CCW
Counter Clockwise
ECU
Electronic Control Unit
ECM
Electronic Control Module
ENG
Engine
EXGND
External Ground
F.G.
Frame Ground
GND
Ground
IMA
Inlet Metering Actuator
NC
No Connection
S/T STRG
Steering
SIG
Signal
SOL
Solenoid
STD
Standard
OPT OP PRESS SPEC SW TEMP
Option Pressure Specification Switch Temperature
T/C
Torque Converter
T/M
Transmission
GD535-5 (01)
1
01-2-5
Acronyms
01-2-6
01 Specification
GD535-5 (01)
01 Specification
Specification drawing (Canopy specification)
Specifications
1
Specification drawing (Canopy specification)
1
Item Operating weight (including one operator weighing 75 kg)
Unit
GD535-5
kg
13,820
Engine model
Komatsu SAA6D107E-1 diesel engine E mode
P mode
Engine rated horsepower q
101 {135}/2,000 {2,000} 108 {145}/2,000 {2,000}
ISO 9249/SAE J1349 (net)
q
ISO 14396
q
SAE J1995 (gross)
kW {HP} min-1 {rpm}
-
115 {153}/2,000 {2,000}
107 {143}/2,000 {2,000} 115 {154}/2,000 {2,000}
A
Overall length
mm
8,540
B
Overall height (including yellow revolving lamp)
mm
3,145
C
Overall width
mm
2,425
Min. ground clearance (to bottom surface of articulate center pin)
mm
365
Min. turning radius
mm
7,000
Travel speed 1st (Forward/Reverse)
4.2/4.7
2nd (Forward/Reverse)
5.9/9.1
3rd (Forward/Reverse)
8.0/17.8
4th (Forward/Reverse)
km/h
11.3/34.1
5th (Forward/Reverse)
15.7/-
6th (Forward/Reverse)
22.0/-
7th (Forward/Reverse)
30.1/-
8th (Forward/Reverse)
42.0/-
a The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horsepower measured on the basic engine unit, while net denotes the measured value of an engine under conditions that are essentially the same as those when it is installed on a machine.
GD535-5 (03)
01-3
Specification drawing (Cab specification)
01 Specification
Specification drawing (Cab specification)
Item Operating weight (including one operator weighing 75 kg)
1
Unit
GD535-5
kg
13,760 [14,400]
Engine model
Komatsu SAA6D107E-1 diesel engine E mode
P mode
Engine rated horsepower q
ISO 9249/SAE J1349 (net)
q
ISO 14396
q
SAE J1995 (gross)
101 {135}/2,000 {2,000} 108 {145}/2,000 {2,000} kW {HP} min-1 {rpm}
-
115 {153}/2,000 {2,000}
107 {143}/2,000 {2,000} 115 {154}/2,000 {2,000}
A
Overall length
mm
8,565
B
Overall height (including yellow revolving lamp)
mm
3,410
C
Overall width
mm
2,455
Min. ground clearance (to bottom surface of articulate center pin)
mm
385
Min. turning radius
mm
7,000
Travel speed 1st (Forward/Reverse)
4.3/4.8
2nd (Forward/Reverse)
6.1/9.4
3rd (Forward/Reverse)
8.2/18.4
4th (Forward/Reverse)
km/h
11.6/35.2
5th (Forward/Reverse)
16.2/-
6th (Forward/Reverse)
22.7/-
7th (Forward/Reverse)
31.1/-
8th (Forward/Reverse)
43.4/-
a The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horsepower measured on the basic engine unit, while net denotes the measured value of an engine under conditions that are essentially the same as those when it is installed on a machine. a [ ]: with scarifier
01-3-1
GD535-5 (03)
01 Specification
GD535-5 (03)
Specification drawing (Cab specification)
01-3-2
Specifications (Canopy specification)
01 Specification
Specifications (Canopy specification)
Weight
Item
1
Unit
GD535-5
Operating weight (including one operator weighing 75 kg)
kg
13,820
Load on front axle
kg
4,090
Load on rear axle
kg
9,730
Performance
Travel speed Forward 1st
4.2
Forward 2nd
5.9
Forward 3rd
8.0
Forward 4th
11.3
Forward 5th
15.7
Forward 6th
Dimensions
22.0
Forward 7th
30.1
Forward 8th
42.0
Reverse 1st
4.7
Reverse 2nd
9.1
Reverse 3rd
17.8
Reverse 4th
34.1
Maximum rim pull
kN {kg}
76.3 {7,785}
Gradeability
deg.
24
Min. turning radius
mm
7,000
Overall length
mm
8,540
Overall height
mm
3,145
Wheelbase
mm
6,100
Tandem wheelbase
mm
1,525
Tread Front wheel Rear wheel
01-4
km/h
mm
2,070 2,060
Blade base
mm
2,265
Min. ground clearance
mm
365
GD535-5 (03)
01 Specification
Specifications (Canopy specification)
Item
Unit
GD535-5
Model
Komatsu SAA6D107E-1 4-cycle, water-cooled, in-line, vertical, direct injection type, with turbocharger and air-cooled aftercooler
Type No. of cylinders - bore x stroke Total piston displacement
mm
6 - 107×124
l (cc)
6.69 (6,690) E mode
P mode
Engine rated horsepower
Performance
Engine
q
ISO 9249/SAE J1349 (net)
q
ISO 14396
q
SAE J1995 (gross)
101 {135}/2,000 {2,000} 108 {145}/2,000 {2,000} kW {HP}/ min-1 {rpm}
-
115 {153}/2,000 {2,000}
107 {143}/2,000 {2,000} 115 {154}/2,000 {2,000} Nm {kgm}/ min-1 {rpm}
658 {67.1}/1,450 {1,450}
g/kWh {g/HPh}
246 {184}
Max. speed with no load
min-1 {rpm}
2,280 {2,280}
Min. speed with no load
min-1 {rpm}
825 {825}
Max. torque Fuel consumption ratio at rated horsepower (in high power mode)
Starting motor Alternator Battery Radiator core type
24 V, 4.5 kW 24 V, 35 A or 60 A 12 V, 112 Ah Corrugated (aluminum)
a The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horsepower measured on the basic engine unit, while net denotes the measured value of an engine under conditions that are essentially the same as those when it is installed on a machine.
GD535-5 (03)
01-5
Specifications (Canopy specification)
Item
01 Specification
Unit
GD535-5
Torque converter -
3-element, 1-stage, 2-phase, with hydraulically actuated wet type disc for lockup
Type
-
Counter-shaft type, full automatic electronically controlled automatic gear shift, pump feed lubrication
Gear range
-
8-forward and 4-reverse
-
Spiral bevel gear and planet gear type, splash lubrication
-
Double row, chain-drive type, splash lubrication
-
Reverse Elliot type, angular type, hydraulic leaning
Type
Power train
Transmission
Final drive Type Tandem drive Type Front axle
Axle
Type Max. leaning angle
deg.
16
Rear axle
Tire
Type
-
Full floating, tandem type
Size
-
13.00-24-12PR
Rim size
-
9.00/1.5×24
Inflation pressure Front wheel Rear wheel
kPa {kg/cm2}
260 {2.6} 260 {2.6}
Service brake Braking method
Brake
Brake type
Rear 4-wheel braking -
Operation method
Hydraulically operated type
Parking brake Braking method Brake type
Final drive input shaft braking -
Steering
Operation method
01-6
Wet, multiple disc type
Type
Dry, single disc type Spring applied and hydraulically released
-
Full hydraulic power steering
Steering angle
deg.
49
Articulation angle
deg.
25
GD535-5 (03)
01 Specification
Specifications (Canopy specification)
Item
Unit
GD535-5
Work equipment and steering pump Type Discharged volume
-
Gear type
cm /rev
40.2+20.4
3
Power train pump Type Discharged volume
-
Gear type
cm3/rev
63.5
Power train pump and differential lock pump (*1) Type Discharged volume
-
Gear type
cm3/rev
63.5+10.5
Brake pump Type Discharged volume
-
Gear type
cm3/rev
20.4
Control valve
Hydraulic system
Type Set pressure
-
9-spool type
MPa {kg/cm2}
19.6 {200}
Steering valve Type Set pressure
MPa {kg/cm2}
Orbitrol type 18.1 {185}
Steering cylinder Type
-
Double-acting piston type
Cylinder bore
mm
50
Piston rod outer diameter
mm
35
Stroke
mm
330
Max. distance between pins
mm
911.5
Min. distance between pins
mm
581.5
Leaning cylinder Type
-
Double-acting piston type
Cylinder bore
mm
75
Piston rod outer diameter
mm
40
Stroke
mm
160
Max. distance between pins
mm
608.5
Min. distance between pins
mm
448.5
*1: For machines with differential lock type rear axle
GD535-5
01-7
Specifications (Canopy specification)
Item
01 Specification
Unit
GD535-5
Articulate cylinder Type
-
Double-acting piston type
Cylinder bore
mm
75
Piston rod outer diameter
mm
45
Stroke
mm
420
Max. distance between pins
mm
1,131
Min. distance between pins
mm
711
Blade lift cylinder Type
-
Double-acting piston type
Cylinder bore
mm
80
Piston rod outer diameter
mm
50
Stroke
mm
1,000
Max. distance between pins
mm
1,520
Min. distance between pins
mm
520
Hydraulic system
Blade shift cylinder Type
-
Double-acting piston type
Cylinder bore
mm
80
Piston rod outer diameter
mm
50
Stroke
mm
1,250
Max. distance between pins
mm
2,789
Min. distance between pins
mm
1,539
Power tilt cylinder Type
-
Double-acting piston type
Cylinder bore
mm
80
Piston rod outer diameter
mm
40
Stroke
mm
300
Max. distance between pins
mm
890
Min. distance between pins
mm
590
Drawbar shift cylinder Type
01-8
-
Double-acting piston type
Cylinder bore
mm
80
Piston rod outer diameter
mm
45
Stroke
mm
450
Max. distance between pins
mm
1,335
Min. distance between pins
mm
885
GD535-5
01 Specification
Specifications (Canopy specification)
Work equipment
Item
Unit
GD535-5
Blade length
mm
3,710
Blade height
mm
645
Blade thickness
mm
16
Cutting edge length
mm
1,829
Cutting edge width
mm
152
Cutting edge thickness
mm
15.9
Max. lift above ground
mm
480
Max. drop below ground
mm
565
kN {kg}
63.8 {6,510}
deg.
360
mm
625±154
Blade load Turning angle Blade side shift amount (move by cylinder + move by bolt adjustment) L.H. blade side shift R.H. blade side shift
625±154
Blade tipping angle Forward Rearward
GD535-5 (03)
deg.
40 3
01-9
Specifications (Cab specification)
01 Specification
Specifications (Cab specification)
Weight
Item
1
Unit
GD535-5
Operating weight (including one operator weighing 75 kg)
kg
13,760 [14,400]
Load on front axle
kg
3,730 [4,250]
Load on rear axle
kg
10,030 [10,150]
Travel speed Forward 1st
4.3
Forward 2nd
6.1
Forward 3rd
8.2
Forward 4th
11.6
Forward 5th
16.2
Performance
Forward 6th
22.7
Forward 7th
31.1
Forward 8th
43.4
Reverse 1st
4.8
Reverse 2nd
9.4
Reverse 3rd
18.4
Reverse 4th
35.2
Maximum rim pull
Dimensions
km/h
kN {kg}
78.7 {8,024} [79.6 {8,120}]
Gradeability
deg.
24
Min. turning radius
mm
7,000
Overall length
mm
8,565
Overall height
mm
3,410
Wheelbase
mm
6,100
Tandem wheelbase
mm
1,525
Tread Front wheel Rear wheel
mm
2,070 2,060
Blade base
mm
2,265
Min. ground clearance
mm
365
a [ ]: with scarifier
01-9-1
GD535-5 (03)
01 Specification
Specifications (Cab specification)
Item
Unit
GD535-5
Model
Komatsu SAA6D107E-1 4-cycle, water-cooled, in-line, vertical, direct injection type, with turbocharger and air-cooled aftercooler
Type No. of cylinders - bore x stroke Total piston displacement
mm
6 - 107×124
l (cc)
6.69 (6,690) E mode
P mode
Engine rated horsepower
Performance
Engine
q
ISO 9249/SAE J1349 (net)
q
ISO 14396
q
SAE J1995 (gross)
101 {135}/2,000 {2,000} 108 {145}/2,000 {2,000} kW {HP}/ min-1 {rpm}
-
115 {153}/2,000 {2,000}
107 {143}/2,000 {2,000} 115 {154}/2,000 {2,000} Nm {kgm}/ min-1 {rpm}
658 {67.1}/1,450 {1,450}
g/kWh {g/HPh}
246 {184}
Max. speed with no load
min-1 {rpm}
2,280 {2,280}
Min. speed with no load
min-1 {rpm}
825 {825}
Max. torque Fuel consumption ratio at rated horsepower (in high power mode)
Starting motor Alternator Battery Radiator core type
24 V, 4.5 kW 24 V, 60 A 12 V, 112 Ah or 120 Ah Corrugated (aluminum)
a The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horsepower measured on the basic engine unit, while net denotes the measured value of an engine under conditions that are essentially the same as those when it is installed on a machine.
GD535-5 (03)
01-9-2
Specifications (Cab specification)
Item
01 Specification
Unit
GD535-5
Torque converter -
3-element, 1-stage, 2-phase, with hydraulically actuated wet type disc for lockup
Type
-
Counter-shaft type, full automatic electronically controlled automatic gear shift, pump feed lubrication
Gear range
-
8-forward and 4-reverse
-
Spiral bevel gear and planet gear type, splash lubrication
-
Double row, chain-drive type, splash lubrication
-
Reverse Elliot type, angular type, hydraulic leaning
Type
Power train
Transmission
Final drive Type Tandem drive Type Front axle
Axle
Type Max. leaning angle
deg.
16
Rear axle
Tire
Type
-
Full floating, tandem type
Size
-
14.00-24-12PR
Rim size
-
9.00/1.5×24
Inflation pressure Front wheel Rear wheel
kPa {kg/cm2}
260 {2.6} 260 {2.6}
Service brake Braking method
Brake
Brake type
Rear 4-wheel braking -
Operation method
Hydraulically operated type
Parking brake Braking method Brake type
Final drive input shaft braking -
Operation method Steering
Wet, multiple disc type
Type
Dry, single disc type Spring applied and hydraulically released
-
Full hydraulic power steering
Steering angle
deg.
49
Articulation angle
deg.
25
01-9-3
GD535-5 (03)
01 Specification
Specifications (Cab specification)
Item
Unit
GD535-5
Work equipment and steering pump Type Discharged volume
-
Gear type
cm /rev
40.2+20.4
3
Power train pump Type Discharged volume
-
Gear type
cm3/rev
63.5
Power train pump and differential lock pump (*1) Type Discharged volume
-
Gear type
cm3/rev
63.5+10.5
Brake pump Type Discharged volume
-
Gear type
cm3/rev
20.4
Control valve
Hydraulic system
Type Set pressure
-
9-spool type
MPa {kg/cm2}
19.6 {200}
Steering valve Type Set pressure
MPa {kg/cm2}
Orbitrol type 18.1 {185}
Steering cylinder Type
-
Double-acting piston type
Cylinder bore
mm
50
Piston rod outer diameter
mm
35
Stroke
mm
330
Max. distance between pins
mm
911.5
Min. distance between pins
mm
581.5
Leaning cylinder Type
-
Double-acting piston type
Cylinder bore
mm
75
Piston rod outer diameter
mm
40
Stroke
mm
160
Max. distance between pins
mm
608.5
Min. distance between pins
mm
448.5
*1: For machines with differential lock type rear axle
GD535-5 (03)
01-9-4
Specifications (Cab specification)
Item
01 Specification
Unit
GD535-5
Articulate cylinder Type
-
Double-acting piston type
Cylinder bore
mm
75
Piston rod outer diameter
mm
45
Stroke
mm
420
Max. distance between pins
mm
1,131
Min. distance between pins
mm
711
Blade lift cylinder Type
-
Double-acting piston type
Cylinder bore
mm
80
Piston rod outer diameter
mm
50
Stroke
mm
1,000
Max. distance between pins
mm
1,520
Min. distance between pins
mm
520
Blade shift cylinder Hydraulic system
Type
-
Double-acting piston type
Cylinder bore
mm
80
Piston rod outer diameter
mm
50
Stroke
mm
1,250
Max. distance between pins
mm
2,789
Min. distance between pins
mm
1,539
Power tilt cylinder Type
-
Double-acting piston type
Cylinder bore
mm
80
Piston rod outer diameter
mm
40
Stroke
mm
300
Max. distance between pins
mm
890
Min. distance between pins
mm
590
Drawbar shift cylinder Type
01-9-5
-
Double-acting piston type
Cylinder bore
mm
80
Piston rod outer diameter
mm
45
Stroke
mm
450
Max. distance between pins
mm
1,335
Min. distance between pins
mm
885
GD535-5 (03)
01 Specification
Specifications (Cab specification)
Item
Unit
GD535-5
Scarifier cylinder (*1)
Work equipment
Hydraulic system
Type
-
Double-acting piston type
Cylinder bore
mm
80
Piston rod outer diameter
mm
50
Stroke
mm
355
Max. distance between pins
mm
996
Min. distance between pins
mm
641
Blade length
mm
3,710
Blade height
mm
645
Blade thickness
mm
16
Cutting edge length
mm
1,829
Cutting edge width
mm
152
Cutting edge thickness
mm
15.9
Max. lift above ground
mm
500
Max. drop below ground
mm
545
kN {kg}
58.1 {5,920} [66.2 {6,760}]
deg.
360 [130]
mm
625±154
Blade load Turning angle Blade side shift amount (move by cylinder + move by bolt adjustment) L.H. blade side shift R.H. blade side shift
625±154
Blade tipping angle Forward Rearward
a
deg.
40 3
[ ]: with scarifier
GD535-5 (03)
01-9-6
Weight table
01 Specification
Weight table k k
1
This weight table has been prepared for your reference when handling or transporting the components. This weight table shows the dry weight. Unit: kg Item
GD535-5
Engine assembly
585
Cooling system assembly
106
Transmission assembly
810
Power train pump and differential lock pump
11
Final drive assembly
825
Tandem drive assembly
761
Front axle assembly
413
Parking brake assembly (including disc)
23
Tire and rim assembly (13.00-24-12PR) (each)
130
q
Tire (13.00-24-12PR) (each)
68
q
Rim (9.00/1.5×24) (each)
62
Tire and rim assembly (14.00-24-12PR) (each)
144
q
Tire (14.00-24-12PR) (each)
82
q
Rim (9.00/1.5×24) (each)
62
Scarifier assembly
490
Work equipment and steering pump
15
Fuel tank
154
Hydraulic tank
66
Circle rotation gear
10
Steering cylinder assembly
11
Leaning cylinder assembly
14
Articulate cylinder assembly
21
Blade lift cylinder assembly
46
Blade side shift cylinder assembly
48
Power tilt cylinder assembly
19
Drawbar shift cylinder assembly
27
Scarifier cylinder assembly
21
Blade assembly
609
Circle and drawbar assembly
440
Circle rotation gear assembly
107
Front frame assembly
1,598
Rear frame assembly
1,118
Operator's compartment assembly (including controls and operator's seat, canopy assembly)
322
Canopy assembly
537
Operator's compartment assembly (including controls and operator's seat, cab assembly)
415
Cab assembly
825
01-10
GD535-5 (03)
01 Specification
Table of fuel, coolant, and lubricants
Table of fuel, coolant, and lubricants
1
a For details of the notes (Note 1, Note 2...) in the table, see "Operation and Maintenance Manual".
GD535-5 (03)
01-11
Table of fuel, coolant, and lubricants
01 Specification
Unit: l Subject component
Specified capacity
Refill capacity
25.4
23.1
Transmission case
60
45
Hydraulic oil system
107
51.5
Final drive case
14
14
Tandem case (each of R.H. and L.H. cases)
51
51
Circle rotation gear case
4.1
4.1
Cooling system
24
24
Fuel tank
271
-
Engine oil pan
01-12
GD535-5 (03)
10 Structure and function
GD535-5
10-1
Contents
10 Structure and function
Contents
1
Acronyms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Engine and cooling system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Cooling system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Fan drive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Power train system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Power train system drawing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Power train piping drawing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Transmission control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Torque converter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Transmission - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Transmission control valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ECMV - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Main relief valve and torque converter relief valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Front axle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Rear axle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Differential (Non-differential specification) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Differential (Differential lock specification) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Differential lock solenoid valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Final drive- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Tandem drive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Steering system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Steering piping drawing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Priority valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Steering valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Brake system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Hydraulic piping drawing of brake system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Brake valve- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Brake circuit accumulator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Brake circuit accumulator charge valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Wheel brake - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Parking brake solenoid valve and lifter lock pin solenoid valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Parking brake - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Undercarriage and frame - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Frame - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Tire - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Hydraulic system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Hydraulic system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Hydraulic piping drawing of work equipment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Work equipment control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Hydraulic tank - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Work equipment pump and steering pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Power train pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Power train pump and differential lock pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Brake pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Control valve- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Functions and valve operations- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Hydraulic cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Swivel joint - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Pilot check valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Work equipment system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Circle and drawbar - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Blade - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Lifter- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
10-2
10-3-1 10-4 10-4 10-6 10-7 10-7 10-8 10-9 10-10 10-14 10-33 10-35 10-42 10-44 10-47 10-48 10-50 10-53 10-54 10-56 10-59 10-59 10-60 10-65 10-73 10-73 10-74 10-79 10-80 10-86 10-87 10-88 10-89 10-89 10-90 10-92 10-92 10-94 10-96 10-97 10-98 10-99 10-100 10-101 10-102 10-104 10-105 10-106 10-107 10-110 10-110 10-112 10-114
GD535-5 (01)
10 Structure and function
Circle rotation motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Circle rotation gear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Cab and its attachments- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ROPS canopy - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ROPS cab - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Machine monitor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Automatic gear shift control system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Transmission controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Engine controller- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - KOMTRAX system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - KOMTRAX terminal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Engine starting circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Engine stop circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Preheating circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Sensors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Engine power mode selector circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
GD535-5 (03)
Contents
10-116 10-118 10-120 10-120 10-121 10-122 10-122 10-133 10-140 10-143 10-146 10-147 10-149 10-151 10-152 10-153 10-162
10-3
Acronyms
10 Structure and function
Acronyms q q q q
1
The abbreviations of unknown parts, equipment and functions have been extracted from the Shop Manual, and their official names and details are defined in this Acronyms. Abbreviations that are commonly used in society might not be described. Special and rarely used abbreviations are described in the supplementary explanation in the text. The acronyms consist of two parts: the list of abbreviations that are used in the text, and the list of abbreviations that are used in circuit diagrams.
Abbreviations that are used in the text Abbreviations
Official name
Application (Applicable models (*1) and equipment) Traveling, brake
ABS
Antilock Brake System
AISS
Automatic Idling Setting Engine System
AJSS
Advanced Joystick Steering System
ARAC
Automatic Retarder Accelerator Control
(HD series, HM series)
Steering (WA series) Traveling, brake (HD series, HM series) Traveling, brake
ARSC
Automatic Retarder Speed Control
ASR
Automatic Spin Regulator
ATT
Attachment
BCV
Brake Cooling oil control Valve
CAN
(HD series, HM series) Traveling, brake (HD series, HM series) Work equipment
Explanation With this function, when the tires skid (wheels stop rotating), the brakes are released, and when the wheels start to rotate, the brakes are applied again. This function automatically sets the idle speed. A lever is used to perform the steering operations instead of a steering wheel. Moreover, it shifts gear and changes direction (FORWARD or REVERSE). When the accelerator pedal is released while the machine is traveling downhill, this function automatically applies the retarder with a constant braking force. When the accelerator pedal is released while the machine is traveling downhill, this function automatically applies the retarder to ensure that the machine speed does not accelerate above the speed set by the operator. When the tires spin on soft ground surfaces, this function automatically uses the optimum braking force to drive both wheels. The function or parts which are attached to the standard model and used
(HD series)
When the retarder is not being used, this valve bypasses part of the brake cooling oil to reduce the load on the hydraulic pump.
Controller Area Network
Communication, electronic control
One of communication standards that is used in the network on the machine
CDR
Crankcase Depression Regulator
Engine
A regulator valve which is installed to KCCV ventilator. It is written as CDR valve and it is not used independently.
CLSS
Closed-center Load Sensing System
Hydraulic system
This system can simultaneously actuate multiple actuators regardless of the load (provides better combined operation than OLSS).
Engine
Engine controller electronically controls supply pump, common rail, and injector. This function maintains optimum fuel injection amount and fuel injection timing.
Electronic control
Electronic control device that receives signals from each sensor of the machine and that specifies the optimum operation to the actuators. (Same as ECU)
CRI
Common Rail Injection
ECM
Electronic Control Module
10-3-1
Brake
1
GD535-5 (03)
10 Structure and function
Abbreviations
Official name
ECMV
Electronic Control Modulation Valve
ECSS
Electronically Controlled Suspension System
Acronyms
Application (Applicable models (*1) and equipment) Transmission (D series, HD series, WA series and others) Traveling (WA series)
Explanation Proportional solenoid valve that reduces the connection shock by gradually increasing the hydraulic pressure to engage the clutch. This system ensures smooth high-speed travel by absorbing vibration of machine during travel with hydraulic spring effect of accumulator.
ECU
Electronic Control Unit
Electronic control
Electronic control device that receives signals from each sensor of the machine and that specifies the optimum operation to the actuators. (Same as ECM)
EGR
Exhaust Gas Recirculation
Engine
This function recirculates part of exhaust gas to the combustion chamber in order to reduce combustion temperature and control the emission of NOx.
Equipment Management Monitoring System
Machine monitor
This system allows data (filter, oil replacement interval, malfunctions on machine, failure code, and failure history) from each sensor on the machine to be checked on the monitor.
EPC
Electromagnetic Proportional Control
Hydraulic system
Electromagnetic proportional control This mechanism allows actuators to be operated in proportion to the current supplied.
FOPS
Falling Object Protective Structure
Operator's cab, canopy
F-N-R
Forward-NeutralReverse
Operation
Forward-Neutral-Reverse
Communication
GPS
Global Positioning System
Global positioning system The satellite positioning system to determine the current position on the earth
GNSS
Global Navigation Satellite System
EMMS
This structure protects the operator's head from falling objects. (Falling Object Protective Structure) This performance is standardized as ISO 3449.
(KOMTRAX, KOMTRAX Plus) Communication (KOMTRAX, KOMTRAX Plus) Steering
Global navigation satellite system A general term for positioning system using satellites such as GPS, GALILEO, etc. This function uses a combination of hydraulic motor and bevel shaft to control difference in travel speed of right and left tracks. Accordingly machine can turn without using steering clutch.
HSS
Hydrostatic Steering System
HST
Hydro Static Transmission
ICT
Information and Communication Technology
Communication, electronic control
A general term for the engineering and its socially applied technology of information processing and communication.
IMA
Inlet Metering Actuator
Engine
Valve that adjusts fuel intake amount at inlet port of pump in order to control fuel discharged volume of supply pump. (Same as IMV)
IMU
Inertial Measurement Unit
Engine
This is a device to detect the angle (or angular velocity) and acceleration of the 3 axes that control motions.
IMV
Inlet Metering Valve
Engine
Valve adjusting fuel intake amount at inlet port of pump in order to control fuel discharged volume of supply pump. (Same as IMA)
GD535-5 (01)
(D series) Transmission (D series, WA series)
This function uses a combination of hydraulic pump and hydraulic motor to shift the speed range steplessly without using gears.
10-3-2
Acronyms
Abbreviations
10 Structure and function
Official name
Application (Applicable models (*1) and equipment)
KCCV
KOMATSU Closed Crankcase Ventilation
Engine
KCSF
KOMATSU Catalyzed Soot Filter
Engine
KDOC
KOMATSU Diesel Oxidation Catalyst
Engine
KDPF
KOMATSU Diesel Particulate Filter
Explanation The mechanism for oil separation from gas in order to re-burn the blow-by gas and for oil return to the intake system. It is mainly composed of filters. The filter to capture the soot from exhaust gas. It is built in the KDPF. The catalyst for exhaust gas purification.
Engine
It may be built in the KDPF or combined with the muffler. This component is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it. It is used instead of the conventional muffler.
Traveling, brake
This function recovers the drive force of the wheels by braking automatically with the optimum force and at the same time activates the inter-axle differential lock when the wheels idle while the machine travels on the soft ground road.
KOMATSU Traction Control System
(HM series)
LCD
Liquid Crystal Display
Machine monitor
The liquid crystal display panel. Image display device such as a monitor which assembles in the liquid crystal element.
LED
Light Emitting Diode
Electronic components
Light emitting diode It refers to semiconductor element that emits light when the voltage is applied in forward direction.
LIN
Local Interconnect Network
Communication, electronic control
One of communication standards that is used in the network on the machine
LS
Load Sensing
Hydraulic system
Function that detects differential pressure of pump and controls discharged volume corresponding to load.
KTCS
Low Voltage Differential Communication, electronic Signaling control
One of communication standards that is used in the network on the machine
MAF
Mass Air Flow
Engine
The intake airflow rate of the engine. It is not used alone, but used in combination with sensors. The intake airflow sensor may be called the MAF sensor.
MMS
Multimedia Messaging Service
Communication
The service to allow transmission and reception of short messages such as characters, voice and images between mobile phones.
Normally Closed
Electric system, hydraulic system
The characteristics of an electric or hydraulic circuit that is normally closed when the system is not operating, and that is normally opened when the system is operating.
Normally Open
Electric system, hydraulic system
The characteristics of an electric or hydraulic circuit that is normally opened when the system is not operating, and that is normally closed when the system is operating.
Open-center Load Sensing System
Hydraulic system
The hydraulic system that can simultaneously operate multiple actuators regardless of the load.
Pressure Compensation
Hydraulic system
The function to compensate for the hydraulic pressure.
LVDS
NC
NO
OLSS PC
10-3-3
GD535-5 (01)
10 Structure and function
Abbreviations
Official name
Acronyms
Application (Applicable models (*1) and equipment)
Explanation
Steering Palm Command Control System (D series)
The function to make the controller analyze the lever, pedal, and dial data instantaneously, and to allow the electronic control of engine, transmission and others appropriately.
PCV
Pre-stroke Control Valve
Engine
This valve is installed at inlet port of pump and it adjusts fuel intake amount in order to control fuel discharged volume of supply pump.
PPC
Proportional Pressure Control
Hydraulic system
Used for controlling proportional pressure. This system moves actuators in proportion to the hydraulic pressure.
PPM
Piston Pump and Motor
PTO
Power Take Off
Power transmission
Power take-off mechanism
PTP
Power Tilt and power Pitch dozer
Work equipment (D series)
This function performs hydraulic control of the tilt and pitch of the bulldozer blade.
Operator's cab, canopy
The structure to protect the operator (fastened with seat belt) if the machine falls. (Roll-over protective structure for operator)
PCCS
ROPS
Roll-Over Protective Structure
Hydraulic system (D series, PC series, others)
Piston hydraulic pump and motor.
This performance is standardized as ISO 3471.
Selective Catalytic Reduction
Urea SCR system
The exhaust gas purification device, that uses urea water and converts the nitrogen oxides (NOx) into harmless nitrogen and water (by reduction reaction). It may be called part of the exhaust gas purifying catalyst or the related device name.
Le Systeme International d’ Unites
Unit
Abbreviated for the "International System of Units". It is the universal unit system and "A single unit for a single quantity" is the basic principle applied.
SOL
Solenoid
Electrical system
It refers to an actuator consisting of a solenoid and an iron core that is moved by the magnetic force when the solenoid is energized.
TWV
2-Way Valve
Hydraulic system
Solenoid valve that switches over direction of flow.
VGT
Variable Geometry Turbocharger
Engine
Turbocharger having the variable geometry of exhaust passage
SCR
SI
*1: Applicable model codes D: Bulldozer HD: Dump truck HM: Articulated dump truck PC: Hydraulic excavator WA: Wheel loader
GD535-5 (03)
10-3-4
Acronyms
10 Structure and function
Abbreviations used in circuit diagrams Abbreviations Air Conditioner
A/D
Analogue-to-Digital
A/M
Air Mix damper
ACC
Accessory
ADD
Additional
AUX
Auxiliary
BR
Battery Relay
CW
Clockwise
CCW
Counter Clockwise
ECU
Electronic Control Unit
ECM
Electronic Control Module
ENG
Engine External Ground
F.G.
Frame Ground
GND
Ground
IMA
Inlet Metering Actuator
NC
No Connection
S/T STRG
Steering
SIG
Signal
SOL
Solenoid
STD
Standard
OPT OP PRESS SPEC SW TEMP
10-3-5
Official name
A/C
EXGND
1
Option Pressure Specification Switch Temperature
T/C
Torque Converter
T/M
Transmission
GD535-5 (01)
10 Structure and function
1
GD535-5 (01)
10-3-6
Cooling system
10 Structure and function
Engine and cooling system
1
Cooling system
1
10-4
GD535-5
10 Structure and function
Cooling system
A: Power train oil cooler inlet B: Power train oil cooler outlet
C: Hydraulic oil cooler inlet D: Hydraulic oil cooler outlet
1. 2. 3. 4. 5. 6. 7.
8. Shroud 9. Power train oil cooler 10. Aftercooler 11. Radiator 12. Reservoir tank 13. Hydraulic oil cooler 14. Aftercooler outlet hose
Aftercooler inlet hose Radiator inlet hose Radiator cap Drain valve Radiator outlet hose Cooling fan Fan guard
Specifications Radiator
Power train oil cooler
Aftercooler
Core type
CF90-4
CF91-1
CF69
Fin pitch (mm)
3.5/2
3.5/2
4.0/2
Total heat dissipation area (m2)
49.19
4.51
20.91
Cracking pressure of pressure valve (kPa {kg/cm2})
70 ± 15 {0.7±0.15}
-
-
Cracking pressure of vacuum valve (kPa {kg/cm2})
0 to 5 {0 to 0.05}
-
-
GD535-5
10-5
Fan drive
Fan drive
1. 2. 3. 4.
10 Structure and function
1
Fan drive pulley Drive pulley Tension pulley V-belt
10-6
GD535-5
10 Structure and function
Power train system drawing
Power train system
1
Power train system drawing
1
Outline q Power from the engine is transmitted to transmission (2) through torque converter (1). q Counter-shaft type transmission (2) is hydraulically controlled and can provide "8 forward and 4 reverse speeds". q Power from transmission (2) is transmitted to differential (4) through drive shaft (3). q Differential (4) makes 90-degree directional change of the power and transmit it to final drive (5). q Final drive (5) finally reduces the power and transmits it to tandem drive (7) through shaft (6). q Chain (8) in tandem drive (7) transmits the power from shaft (6) to hub shaft (9). q The power transmitted to hub shaft (9) drives tire (10) to make the machine travel.
GD535-5
10-7
Power train piping drawing
10 Structure and function
Power train piping drawing
1. Differential lock pump (*1) 2. Power train pump 3. Power train pump outlet tube 4. Power train oil filter outlet hose 5. Power train oil cooler 6. Power train oil cooler inlet hose 7. Power train oil cooler outlet hose
1
8. Power train oil filter 9. Differential lock pump outlet hose (*1) 10. Differential lock pump inlet hose (*1) 11. Power train pump inlet tube 12. Transmission 13. Transmission oil filer/dipstick port 14. Differential lock solenoid valve (*1)
*1: For machines with differential lock type rear axle
10-8
GD535-5 (03)
10 Structure and function
Transmission control
Transmission control
1
1. Transmission controller 2. Gear shift lever 3. Transmission mode selector switch
GD535-5
10-9
Torque converter
10 Structure and function
Torque converter
1. PTO drive gear (number of teeth: 70) 2. Pump 3. Drive case 4. Stator 5. Turbine 6. Damper 7. Lockup clutch piston 8. Lockup clutch housing (number of teeth: 72) 9. Pilot 10. Boss 11. Disc 12. One-way clutch
10-10
1
13. Race 14. Guide 15. Stator shaft Specifications Type
Lockup clutch Stall torque ratio
3-element, 1-stage, 2-phase With lockup clutch Wet, single disc clutch Hydraulically controlled (With modulation mechanism) 2.71
GD535-5
10 Structure and function
Torque converter
Power transmission route With lockup clutch disengaged
With lockup clutch "engaged"
Because drive case (3) disconnected from boss (10) and turbine (9), the torque converter works as a normal torque converter.
Since drive case (3) is connected to damper (8), boss (10), and turbine (9), the torque converter provides lockup function.
Power generated in the engine
Power generated in the engine
↓ Flywheel (1)
↓ Flywheel (1)
↓ Clutch housing (2)
↓ Clutch housing (2)
↓ Drive case (3), pump (5), and PTO drive gear (6) rotate as a unit. ↓
↓ Lockup clutch (4) ↓ Damper (8)
Oil works as a power transmission medium. ↓
↓ Boss (10)
Turbine (9) and boss (10) ↓
↓ Transmission input shaft (11)
Transmission input shaft (11) q q
The power transmitted to PTO drive gear (6) is used to drive the pump through PTO idler gear (7).
GD535-5
The power transmitted to PTO drive gear (6) is used to drive the pump through PTO idler gear (7).
10-11
Torque converter
10 Structure and function
Flow of oil
q
q q
The pressure of oil that has passed through the main relief valve is regulated below the set pressure by the torque converter relief valve. Then the oil enters inlet port (A) and flows to pump (3) through the oil paths of stator shaft (1) and guide (2). The oil is moved via centrifugal force by pump (3) and enters turbine (4) to power it. The oil from turbine (4) is sent to stator (5) and enters pump (3) again. Some oil passes between turbine (4) and stator (5) and flows from outlet port (B) to lubricate the transmission through the oil cooler.
10-12
GD535-5
10 Structure and function
GD535-5
Torque converter
10-13
Transmission
Transmission
10-14
10 Structure and function
1
GD535-5
10 Structure and function
A: From power train oil filter B: To power train oil cooler C: From power train oil cooler D: To power train pump E: Work equipment pump and steering pump mounting location F: Power train pump mounting location (*1) G: Oil filer pipe mounting location
Transmission
1. Transmission control valve 2. Main relief valve, torque converter relief valve 3. Torque converter internal pressure sensor 4. Torque converter oil temperature sensor 5. Transmission case (rear) 6. Transmission case (front) 7. Transmission oil temperature sensor 8. Transmission intermediate shaft speed sensor 9. Transmission output shaft speed sensor 10. Transmission input shaft speed sensor
*1. Power train pump and differential lock pump mounting location for machines with differential lock type rear axle
GD535-5
10-15
Transmission
1. 2. 3. 4. 5. 6. 7. 8.
Torque converter Input shaft FL clutch Upper shaft FH clutch Lower shaft 3rd clutch Coupling
10-16
10 Structure and function
9. 4th clutch 10. Output shaft 11. 2nd clutch 12. 1st clutch 13. R clutch 14. PTO idler gear A (number of teeth: 61) 15. PTO driven gear A (number of teeth: 62)
GD535-5
10 Structure and function
1. 2. 3. 4. 5. 6. 7.
Transmission
PTO driven gear B (number of teeth: 62) PTO idler gear B (number of teeth: 61) R idler gear (number of teeth: 35) Strainer Drain plug Drain plug Drain plug
GD535-5
10-17
Transmission
Outline q The transmission is a combination of the countershaft type constant mesh gear mechanism and disc clutches and provides "8 forward and 4 reverse speeds". q The transmission selects one rotation direction and one gear speed by fixing 2 of the 7 disc clutches hydraulically via the operation of the ECMV in the counter-shaft type constant mesh gear mechanism. q The transmission receives the power from the input shaft and transfers it to the output shaft while changing its speed to the forward 1st to 8th or reverse 1st to 4th by combining the FL, FH, and R clutches and 4-speed clutches.
10-18
10 Structure and function
Number of plates and discs used Clutch No.
Number of plates
Number of discs
FL clutch
9
8
FH clutch
12
11
R clutch
9
8
1st clutch
7
6
2nd clutch
12
11
3rd clutch
9
8
4th clutch
7
6
Table of clutch combination and reduction ratio for each gear speed Gear speed
Clutches used
Reduction ratio
Forward 1st
FL and 1st
6.773
Forward 2nd
FH and 1st
4.787
Forward 3rd
FL and 2nd
3.499
Forward 4th
FH and 2nd
2.473
Forward 5th
FL and 3rd
1.771
Forward 6th
FH and 3rd
1.251
Forward 7th
FL and 4th
0.900
Forward 8th
FH and 4th
0.636
NEUTRAL
-
-
Reverse 1st
R and 1st
5.957
Reverse 2nd
R and 2nd
3.077
Reverse 3rd
R and 3rd
1.557
Reverse 4th
R and 4th
0.791
GD535-5
10 Structure and function
Transmission
FL and R clutches
A: FL clutch oil port B: R clutch oil port
C: Lubricating oil port D: Lockup clutch oil port
1. 2. 3. 4.
5. FL clutch gear (number of teeth: 34) 6. Input gear (number of teeth: 42) 7. Input shaft
R clutch gear (number of teeth: 27) R clutch FL and R cylinder FL clutch
GD535-5
10-19
Transmission
10 Structure and function
FH and 1st clutches
A: FH clutch oil port B: 1st clutch oil port
C: Lubricating oil port
1. 2. 3. 4.
5. FH clutch 6. FH clutch gear (number of teeth: 55) 7. Upper shaft
Upper gear (number of teeth: 44) 1st clutch gear (number of teeth: 28) 1st clutch FH and 1st cylinder (number of teeth: 63)
10-20
GD535-5
10 Structure and function
Transmission
2nd and 3rd clutches
A: 3rd clutch oil port B: 2nd clutch oil port
C: Lubricating oil port
1. 2nd clutch gear (number of teeth: 69) 2. 2nd clutch 3. 2nd and 3rd cylinder (number of teeth: 85 and 49)
4. 3rd clutch 5. 3rd clutch gear (number of teeth: 67 and 50) 6. Lower shaft
GD535-5
10-21
Transmission
10 Structure and function
4th clutch
A: 4th clutch oil port B: Lubricating oil port 1. 4th cylinder (number of teeth: 59) 2. 4th clutch
10-22
3. 4th clutch gear (number of teeth: 41) 4. Output shaft
GD535-5
10 Structure and function
Transmission
Operation of disc clutch When clutch is "engaged" (locked)
q
q
The oil sent from the transmission valve flows through the oil path in shaft (1) to the backside of piston (5) and activates piston (5). When piston (5) is activated, it presses separator plate (2) against friction plate (3). This causes integration of shaft (1) and clutch gear (4), allowing the power to be transmitted. At this time, while some oil drains through oil drain hole (a), the clutch operation is not affected because the amount of oil drained is much less than the oil supply.
GD535-5
When clutch is disengaged (released)
q
q
q
The oil sent from the transmission valve is blocked and the pressure of oil acting on the rear of piston (5) drops. Piston (5) is returned to the original position by wave spring (6). This causes separation of shaft (1) and clutch gear (4). Oil drain hole (a) serves to spin-drain the oil from the rear of the piston so that the clutch will not be left in a partially engaged state.
a The structure of oil drain hole (a) is that of the 2nd, 3rd, and 4th clutches.
10-23
Transmission
10 Structure and function
Power transmission route Forward 1st
FL clutch (3) and 1st clutch (11) are hydraulically locked. Power from torque converter ↓ Input shaft (1) ↓ FL and R cylinder (2) ↓ FL clutch (3) ↓ FL clutch gear (5) ↓ FH and 1st cylinder (12) ↓ (Continues to top center) →
10-24
→ (Continues from lower left) ↓ 1st clutch (11) ↓ 1st clutch gear (14) ↓ 2nd and 3rd cylinder (20) ↓ 4th cylinder (25) ↓ Output shaft (26)
GD535-5
10 Structure and function
Transmission
Forward 2nd
FH clutch (10) and 1st clutch (11) are hydraulically locked. Power from torque converter ↓ Input shaft (1) ↓ Input gear (7) ↓ FH clutch gear (9) ↓ FH clutch (10) ↓ FH and 1st cylinder (12) ↓ 1st clutch (11) ↓ (Continues to upper right) →
GD535-5
→ (Continues from lower left) ↓ 1st clutch gear (14) ↓ 2nd and 3rd cylinder (20) ↓ 4th cylinder (25) ↓ Output shaft (26)
10-25
Transmission
10 Structure and function
Forward 3rd
FL clutch (3) and 2nd clutch (18) are hydraulically locked. Power from torque converter ↓ Input shaft (1) ↓ FL and R cylinder (2) ↓ FL clutch (3) ↓ FL clutch gear (5) ↓ FH and 1st cylinder (12) ↓ Upper shaft (13) ↓ (Continues to top center) →
10-26
→ (Continues from lower left) ↓ Upper gear (15) ↓ 2nd clutch gear (16) ↓ 2nd clutch (18) ↓ 2nd and 3rd cylinder (20) ↓ 4th cylinder (25) ↓ Output shaft (26)
GD535-5
10 Structure and function
Transmission
Forward 4th
FH clutch (10) and 2nd clutch (18) are hydraulically locked. Power from torque converter ↓ Input shaft (1) ↓ Input gear (7) ↓ FH clutch gear (9) ↓ FH clutch (10) ↓ FH and 1st cylinder (12) ↓ Upper shaft (13) ↓ (Continues to top center) →
GD535-5
→ (Continues from lower left) ↓ Upper gear (15) ↓ 2nd clutch gear (16) ↓ 2nd clutch (18) ↓ 2nd and 3rd cylinder (20) ↓ 4th cylinder (25) ↓ Output shaft (26)
10-27
Transmission
10 Structure and function
Forward 5th
FL clutch (3) and 3rd clutch (19) are hydraulically locked. Power from torque converter ↓ Input shaft (1) ↓ FL and R cylinder (2) ↓ FL clutch (3) ↓ FL clutch gear (5) ↓ FH and 1st cylinder (12) ↓ 3rd clutch gear (17) ↓ (Continues to upper right) →
10-28
→ (Continues from lower left) ↓ 3rd clutch (19) ↓ 2nd and 3rd cylinder (20) ↓ 4th cylinder (25) ↓ Output shaft (26)
GD535-5
10 Structure and function
Transmission
Forward 6th
FH clutch (10) and 3rd clutch (19) are hydraulically locked. Power from torque converter ↓ Input shaft (1) ↓ Input gear (7) ↓ FH clutch gear (9) ↓ FH clutch (10) ↓ FH and 1st cylinder (12) ↓ 3rd clutch gear (17) ↓ (Continues to upper right) →
GD535-5
→ (Continues from lower left) ↓ 3rd clutch (19) ↓ 2nd and 3rd cylinder (20) ↓ 4th cylinder (25) ↓ Output shaft (26)
10-29
Transmission
10 Structure and function
Forward 7th
FL clutch (3) and 4th clutch (24) are hydraulically locked. Power from torque converter ↓ Input shaft (1) ↓ FL and R cylinder (2) ↓ FL clutch (3) ↓ FL clutch gear (5) ↓ FH and 1st cylinder (12) ↓ 3rd clutch gear (17) ↓ (Continues to upper right) →
10-30
→ (Continues from lower left) ↓ 4th clutch gear (23) ↓ 4th clutch (24) ↓ 4th cylinder (25) ↓ Output shaft (26)
GD535-5
10 Structure and function
Transmission
Forward 8th
FH clutch (10) and 4th clutch (24) are hydraulically locked. Power from torque converter ↓ Input shaft (1) ↓ Input gear (7) ↓ FH clutch gear (9) ↓ FH clutch (10) ↓ FH and 1st cylinder (12) ↓ 3rd clutch gear (17) ↓ (Continues to upper right) →
GD535-5
→ (Continues from lower left) ↓ 4th clutch gear (23) ↓ 4th clutch (24) ↓ 4th cylinder (25) ↓ Output shaft (26)
10-31
Transmission
10 Structure and function
Reverse 1st
R clutch (4) and 1st clutch (11) are hydraulically locked. Power from torque converter ↓ Input shaft (1) ↓ FL and R cylinder (2) ↓ R clutch (4) ↓ R clutch gear (6) ↓ R idler gear (8) (Through R idler gear (8), rotation direction of output power is reversed.) ↓ (Continues to top center) →
10-32
→ (Continues from lower left) ↓ Upper gear (15) ↓ Upper shaft (13) ↓ FH and 1st cylinder (12) ↓ 1st clutch (11) ↓ 1st clutch gear (14) ↓
→ (From lower center) ↓ 4th cylinder (25) ↓ Output shaft (26)
2nd and 3rd cylinder (20) ↓ (Continues to upper right) →
GD535-5
10 Structure and function
Transmission control valve
Transmission control valve
1
Control valves for lockup control, directional change, and gear shifting
A: FL clutch pressure detection port B: FH clutch pressure detection port C: R clutch pressure detection port D: 1st clutch pressure detection port E: 2nd clutch pressure detection port F: 3rd clutch pressure detection port G: 4th clutch pressure detection port H: Lockup clutch pressure detection port
GD535-5
1. FL clutch ECMV 2. FH clutch ECMV 3. R clutch ECMV 4. 1st clutch ECMV 5. 2nd clutch ECMV 6. 3rd clutch ECMV 7. 4th clutch ECMV 8. Lockup clutch ECMV 9. Seat 10. Last chance filter
10-33
Transmission control valve
10 Structure and function
Outline q The oil from the pump flows into the transmission case through the oil filter, and then divides into the main relief circuit and clutch operation circuit. q The oil, that has been pressure regulated by the main relief valve and branched off to the clutch operation circuit, passes through the last chance filter and activate the clutch. The oil that has been relieved by the main relief valve is supplied to the torque converter. q When the transmission gear is shifted, the ECMV smoothly increases the clutch oil pressure in line with the command current received from the transmission controller to reduce the gear shifting shocks. The ECMV keeps the clutch pressure constant during travel. q When some ECMVs are selected and turned on from among those for FL, FH, and R clutches and 1st to 4th clutches, pressure regulated oil is supplied to the selected clutches to realize required gear speed. q This machine uses three types of ECMVs, which have the following identifications and differences. Print (A) on nameplate
Identification color (B)
Fill switch Operating pressure (MPa {kg/cm2})
Clutches used
OA2******
(*1) Yellow
Provided (0.26 {2.7})
FL, FH, R, and 1st
0E1******
(*1) Pink
Provided (0.26 {2.7})
2nd, 3rd, and 4th
K7*******
-
None
L/U
L/U: Denotes lockup clutch ECMV. *1: ECMVs installed on the transmission assembly are coated with paint, which prevents them from being distinguished by identification color. (ECMVs can be distinguished by identification color ECMV operation table only when they are not installed and coated. ) ECMV Gear speed F1
FL
F8
2nd 3rd
4th
Q
Q
Q Q
Q
Q
Q Q
F6 F7
1st Q
Q
F4 F5
R
Q
F2 F3
FH
Q
Q
Q Q
Q
R1
Q
R2
Q
R3
Q
R4
Q
Q Q Q Q
N
10-34
GD535-5
10 Structure and function
ECMV
ECMV
1
a ECMV: Stands for Electronic Control Modulation Valve. For FL, FH, R, 1st, 2nd, 3rd, and 4th clutches a Do not disassemble them. Doing so requires adjustment to keep their performances.
A: To clutch P: From pump T: Drain DR: Drain P1: Clutch pressure detection port 1. 2. 3. 4. 5. 6. 7.
Fill switch connector Proportional solenoid connector Pressure detection valve Fill switch Proportional solenoid Pressure control valve Nameplate
GD535-5
10-35
ECMV
Outline of ECMV q An ECMV consists of two components, pressure control valve and fill switch. q Pressure control valve This valve receives the current sent from the transmission controller with its proportional solenoid and converts the current to oil pressure. q Fill switch This switch determines at the clutch is filled with oil and has the following functions. 1. Outputs a signal (a fill signal) to the controller as notification that filling is complete when the clutch is filled with oil. 2. Continues to output a signal (a fill signal) to the controller while oil pressure is applied to the clutch as notification that there is a certain degree of oil pressure.
10 Structure and function
ECMV and proportional solenoid q Each ECMV has one proportional solenoid. The proportional solenoid generates the level of thrust shown below corresponding to the command current from the controller. The thrust generated by the proportional solenoid acts on the pressure control valve spool to produce the oil pressure shown below. Therefore, control of the command current enables oil flow and oil pressure to be controlled because the thrust changes and activates the pressure control valve according to the current. Current - Thrust characteristics of proportional solenoid
Thrust - Oil pressure characteristics of proportional solenoid
Range A: Before gear shifting (when oil is being drained) Range B: Filling in process Range C: Pressure regulation Range D: Filling (triggering) in process Point E: Start of filling Point F: End of filling a The logic is designed so that the controller does not recognize when filling is complete even if the fill switch is turned ON during the triggering period (Range D).
10-36
ECMV and fill switch Each ECMV has one fill switch. When the clutch is filled with oil, the fill switch is turned ON by the pressure of the clutch. This signal starts buildup of oil pressure.
q
GD535-5
10 Structure and function
Operation of ECMV q The ECMV is controlled with the command current from the controller to the proportional solenoid and the fill switch output signal The relationships between ECMV proportional solenoid command current, clutch input pressure, and fill switch output signal are shown below.
ECMV
Before gear shifting (when oil is being drained) (Range A in the diagram)
q
Range A: Before gear shifting (when oil is being drained) Range B: Filling in process Range C: Pressure regulation Range D: Filling (triggering) in process Point E: Start of filling Point F: End of filling a The logic is designed so that the controller does not recognize when filling is complete even if the fill switch is turned ON during the triggering period (Range D).
GD535-5
With proportional solenoid (1) is de-energized, pressure control valve (3) drains the oil in clutch port (A) through drain port (T). At this time, fill switch (5) remains OFF because no oil pressure applies to oil pressure detection valve (4).
10-37
ECMV
Filling in process (Range B in the diagram)
q
When no oil is in the clutch, if proportional solenoid (1) is energized, and pressure force that is equal to the solenoid force acts in chamber (B) and pushes pressure control valve (3) to the left. As a result, pump port (P) connects to clutch port (A) and the clutch starts to be filled with oil. When the clutch is filled up with oil, oil pressure detection valve (4) works to turn fill switch (5) ON.
10-38
10 Structure and function
Pressure regulation (Range C in the diagram)
q
When proportional solenoid (1) is energized, the solenoid generates a thrust proportional to the current. The pressure is regulated so that the thrust of this solenoid balances with the sum of the thrust exerted by the clutch port pressure and repulsive force of pressure control valve spring (2).
GD535-5
10 Structure and function
ECMV
For lockup clutch a Do not disassemble them. Doing so requires adjustment to keep their performances.
A: To clutch P: From pump T: Drain DR: Drain P1: Clutch pressure detection port 1. 2. 3. 4. 5.
Proportional solenoid connector Sleeve Proportional solenoid Pressure control valve Nameplate
GD535-5
10-39
ECMV
Outline of ECMV q This valve regulates the clutch pressure to the set pressure and switches the clutch function as well. With modulation waveform clutch pressurization characteristics, this valve realizes smooth lockup clutch engagement and reduces gear shifting shocks. In addition, this prevents generation of peak torque in the power train. As a result, this m a c h i n e p r o v i d e s a c o m f o r ta b l e r i d e a n d increased power train durability.
10 Structure and function
Operation When clutch is disengaged (released)
Switching from torque converter drive to direct drive
At gear shifting (in direct drive)
q
10-40
With proportional solenoid (1) is de-energized, pressure control valve (3) drains the oil in clutch port (A) through drain port (T).
GD535-5
10 Structure and function
ECMV
When clutch is engaged (locked)
q
q
When proportional solenoid (1) is energized, an pressure force that is equal to the solenoid force acts on chamber (B) and pushes pressure control valve (3) to the left. As a result, pump port (P) connects to clutch port (A) and the clutch starts to be filled with oil. When the clutch is filled up with oil, the pressure is regulated so that the thrust of the solenoid balances with the sum of the thrust exerted by the clutch port pressure and repulsive force of pressure control valve spring (2).
GD535-5
10-41
Main relief valve and torque converter relief valve
Main relief valve and torque converter relief valve
10 Structure and function
1
A: Drain (torque converter relief) B: Drain C: From pump D: Drain E: To torque converter P1: Main relief pressure detection port P2: Torque converter relief pressure detection port 1. 2. 3. 4. 5.
Body Piston Torque converter relief valve Piston Main relief valve
10-42
GD535-5
10 Structure and function
Outline
Main relief valve and torque converter relief valve
Operation of main relief valve
Torque converter relief valve q The torque converter relief valve constantly regulates the torque converter inlet circuit pressure below the set pressure to protect the torque converter from abnormally high pressure. Set pressure: 1.02 MPa {10.4 kg/cm2} (Cracking pressure) Main relief valve The main relief valve regulates the pressure in the transmission and parking brake hydraulic circuits to the set pressure. Set pressure: 2.73 MPa {27.9 kg/cm2} (At rated engine speed)
q
q
The oil from the hydraulic pump flows to port (C) through the filter. Then it flows to chamber (F) through orifice (a) in main relief valve (1).
q
When the oil pressure in the circuit increases beyond the set pressure, the oil in chamber (F) pushes piston (2) and the resulting pushing force against the spring force pushes main relief valve (1) leftward. This connects ports (C) and (E). Then, the oil from pump flows through port (E) into the torque converter.
Operation Operation of torque converter relief valve
q
q
The oil relieved through the main relief valve flows through port (E) into the torque converter. It also flows through orifice (b) in torque converter relief valve (3) into chamber (G). When the oil pressure to the torque converter exceeds the set pressure, the oil conducted to chamber (G) pushes piston (4) and the resulting pushing force pushes torque converter relief valve (3) to the right. This connects ports (E) and (A). Then, the oil in port (E) is drained through port (A).
GD535-5
10-43
Front axle
10 Structure and function
Front axle
1. Tie rod 2. Leaning rod 3. Bracket 4. Support axle 5. Leaning cylinder 6. Steering cylinder 7. Hub shaft
10-44
1
Specifications Toe-in angle (degrees)
-5 to 0
Camber angle (degrees)
0
Leaning angle (degrees) (*1)
16
*1: Tilt angle of tire center to the normal from the axle
GD535-5
10 Structure and function
Front axle
Operation of front axle 1. Prevention of tilting and fluctuation of blade q The front axle is mounted on the frame at its center with the center pin and can oscillate 16 degrees. In the same manner as the tandem drive, this mechanism can reduce fluctuation of the blade even when a wheel on one side runs into a bump or falls into a hole. As shown in the figure, the front axles rise by H/2 at its center when either front wheel runs into a bump. Because the front axle can oscillate, the blade moves by H/4 while being kept horizontal.
The blade can fluctuate while being kept horizontal if the front axle does not tilt to a degree that exceeds its oscillation range (16 degrees to the right and left).
2. Prevention of side slipping of front wheel (leaning device) q Front wheels can lean to both sides. This mechanism, called a leaning device, can prevent side slipping of front wheels and reduce the turning radius. In many motor grader operations, a motor grader is operated with the blade set at an advancing angle. In such cases, as the advancing angle increases, the force applied to the blade, that can cause side slipping of front wheels, becomes large. q
The mass distribution ratio to the front and rear wheels is approximately 3:7. If the blade digs into the ground, the load on the front axle is reduced, causing the front wheels to side slip easily. To handle this side-slipping problem, motor graders are designed with front wheels that lean so that it can withstand side slipping and move the center location of the load on the front axle as well as the center of gravity of the machine.
GD535-5
10-45
Front axle
q
10 Structure and function
A motor grader has a wide turning radius because it has a long wheel base and also because the driving mechanism does not have a differential. So, as for the distance S = 2xr that is obtained from tire rotation, if the wheels lean, the wheel with larger loader loaded radius tends to advance faster than the wheel with the smaller loaded radius. As a result, the machine tends to advance in the direction in which wheels are leaning. By using this characteristics, leaning operations can facilitate smaller turning radii. q
10-46
In the reverse operation, the front wheels are leaned in the direction opposite to that of steering wheel rotation (opposite direction to that of forward movement).
GD535-5
10 Structure and function
Rear axle
1. Differential 2. Tandem drive 3. Final drive
GD535-5
Rear axle
1
Outline q When a motor grader is operated with the blade set at an advancing angle or with the machine body inclined, the front of the machine receives a lateral force as a reaction and the machine tends to turn to the right or left. To manage this problem, the machine is required to have straighttravel capability. So, a motor grader usually has no differential function in the rear axle structurally. q When a motor grader conducts operations while it is turning, the tire slip ratio of the rear wheels becomes high due to trajectory differences. In this case, machines with differential lock type rear axles help extend the service lives of tires.
10-47
Differential (Non-differential specification)
Differential (Non-differential specification)
10 Structure and function
1
1. Sun gear shaft (number of teeth: 18) 2. Bevel gear (number of teeth: 43) 3. Coupling 4. Bevel pinion (number of teeth: 12) 5. Cage
10-48
GD535-5
10 Structure and function
Differential (Non-differential specification)
Operation
q
q
q
Power from the transmission is input to the coupling, and then the power is transmitted to bevel pinion (1) from the coupling. The power changes its direction by 90 degrees and reduces its speed due to the combination of bevel pinion (1) and bevel gear (2), and is then transmitted to sun gear shaft (4) through cage (3). The power transmitted to the sun gear shaft is output to the final drive.
GD535-5
10-49
Differential (Differential lock specification)
10 Structure and function
Differential (Differential lock specification)
1
(Machines with differential lock type rear axle)
1. 2. 3. 4. 5. 6.
Sun gear shaft (number of teeth: 18) Bevel gear (number of teeth: 43) Coupling Bevel pinion (number of teeth: 12) Shaft Pinion (number of teeth: 12)
10-50
7. Side gear (number of teeth: 24) 8. Differential case 9. Disc 10. Plate 11. Differential lock solenoid valve
GD535-5 (03)
10 Structure and function
Differential (Differential lock specification)
Outline q The differential switches between ON and LOCK (OFF) by hydraulically pressing disc (9) and plate (10) simultaneously or separately. q When the machine is in high-speed operation (gear shift lever positioned at F8), the transmission controller automatically cancels the differential lock even if the differential lock switch is switched to "ON".
GD535-5
10-51
Differential (Differential lock specification)
Operation At normal traveling
q
q
q
Power from the transmission is input to the coupling, and then the power is transmitted to bevel pinion (1) from the coupling. The power changes its direction by 90 degrees and reduces its speed due to the combination of bevel pinion (1) and bevel gear (2), and is then transmitted from side gear (4) to the sun gear shaft through pinion (3). The power transmitted to the sun gear shaft is output to the final drive.
10 Structure and function
At turning
q
While the machine is turning, the right and left wheels rotate at different speeds. Pinion (1) and side gear (2) inside the differential rotate and transmit the power of differential case (3) to the right and left sun gear shafts (4) according to the difference between the speeds of the right and left.
At differential lock
At straight traveling
q
q
While the machine is traveling straight, the right and left wheels rotate at a same speed. So, pinion (1) inside the differential does not rotate and the power of differential case (2) is transmitted equally to the right and left sun gear shafts through pinion (1) and side gear (3).
10-52
q
If either tire of the right or left tandem drive falls into mud or similar substance and loses its load resistance, the tire with the smaller load resistance alone rotates and the power cannot be transmitted. To enable the machine to travel even when the power cannot be transmitted, the differential lock (1) is activated to stop the rotation of pinion (2) and transmit the power equally to the right and left sun gear shafts (3).
GD535-5
10 Structure and function
Differential lock solenoid valve
Differential lock solenoid valve
1
(Machines with differential lock type rear axle)
GD535-5
10-53
Final drive
Final drive
10 Structure and function
1
a The figure shows the final drive for machines with differential lock type rear axle
1. Sprocket (number of teeth: 18) 2. Shaft 3. Planetary carrier 4. Planetary gear (number of teeth: 25) 5. Ring gear (number of teeth: 69)
10-54
GD535-5 (03)
10 Structure and function
Final drive
Operation
q q q
The power from the differential is input to the final drive through sun gear shaft (1). The power input to the final drive is reduced via planet gear mechanism (2). The reduced power is input from sprocket (4) to the tandem drive through shaft (3).
GD535-5
10-55
Tandem drive
Tandem drive
10 Structure and function
1
1. Sprocket (number of teeth: 18) 2. Hub shaft 3. Breather 4. Oil level plug 5. Drain plug
10-56
GD535-5
10 Structure and function
Tandem drive
Outline q The tandem drive transmits the power transmitted from the final drive to the front/rear rear wheels with chains. q The tandem case can oscillate 11 degrees and 13 degrees in forwards upward and forwards downward directions respectively. This allows the 4 rear wheels to stay on the ground even when the ground is uneven. So, fluctuation of the blade can be minimized. Operation If the rear wheels of the motor grader hit a bump in the road, the blade moves as shown below.
q
1. If both the right and left wheels hit a bump (height H), the rear axles rises by H/2 at its center as shown in the figure. Because the blade is located almost halfway between the front and rear axles, the movement of the blade is further reduced to H/ 4.
2. Among the rear wheels, if one wheel on the left side alone hits a bump (height H), the rear axle rises at its center by H/2, and the distance it rises halves further to H/4 at the machine center point on the rear axle as shown in the figure. The distance the blade rises further halves to H/8 at its center.
GD535-5
10-57
Tandem drive
10-58
10 Structure and function
GD535-5
10 Structure and function
Steering piping drawing
Steering system
1
Steering piping drawing
1
1. Steering valve 2. Steering wheel 3. Steering cylinder 4. Hydraulic tank 5. Priority valve 6. Hydraulic oil line filter 7. Work equipment and steering pump
GD535-5
10-59
Priority valve
Priority valve
10 Structure and function
1
P: From pump EF: To hydraulic tank CF: To steering valve LS: To pilot circuit T: To hydraulic tank
10-60
GD535-5
10 Structure and function
a: Orifice b: Orifice c: Orifice 1. Spring 2. Relief valve 3. Spool
GD535-5
Priority valve
Outline q This valve restricts flow rate to the steering circuit to a minimum (approximately 1 l/min) when no steering operations are performed. Thus, the load on the steering pump is minimized. q The relief valve built in this valve regulates the steering circuit pressure and prevents abnormally high pressure from developing.
10-61
Priority valve
10 Structure and function
Operation When engine is stopped q Spool (1) is pushed to the right by the repulsive force of spring (2). As a result, port (EF) is closed and the opening area of port (CF) is maximized. When engine is started (Control valve and steering valve in neutral state) q The oil from the main pump flows from port (A) through port (CF) to the steering circuit. q Because the steering valve is in neutral the position, the oil pressure in port (CF) rises. q The oil in chamber (A) enters chamber (B) through orifice (a) and pushes spool (1) to the left. q The oil in port (CF) drains through the steering valve. q The normal flow rate of the LS circuit is approximately 1 l/min. q The differential pressure across orifice (b) is approximately 0.98 MPa {10 kg/cm2} when oil flow of the LS circuit passes through the orifice. The formula Pressure in chamber (B) = Pressure in chamber (C) + 0.98 MPa {10kg/cm2 } holds. So, spool (1) moves to the left and starts to close part (d). q When the opening area of part (d) becomes reduced, the drain amount through orifice (b) lowers and differential pressure across orifice (b) falls. q When spool (1) is pushed to the right by the repulsive force of spring (2), it opens part (d). As a result, the flow rate increases and spool (1) is pushed to the left again. q These operations are repeated until the spool balances. q Leftward force (reduced oil pressure) : Pressure in chamber (B) (= 1.57 MPa {16 kg/ cm2}) q Rightward force : Pressure in chamber (C) + 0.98 MPa {10 kg/ cm2}) (= 1.57 MPa {16 kg/cm2}) (0.98 MPa {10 kg/cm2} is reduced oil pressure of spring (2))
10-62
GD535-5
10 Structure and function
Priority valve
When machine is being steered (Control valve in neutral state) q When the steering wheel is operated, port (CF), the steering cylinder, and port (LS) are interconnected. q Spool (1) is pushed to the right by the force exerted by the increased pressure in chamber (C) and the repulsive force of spring (2). As a result, the opening area of part (d) becomes large. q While the steering wheel is being operated, the oil from the main pump flows from port (CF) through the steering valve to the steering cylinder at a flow rate corresponding to the steering wheel operation. q When the steering wheel is operated quickly, the throttle area of the variable throttle orifice of the steering valve increases. q When differential pressure across the variable throttle orifice in the steering valve falls, the oil pressure in (LS) circuit increases (oil pressure in chamber (B) lowers) and oil pressure in chamber (C) increases. q So, spool (1) moves further to the right further and the opening area of part (d) increases further, resulting in increased oil flow to the steering cylinder. q When the steering wheel is operated slowly, the throttle area of the variable throttle orifice of the steering valve decreases. q As the throttle area becomes small, the differential pressure across the variable throttle orifice in the steering valve becomes high. As a result, the pressure in chamber (C) becomes larger than that in chamber (B). q Spool (1) moves to the left and the opening area of part (d) becomes small. So, the pol flow to the steering cylinder is reduced. q Spool (1) balances at a position corresponding to the steering wheel operation. q Spool (1) is controlled so that the opening area of part (d) will correspond to the oil flow required by port (CF) while the differential pressure between chambers (A) and (B) is kept at 0.98 MPa {10 kg/ cm2},. (All oil other than that required for the steering operation returns from port (EF) to the hydraulic tank .) q As for the oil flowing from port (CF) to the steering cylinder, if load is applied, the oil pressure in (PLS) line increases.
GD535-5
10-63
Priority valve
10 Structure and function
When the steering cylinder is at the end of its stroke q When the steering cylinder has reached the end of its stroke end if the steering wheel continues to be operated, the oil flow from the steering valve to the steering cylinder is stopped while the circuit remains connected. q When the oil flow is stopped, both (CF) and (LS) circuit pressures increase to a level equivalent to the pressure in pump port (P). q Both pressures in chambers (B) and (C) increase and spool (1) moves to the right. q When the pressure in chamber (C) exceeds 15.2 MPa {155 kg/cm2}, the steering relief valve opens to drain the oil in chamber (C). q Differential pressure is developed across orifice (b), and the pressure in chamber (C) lowers that in chamber (B). So, spool (1) moves to the left. q Spool (1) balances at a position where the opening area of part (d) is throttled so that the flow rate becomes 1 l/min. to prevent flow rate loss at relief. q When spool (1) moves to the left to an excessive degree, part (d) is closed and no oil flows to orifice (b). q When the oil pressure in chamber (C) becomes equal to that in chamber (B), spool (1) is moved to the right by the repulsive force of spring (2) and part (d) is connected. q These operations are repeated to keep the steering circuit pressure below 15.2 MPa {155 kg/cm2}.
10-64
GD535-5
10 Structure and function
Steering valve
Steering valve
1
(Q/Amp manual Orbitrol type)
1. Bushing 2. Valve body 3. Check valve 4. Gerotor 5. Spacer 6. Cover 7. Spacer 8. Drive shaft 9. Sleeve 10. Spool 11. Center pin 12. Center spring
GD535-5
Outline q The Q/Amp manual Orbitrol consists of a directional control valve and a flow amplifier orifice. q This Orbitrol controls the steering discharge according to the control speed of the steering wheel. It shows a flow characteristic that the oil flow is amplified more than the flow metered by gerotor especially in the high speed range. (Variable ratio steering function) q The Q/Amp manual Orbitrol has the following features. q Provides stable steering performance by allowing fine steering correction during high-speed travel. q Allows flip turns during low-speed travel and stationary steering. q Allows secondary steering with Orbitrol alone.
10-65
Steering valve
10 Structure and function
Variable ratio steering function
q q
The steering discharge varies according to the control speed of the steering wheel. The steering discharge decreases in the low speed control range of the steering wheel and increases in the high speed control range.
q
q
During high-speed travel, if the steering wheel is operated gently, the steering discharge decreases to allow fine steering correction, therefore creating superior steering performance during high-speed travel. During stationary steering or low-speed travel, if the steering wheel is operated quickly, the steering discharge increases easily to allow flip turns.
Flow amplifier function The Orbitrol has a bypass flow control function via a built-in flow amplifier orifice in addition to the primary metering function provided by the gerotor. So, the Orbitrol can supply a large amount of oil to the steering cylinder. q In the high speed range, even a small Orbitrol can supply a large amount of oil to the steering cylinder. q
10-66
GD535-5
10 Structure and function
Steering valve
Q/Amp manual Orbitrol
q q
q
q
q
Q/Amp Orbitrol with secondary steering function is called Q/Amp manual Orbitrol. The secondary steering function is realized by closing the characteristics of bypass orifice (characteristics of flow amplifier orifice (AA)), that does not go through metering (gerotor), in a secondary steering condition (with the valve in the maximum displacement state). The Q/Amp manual Orbitrol will create a large advantage if it is used for the steering system of mid-sized machines. Actually, only the small-capacity Orbitrol can provide secondary steering function separately. If a large-capacity Orbitrol is employed, a hydraulic power source for secondary use is needed. Employment of Q/Amp manual Orbitrol helped create a realized simplified system while also improving reliability.
GD535-5
10-67
Steering valve
10 Structure and function
Structure q Spool (10) is connected to the drive shaft of the steering wheel, to sleeve (9) through center pin (7) (not in contact with the spool steering wheel is in the "Neutral" position), and centering spring (4). q Drive shaft (3) meshes with center pin (7) at its top and is united with sleeve (9). Its bottom is splined to rotor (1) of the gerotor set (combination of rotor (1) and stator (11)). q The valve body has 4 ports that connect to the pump circuit, tank circuit, steering cylinder head side, and steering cylinder bottom side respectively. The pump-side port and tank-side port are connected through the check valve in the body. If the pump or engine fails, this structure enables oil to be sucked directly from the tank side through the check valve.
10-68
GD535-5
10 Structure and function
Steering valve
Connection of hand pump with sleeve
q
q
q
q
q
q
The above figure shows the connection between the gerotor suction and discharge ports and connection of sleeve ports that serves to connect the suction and discharge ports. When the steering wheel is turned to the right, ports (a), (c), (e), (g), (i), and (k) are connected to the pump side through vertical grooves. Similarly, ports (b), (d), (f), (h), (j), and (l) are connected to the left steering cylinder head side. Under the condition of the left figure shown above, ports (1), (2), and (3) are in the discharge state of the gerotor set. At this time, they are connect to ports (l), (b), and (d) respectively and cylinder oil is supplied. In addition, ports (5), (6), and (7) are connected, and oil flows in from the pump The figure on the right shown above shows the condition when the steering wheel is turned 90 degrees from this position. At this time, ports (1), (2), and (3) are in the suction state and connected to ports (i), (k), and (c) respectively. Ports (5), (6), and (7) are in the discharge state and connected to ports (d), (f), and (h) respectively As described above, hand pump ports in the discharge state are connected to respective ports that lead to the steering cylinder, and those in the suction state are connected to pump circuit. If the pump or engine fails, forcibly performing suction and discharge of this hand pump allows you to supply oil to the steering cylinder to carry out steering operations.
GD535-5
10-69
Steering valve
q
q
10 Structure and function
The discharge is adjusted according to the steering angle of the steering wheel. That is, oil from the pump always passes through this hand pump. Because the hand pump advances its internal gear by one tooth for each 1/7 turn of the steering wheel to discharge oil, the discharge is directly proportional to the steering angle of the steering wheel. This applies even if the pump or engine fails, the same amount of discharge is obtained as that under normal conditions.
Difference between trochoid pump and hand pump for steering pump Trochoid pump
q
The inlet port and outlet port are provided separately. As shown in figures (2) to (6) above, the oil is sucked in from the inlet side and discharged to the outlet side as the shaft is rotated.
Hand pump for steering pump
q
The hand pump has respective inlet/outlet ports at the bottom of the stator internal gear teeth. When the shaft rotates, as shown in figures (2) and (3) above, the port connects to the steering pump side and oil is sucked in. When the shaft rotates further, as shown in figures (5) and (6) above, the port connects to the steering cylinder side and oil is supplied to the cylinder. Each port conducts this operation.
10-70
GD535-5
10 Structure and function
Steering valve
Role of center spring
q
q
Center spring (2) consists of 4 X-shaped leaf springs and 2 flat leaf springs, and as shown in the figure, it is installed between spool (9) and sleeve (8). When the steering wheel is turned, spool (9) compresses center spring (2) and angular displacement (a) is generated between spool (9) and sleeve (8). As a results, ports in spool (9) interconnect to ports in sleeve (8) and oil is supplied to the steering cylinder. When turning of the steering wheel is stopped, the gerotor rotation is also stopped. So, no oil is sent to the steering cylinder and the oil pressure increases. To prevent this, when turning of the steering wheel is stopped, the repulsive force of center spring (2) turns the steering wheel by angular displacement (a) between spool (9) and sleeve (8) to return it to a neutral position.
GD535-5
10-71
Steering valve
10-72
10 Structure and function
GD535-5
10 Structure and function
Hydraulic piping drawing of brake system
Brake system
1
Hydraulic piping drawing of brake system
1
1. Parking brake sorenoid valve, lifter lock pin solenoid valve 2. Brake pump 3. Wheel brake (rear) 4. Wheel brake (front) 5. Parking brake cylinder 6. Brake circuit accumulator (left) 7. Brake circuit accumulator (right)
GD535-5
8. Hydraulic tank 9. Hydraulic oil line filter 10. Brake circuit accumulator charge valve 11. Brake valve 12. Stop lamp oil pressure switch 13. Brake pedal
10-73
Brake valve
10 Structure and function
Brake valve
1
PA: From ACC2 port of brake circuit accumulator charge valve PB: From ACC1 port of brake circuit accumulator charge valve A: To brake cylinder
B: To brake cylinder TA: Drain TB: Plug SA: Plug SB: Stop lamp oil pressure switch
1. Piston 2. Spool 3. Cylinder
4. Spool 5. Cylinder
10-74
GD535-5
10 Structure and function
Brake valve
Outline q The brake valve is installed at the bottom of the front of the operator's seat. Pressing the brake pedal supplies oil to the brake piston to apply the brake. Operation When brake pedal is pressed
q
q
q
When brake pedal (1) is pressed, the pressing effort is transmitted to spool (5) through rod (2), piston (3), and spring (4). When spool (5) is pushed to the right, port (TA) is closed. The oil from the pump flows in port (PA) through the accumulator, flows from port (A) to the brake piston, and applies the brake [on port (A) side]. At the same time when spool (5) moves to the right, spool (6) is also pushed to the right, and port (TB) is closed. The oil from the pump flows in port (PB) through the accumulator, flows from port (B) to the brake piston, and applies the brake [on port (B) side].
GD535-5
10-75
Brake valve
10 Structure and function
When brake on one side is applied (When either brake failed)
q
Even if an oil leak or the like occurs in the rear brake system and a brake on either side alone can work, the pressing effort on brake pedal (1) mechanically moves spool (5) and spool (6) to the right. Therefore, the oil from the pump can flow to the brake piston of the normal brake as usual and the brake can be applied to stop the machine. Thus, safety is improved.
10-76
GD535-5
10 Structure and function
Brake valve
When brake is balancing
q
q
q
When the brake cylinder is filled with oil from port (A) and the circuit pressure between port (PA) and port (A) rises. The oil in chamber (E), that has entered it through orifice (c) of spool (5), pushes back spool (5) to the left against the repulsive force of spring (4). As a result, port (PA) and port (A) are blocked. At this time, because port (TA) remains closed, the oil from port (A) is held and the brake remains applied. At the same time when spool (5) moves to the left, the brake cylinder is filled with the oil from port (B) and the circuit pressure between port (PB) and port (B) rises. The oil in chamber (F), that has entered it through orifice (d) of spool (6), pushes back spool (6) to the left by the move distance of spool (5). As a result, port (PB) and port (B) are blocked And because port (TB) remains closed, the oil from port (B) is held and the brake remains applied. The oil pressure of the brake circuit [on port (A) side] balances with the brake pedal pressing effort, and the oil pressure of the brake circuit [on port (B) side] balances with that of the brake circuit [on port (A) side] . When spools (5) and (6) move to the right by a full stroke, the circuit between ports (PA) and (A) and that between ports (PB) and (B) are completely formed. The oil pressure of the brake circuit [on port (B) side] and that of the brake circuit [on port (B) side] are made equal to the oil pressure from the brake pump. Thus, the degree that the brake works can be adjusted by adjusting brake pedal pressing effort until spools (5) and (6) move to the right by a full stroke.
GD535-5
10-77
Brake valve
10 Structure and function
When brake pedal is released
q q
q
When brake pedal (1) is returned, the brake pedal pressing effort acting on spool (5) is released. When spool (5) is pushed back to the left by the force exerted by the back pressure of the brake piston [on port (A) side] and the repulsive force of spring (7), port (PA) is closed and the oil in the brake piston [on port (A) side] flows from port (A) to port (TA). Then, the oil is drained from port (TB) to the hydraulic tank. So, the brake [on port (A) side] is released. At the same time when spool (5) moves to the left, spool (6) is also pushed back to the left by the force exerted by the back pressure of the brake piston [on port (B) side] and the repulsive force of spring (7), port (PB) is closed and the oil in the brake piston [on port (B) side] flows from port (B) to port (TB). Then, the oil is drained from port (TB) to the hydraulic tank. So, the brake [on port (B) side] is released.
10-78
GD535-5
10 Structure and function
Brake circuit accumulator
Brake circuit accumulator
1
1. 2. 3. 4. 5. 6.
Plug Gas valve Top cover Cylinder Free piston End cover
Function q The brake circuit accumulator is installed between the brake circuit accumulator charge valve and the brake valve. q Cylinder (4) is charged with nitrogen gas. Free piston (5) uses the pressure of stored compressed nitrogen gas to maintain the brake force even after the engine is stopped. Specifications
GD535-5
Gas to be used
Nitrogen gas
Volume of gas (cc)
3,750
Gas charged pressure (MPa {kg/cm2})
3.4 ± 0.1 {35 ± 1.0} (at 20°C)
Max. operating pressure: (MPa {kg/cm2})
20.6 {210}
10-79
Brake circuit accumulator charge valve
Brake circuit accumulator charge valve
10 Structure and function
1
P: From pump PA: To hydraulic oil cooler ACC1: To brake valve port PA ACC2: To brake valve port PB T: Drain
10-80
GD535-5
10 Structure and function
1. Valve body 2. Relief valve (R2) 3. Shuttle valve (S1) 4. Priority valve 5. Main relief valve (R1)
GD535-5
Brake circuit accumulator charge valve
Function q The charge valve maintains the oil pressure from the pump to the set pressure and accumulates it in the accumulator. q When the oil pressure rises above the preset pressure, the oil from the pump is led to the drain circuit to reduce the load on the pump.
10-81
Brake circuit accumulator charge valve
10 Structure and function
Operation When oil is not supplied to the accumulator (cut-out state)
q q q
q
Plunger (1) is moved to the right direction by the accumulator pressure, and maintains unload. The oil in the spring chamber of unload valve (3) is drained to the hydraulic tank through the port. Since oil pressure in port (F) is reduced, unload valve (3) moves to the right and is subjected to the action of the oil from chamber (B). Port (C) and port (D) are opened, supplying most of the oil from the pump to the hydraulic oil cooler through port (P), ports (C) and (D), and port (PA).
10-82
GD535-5
10 Structure and function
Brake circuit accumulator charge valve
When oil is supplied to the accumulator q Cut-in state
q
q
q q
q
q
As the accumulator pressure falls, pressure on port (E) goes low, allowing plunger (1) to move to the left and unload relief valve (2) to close the drain circuit. Since the oil pressure in port (F) and the spring chamber of unload valve (3) increases, unload valve (3) moves to the left. Port (C) and port (B) are opened, conducting the oil from the pump to port (B). As oil pressure in port (B) increases beyond the set pressure of check valve (4), check valve opens, allowing the oil to be supplied to the accumulator through port (E). The pressure for supplying oil to the accumulator depends on the set pressure of check valve (4). The amount of oil supplied to the accumulator is constant independent of the engine speed, thus surplus oil flows to the hydraulic oil cooler through port (PA). Inverse shuttle valve (5) supplies precedence to the accumulator of lower pressure when supplying oil.
GD535-5
10-83
Brake circuit accumulator charge valve
10 Structure and function
2. When pressure reaches cut-out pressure
q
q
q
q
As pressure in port (F) reaches the set pressure (cut-out pressure of unload relief valve (2)), oil in the spring chamber of unload valve (3) is drained to the hydraulic tank through port (F), unload relief valve (2) and port (T). Plunger (1) is moved to the right by the accumulator pressure, and unload relief valve (2) remains pushed open. Since oil pressure in port (F) is decreased, unload valve (3) moves to the right and is subjected to the action of the oil from chamber (B). Port (C) and port (D) are opened, supplying most of the oil from the pump to the hydraulic oil cooler through port (P), ports (C) and (D), and port (PA).
10-84
GD535-5
10 Structure and function
Main relief valve (R1)
q
q
q
If the pressure in port (P) (pump pressure) rises above the set pressure, it compresses spring (1) and moves ball (2) to the left. The pressure of the oil from the pump is reduced across orifice (a), and the resulting pressure difference compresses spring (3) and moves valve (4) to the left to a large extent. Port (P) being connected to port (T) drains the pump pressure and, thereby, regulates the maximum pressure in the charge circuit in order to protect the circuit.
GD535-5
Brake circuit accumulator charge valve
Shuttle valve (S1)
q
q
q
When the pressure in port (ACC2) is higher than that in port (ACC1), shuttle valve (1) moves to the left to disconnect port (ACC2) from oil passage (B). The open area between port (ACC1) and oil passage (B) is increased and the oil is supplied to the accumulator on port (ACC1) side. When the pressure in port (ACC1) is higher than that in port (ACC2), the oil is supplied to the accumulator on port (ACC2) side. The oil from the pump is supplied first to the lowpressure side of the 2 systems.
10-85
Wheel brake
Wheel brake
10 Structure and function
1
1. Cage 2. Piston 3. Guide pin 4. Gear 5. Disc 6. Plate
10-86
GD535-5
10 Structure and function
Parking brake solenoid valve and lifter lock pin solenoid valve
Parking brake solenoid valve and lifter lock pin solenoid valve
P: From accumulator B1: To lifter lock pin cylinder B2: To lifter lock pin cylinder PB: To parking brake T: To hydraulic tank G2: To the accumulator pressure detection port 1. Lifter lock pin solenoid 2. Parking brake solenoid 3. Filter 4. Check valve
GD535-5 (03)
1
Outline q The parking brake solenoid valve and lifter lock pin solenoid valve have built-in solenoid valve for parking brake and solenoid valve for lifter lock pin respectively. q When the parking brake solenoid is energized, oil is sent to the parking brake to release it. q When the lifter lock pin solenoid is energized, oil is sent to the lifter lock pin cylinder to move it in the lock pin removal direction.
10-87
Parking brake
10 Structure and function
Parking brake
1. Piston 2. Adjustment bolt 3. Pad
1
4. Caliper 5. Disc
Outline q The parking brake is the disc type and installed on the differential. q Structurally, the parking brake is mechanically applied with the repulsive force of the spring in the caliper and released with the force exerted by oil pressure. q The disc is installed on the coupling of the differential and rotates along with the coupling. q When the accumulator pressure is sufficiently high, if the gear shift lever is set to a position other than P (PARK), the oil pressure acts on the chamber to release the parking brake.
10-88
GD535-5
10 Structure and function
Frame
Undercarriage and frame
1
Frame
1
1. Front frame 2. Rear frame 3. Upper center hinge pin 4. Lower center hinge pin 5. Articulate lock pin 6. Articulate cylinder
GD535-5
Outline q Front frame (1) and rear frame (2) are connected with center hinge pins (3) and (4). q Left and right articulate cylinders (6) connect to both front frame (1) and rear frame (2) and the frames can pivot 25 degrees to both sides on the center hinge pin according to telescopic motion of the cylinders. q The articulate mechanism reduces turning radii and assists with offset operations, escaping from mud, and operations at corners.
10-89
Tire
Tire
10 Structure and function
1
Bias tire
Structure q Cords composing carcass (1) are arranged diagonally to the center line of tread (T) (radially). q Sidewall (W) and tread (T) are structurally integrated.
10-90
GD535-5
10 Structure and function
GD535-5
Tire
10-91
Hydraulic system
10 Structure and function
Hydraulic system
1
Hydraulic system
1
System outline
*1. For machines with power tilt mechanism *2. For machines with scarifier Work equipment circuit 1. Hydraulic oil in the hydraulic tank is sent to the control valve through the work equipment pump. Steering circuit 1. The steering valve is an energy saving closedcenter type that allows hydraulic oil to flow only when it is needed and does not allow it to flow when the machine is not being steered. At the same time, the LS pressure is transmitted to the priority valve so that the priority valve spool will wait at a position where the flow rate needed for the steering circuit can be assured. 2. The steering valve is the Q/Amp type that provides excellent controllability during high-speed travel and allows steering operation even if the engine stops or the main pump fails. 3. The maximum steering circuit pressure is set by the relief valve built in the priority valve. So, it differs from the work equipment circuit pressure.
10-92
GD535-5
10 Structure and function
Hydraulic system
Brake circuit 1. The oil pressure from the brake pump is boosted to the required pressure and accumulated in the accumulators installed in the 2 brake circuits. 2. When the brake is used and the brake circuit pressure drops below the set pressure of 9.36 MPa {95 kg/cm2}, the accumulator charge valve operates to accumulate pressure until the pressure in the accumulator reaches its set pressure of 13.8 MPa {141 kg/cm2}. 3. Even when the engine stops, oil pressure in the accumulator allows braking for a certain period. 4. When pressure in the accumulator drops, the release pressure of the parking brake also lowers. So, the parking brake is automatically applied by the repulsive force of the spring. If the machine is left parked for a certain period, the parking brake can be applied naturally and it will not be released until the engine is started again. 5. When the work equipment postures is changed to/ from the bank-cutting posture or shoulder reach posture, the bank control lock pin needs to be removed or inserted. For this purpose, the pressure in the accumulator is also used as an oil pressure source. Control valve 1. The control valve is the open-center type and hydraulic oil is sent to the control valve by the work equipment pump. The maximum pressure is set by the relief valve in the control valve.
GD535-5
10-93
Hydraulic piping drawing of work equipment
Hydraulic piping drawing of work equipment
10-94
10 Structure and function
1
GD535-5
10 Structure and function
Hydraulic piping drawing of work equipment
1. Lifter lock pin 2. Control valve 3. R.H. articulate cylinder 4. L.H. articulate cylinder 5. Power tilt cylinder (*1) 6. Blade side shift cylinder 7. Circle rotation motor 8. Leaning cylinder 9. Swivel joint 10. Scarifier cylinder (*2) 11. Drawbar shift cylinder 12. L.H. blade lift cylinder 13. R.H. blade lift cylinder 14. Brake circuit accumulator charge valve 15. Parking brake solenoid valve and lifter lock pin solenoid valve 16. Brake pump 17. Work equipment and steering pump 18. Hydraulic tank 19. Hydraulic oil line filter *1. For machines with power tilt mechanism *2. For machines with scarifier
GD535-5
10-95
Work equipment control
Work equipment control
1. 2. 3. 4. 5. 6. 7. 8. 9.
Control valve Machine monitor Steering wheel Blade rotation control lever Blade side shift control lever L.H. blade lift cylinder control lever Scarifier control lever (*1) Power tilt control lever Steering wheel and machine monitor angle adjustment knob 10. Drawbar side shift control lever 11. Articulate control lever 12. Leaning control lever 13. R.H. blade lift cylinder control lever 14. Accelerator pedal 15. Brake pedal 16. Inching pedal 17. Steering console tilt lever 18. Gas spring
10 Structure and function
1
Outline q Work equipment control levers are installed on the shaft of the steering console and connected to the respective control valves through rods. q Steering wheel and machine monitor angle adjustment mechanism When the steering wheel and machine monitor angle adjustment knob (9) are loosened, the lock is released allowing the angle of the steering wheel and machine monitor to be adjusted. When knob (9) is tightened, the angle is fixed. q Steering console tilt mechanism When steering console tilt pedal (17) is pressed, the lock is released allowing the tilt angle of the steering console to be adjusted. When the user's foot is removed from pedal (17), the angle is fixed.
*1. For machines with scarifier
10-96
GD535-5
10 Structure and function
Hydraulic tank
Hydraulic tank
1
1. Breather 2. Oil filler cap 3. Hydraulic tank 4. Sight gauge 5. Bypass valve 6. Filter element 7. Suction strainer
GD535-5 (02)
Specifications Tank capacity (l)
72
Oil quantity in hydraulic tank (l)
51.5
Bypass valve set pressure (kPa {kg/cm2})
150 ± 30 {1.53 ± 0.31}
Cracking pressure of pressure valve (kPa {kg/cm2})
38 ± 5.7 {0.39 ± 0.06}
Cracking pressure of vacuum valve (kPa {kg/cm2})
2 ± 0.3 {0.02 ± 0.003}
10-97
Work equipment pump and steering pump
10 Structure and function
Work equipment pump and steering pump
1. Work equipment pump 2. Steering pump
1
Outline q The work equipment pump and steering pump installed on the PTO shaft of the transmission are driven by the axial rotation and supply oil pressure to the work equipment and steering circuits respectively.
Specifications Name
Work equipment pump
Steering pump
Model
SAR (2) 40
SAR (2) 20
Type
Gear type
Gear type
3,000
3,000
20.6 {210}
20.6 {210}
40.2
20.4
Revolution speed (rpm) Discharge pressure (MPa{kg/cm2}) Theoretical discharge (cm3/rev)
10-98
GD535-5
10 Structure and function
Power train pump
Power train pump
1
Outline q The power train pump installed on the PTO shaft of the transmission is driven by the axial rotation and supply oil pressure to the power train circuit. Specifications Name
Power train pump
Model
SAR (2) 63
Type
Gear type
Revolution speed (rpm) Discharge pressure (MPa {kg/cm2}) Theoretical discharge (cm3/rev)
GD535-5
2,300 4.4 {45} 63.5
10-99
Power train pump and differential lock pump
10 Structure and function
Power train pump and differential lock pump
1
(Machines with differential lock type rear axle)
1. Power train pump 2. Differential lock pump
Outline q The power train pump and differential lock pump installed on the PTO shaft of the transmission are driven by the axial rotation and supply oil pressure to the power train and differential lock circuits respectively.
Specifications Name
Power train pump
Differential lock pump
Model
SAR (2)
SBR (1) 10
Type
Gear type
Gear type
2,300
2,300
4.4 {45}
4.4 {45}
63.5
10.5
Revolution speed (rpm) Discharge pressure (MPa {kg/cm2}) Theoretical discharge (cm3/rev)
10-100
GD535-5
10 Structure and function
Brake pump
Brake pump
1
Outline q The brake pump installed in the engine is driven by the axial rotation and supply oil pressure to the power train circuit. Specifications Name
Brake pump
Model
SGP1A20
Type
Gear type
Revolution speed range (rpm) Discharge pressure (MPa {kg/cm2}) Theoretical discharge (cm3/rev)
GD535-5
500 to 4,000 20.6 {210} 20.4
10-101
Control valve
Control valve
10-102
10 Structure and function
1
GD535-5
10 Structure and function
Control valve
A1: To R.H. blade lift cylinder head A2: To Leaning cylinder bottom A3: To drawbar shift cylinder bottom A4: To articulate cylinder A5: To power tilt cylinder head (*1) A6: To circle motor A7: To blade lift cylinder head A8: To L.H. blade lift cylinder head A9: To scarifier cylinder head (*2) B1: To R.H. blade lift cylinder bottom B2: To leaning cylinder head B3: To drawbar shift cylinder head B4: To articulate cylinder B5: To power tilt cylinder bottom (*1) B6: To circle motor B7: To blade shift cylinder bottom B8: To L.H. blade lift cylinder bottom B9: To scarifier cylinder bottom (*2) P2: From work equipment pump P3: From work equipment pump T1: To tank T2: To tank 1. Main relief valve 2. Main relief valve *1. For machines with power tilt mechanism *2. For machines with scarifier
GD535-5
10-103
Functions and valve operations
Functions and valve operations
10 Structure and function
1
Hydraulic circuit drawing and valve name
1. Main relief valve Set pressure: 19.1 MPa {195 kg/cm2}
10-104
GD535-5
10 Structure and function
Hydraulic cylinder
Hydraulic cylinder
1
1. Piston rod 2. Cylinder 3. Piston 4. Bushing 5. Cylinder head
GD535-5
10-105
Swivel joint
10 Structure and function
Swivel joint
a: To power tilt cylinder head (*1) b: To power tilt cylinder bottom (*1) c: To blade lift cylinder head d: To blade shift cylinder bottom
1
1. Plug 2. Plate 3. Cover 4. Shaft 5. Rotor
*1. For machines with power tilt mechanism
10-106
GD535-5
10 Structure and function
Pilot check valve
Pilot check valve
1
Pilot check valve (with safety valve) (For Blade lift L.H., scarifier (if equipped), ripper (if equipped))
1. Body 2. Piston
3. Check valve 4. Relief valve
The check valve with safety valve prevents hydraulic drift of the cylinder and also protects the cylinder from abnormal pressure caused by external force. When the blade lift is raised to the maximum position and the drawbar is shifted to the side, the drawbar stopper and lifter come into contact. The check valve with safety valve installed to the blade lift cylinder (left) acts to prevent damage to the work equipment caused by this contact.
%
%
$
$
$*
A1: From control valve A2: From control valve B1: To cylinder bottom side B2: To cylinder head side
GD535-5 (02)
10-107
Pilot check valve
10 Structure and function
Operation When the lever is operated to retract the cylinder, oil from the pump enters chamber (A2) and pushes check valve (3). It then passes through chamber (B2) and flows to the chamber at the head of the cylinder to push the cylinder piston. The oil at the cylinder bottom end flows back through chamber (B1) and chamber (A1) and returns to the tank. When the lever is operated to extend the cylinder, the oil from the pump enters chamber (A1) and flows through chamber (B1) to the cylinder bottom end. As the pressure in chambers (A1) and (B1) rises, piston (2) is pushed, This pushes open check valve (3), and the oil at the cylinder head flows from chamber (B2) through the throttle of check valve (3). It then flows from chamber (A2) back to the tank. If there is any shock to the work equipment during operations, and the pressure in chamber (B2) rises to an abnormal pressure, relief valve (4) is pushed open and the oil flows to chamber (B1). Ths raises the work equipment and relieves the shock.
10-108
GD535-5 (02)
10 Structure and function
Pilot check valve
Pilot check valve (For Blade lift R.H.)
1. Piston
2. Check valve
The check valve with safety valve prebents hydraulic drift of the cylinder and also protects the cylinder from abnormal pressure caused by external force. When the blade lift is raised to maximum position and the drawbar is shifted to the side, the drawbar stopper and lifter come into contact. The check valve with safety valve installed to the blade lift cylinder (left) acts to prevent damage to the work equipment caused this contact.
%
$
%
$ $*
A1: From control valve A2: From control valve
GD535-5 (02)
B1: To cylinder bottom side B2: To cylinder head side
10-108-1
Pilot check valve
10 Structure and function
Operation When the control valve is operated to lower the blade, pressure is generated at the bottom end of the blade lift cylinder. This pressure passes through a throttle valve and pushes piston (1). This opens pilot check valve (2), and the oil in chamber (B2) at the cylinder head returns to the tank. The blade hold pressure is acting on the head end of the blade lift cylinder. When it pushes open check valve (2), the oil chamner (B2) suddenly escapes to chamber (A2), and the pressure at the bottom drops. When the happens, if there is no throttle at the pilot valve, the check valve will always open and close according to the changes in the pressure at the bottom and head ends. This will cause blade chattering. To prevent this, a throttle is insalled at (C) which acts as a damper, so even if the pressure at the bottom end drops, the check valve will not close immediately.
10-108-2
GD535-5 (02)
10 Structure and function
Pilot check valve
Leaning cylinder (if equipped)
A1: From control valve A2: From control valve B1: To cylinder head B2: To cylinder bottom
1. Check valve 2. Piston 3. Check valve 4. Piston 5. Relief valve 6. Body
Function q The pilot check valve of the leaning cylinder has a safety valve. q The check valve with safety valve protects the cylinder from abnormal pressure generated when an external force is applied to the leaning cylinder.
GD535-5 (02)
10-108-3
Pilot check valve
10 Structure and function
Operation q When the operator moves the control lever to extend the hydraulic cylinder, the oil from the pump flows in port (A2) through the control valve. q The oil in port (A2) pushes open check valve (1) and flows in port (B2). q When the pressure is applied to port (A2), the oil pushes piston (2) to the right through orifice (a) and opens check valve (3). q If check valve (3) opens, ports (B1) and (A1) are connected and the oil in port (B1) is drained through port (A1). q As check valve (1) opens and closes according to the pressure change on the bottom side and head side of the cylinder, hunting occurs. q When the pressure in port (A2) decreases, check valve (3) does not close immediately because of the damping effect of orifice (a). q If an impact is applied to the work equipment and the oil pressure in port (B2) exceeds 27.4 MPa {280 kg/cm2} during operation, relief valve (4) opens. q If relief valve (4) opens, the oil in port (B1) flows to port (B2) through the notch of collar (5). q The work equipment is protected and impacts are relieved by making the oil in port (B1) flow to port (B2).
10-108-4
GD535-5 (02)
10 Structure and function
Pilot check valve
Articulation and drawbar shift cylinders
A1: From control valve A2: From control valve B1: To cylinder head B2: To cylinder bottom
1. Body 2. Piston 3. Check valve 4. Piston 5. Check valve
Operation q When the operator moves the control lever to retract the hydraulic cylinder, the oil from the pump flows in port (A1) through the control valve. q The oil in port (A1) pushes open check valve (1) and flows in port (B1). q When the pressure is applied to port (A1), the oil pushes piston (2) to the right through orifice (a) to open check valve (3). q If check valve (3) opens, ports (B2) and (A2) are connected and the oil in port (B2) is drained through port (A2). q As check valve (1) opens and closes according to the pressure change on the bottom side and head side of the cylinder, hunting occurs. q When the pressure in port (A1) decreases, check valve (3) does not close immediately because of the damping effect of orifice (a).
GD535-5 (02)
10-108-5
Pilot check valve
10 Structure and function
Power tilt cylinder (if equipped)
A1: From control valve A2: From control valve B1: To cylinder bottom side B2: To cylinder head side
1. Check valve 2. Plug 3. Body 4. Piston 5. Relief valve
Function q The check valve with safety valve prevents hydraulic drift of the work equipment and protects the cylinder from the abnormal pressure caused by external forces.
10-108-6
GD535-5 (02)
10 Structure and function
Pilot check valve
Operation q When the operator operates the control valve to retract the cylinder, the oil from the pump flows in port (A2) and pushes open tube valve (1), then flows through port (B2) to the cylinder head side. q The oil in the cylinder bottom returns to the tank through ports (B1) and (A1). q When the operator operates the control valve to extend the cylinder, the oil from the pump flows in port (A1) and flows through port (B1) to the cylinder bottom side. q When the oil pressures in ports (A1) and (B1) increase, piston (4) is pushed to open check valve (1). q The oil in the cylinder head returns to the tank through port (B2) and check valve (1). q If an impact is applied to the work equipment and the oil pressure in port (B2) exceeds 24.5 MPa {250 kg/cm2} during operation, relief valve (5) opens and the oil in port (B2) flows into port (B1). The work equipment is protected and impacts are relieved in this way.
GD535-5 (02)
10-108-7
Pilot check valve
10-108-8
10 Structure and function
GD535-5 (02)
10 Structure and function
GD535-5
Pilot check valve
10-109
Circle and drawbar
10 Structure and function
Work equipment system
1
Circle and drawbar
1
1. Drawbar 2. Drawbar shift cylinder 3. Blade lift cylinder 4. Circle (number of teeth: 64)
10-110
GD535-5
10 Structure and function
5. Ball stud 6. Guide plate 7. Adjustment bolt 8. Guide
GD535-5
Circle and drawbar
Outline q Drawbar (1) is an vital component that supports the circle and blade. q When ball stud (5) is worn and drawbar (1) has excess play, the play can be adjusted by adjusting shims in the ball joint. q The clearance between circle (4) and drawbar (1) can be adjusted by adjusting shims in the guide mounting portion and adjustment bolt (7).
10-111
Blade
Blade
10-112
10 Structure and function
1
GD535-5
10 Structure and function
1. Blade 2. Side edge 3. Cutting edge 4. Power tilt cylinder (*1) 5. Blade side shift cylinder 6. Adjuster 7. Blade guide rail *1. For machines with power tilt mechanism
GD535-5
Blade
Function q The side edges installed on the blade can be reused structurally by turning them upside down or reversing them so that the right and left edges switch positions. q The blade guide rail acts as a bushing for the sliding part when the blade is side-shifted. When the required level of finishing accuracy cannot be obtained due to excess clearance in the sliding part, adjust the shim or replace the blade guide rail (5). a Machines with power tilt mechanisms can adjust the cutting angle of blade (1) from 32 to 80 degrees freely via operation of the power tilt control lever.
10-113
Lifter
10 Structure and function
Lifter
1. 2. 3. 4. 5.
Upper lifter bracket Lower lifter bracket Cap Bushing Yoke
10-114
1
6. lifter lock pin 7. Bushing 8. Case 9. Cover 10. Shaft
GD535-5
10 Structure and function
Lifter
Outline q Lifter brackets (1) and (2) are installed on the guide that is welded to the front frame and allow the work equipment system to be rotated. q Liter lock pin (6) can be removed or inserted by operating the lifter lock pin switch. q When lifter lock pin (6) is removed, lifter brackets (1) and (2) can rotate around the guide welded to the front frame. q Besides standard position (a), positions (b) and (c) are available as insertion holes for the lifter lock pin (6) to stop lifter rotation. These are used for setting the work equipment to the bank cutting posture and shoulder reach posture respectively. q Bushing (7) is installed in each insertion hole of lifter lock pin (6) to minimize the clearance between lifter lock pin (6) and the hole. q If the clearance between lifter lock pin (6) and the insertion hole becomes large, vertical play of the blade is magnified. q The clearance between the guide welded to the front frame and lifter brackets (1) or (2) can be adjusted by adjusting shims inserted between lifter brackets (1) and (2).
GD535-5
10-115
Circle rotation motor
Circle rotation motor
10 Structure and function
1
1. Output shaft 2. Flange 3. Shaft seal 4. Tapered roller bearing for heavy load 5. Main drive 6. O-ring 7. Gerotor 8. Valve drive 9. Wear compensation mechanism valve 10. PF1/2 O-ring port 11. Check valve 12. Valve plate
10-116
GD535-5
10 Structure and function
Circle rotation motor
Outline q The circle rotation motor is a low-speed, hightorque motor. The gerotor that exhibits a sun-andplanet motion allows this pump to output the same torque as that obtained when the power from a normal hydraulic motor is reduced to 1/6 with a reduction gear. q This motor will have fewer oil leaks because a hydraulic balance type disc valve is used for the valve mechanism and hi-accuracy gerotor is employed. q The valve parts are built in independent from the power transmission mechanism. This ensures the valve timing is always correct and that this motor will demonstrate stable performance over the long term. q A tapered roller bearing for heavy loads is built into the output shaft so that this motor can bear high radial load and high thrust load. Operation
q
q
High pressure oil that has flown into the motor enters gerotor (2) through disc valve (1), and the star of gerotor (2) makes sun-and-planet motion. Main drive (3) takes rotation only out of this sunand-planet motion and rotates output shaft (4). Disc valve (1) is driven by the valve drive and the positional relationship between 12 ports in disc valve (1) and 7 ports in valve plate (5) changes. As a result, the position of oil that flows in the gerotor (2) shifts successively.
GD535-5
10-117
Circle rotation gear
Circle rotation gear
10 Structure and function
1
Slip clutch type
1. Circle rotation motor 2. Oil filler plug 3. Case 4. Pinion (number of teeth: 6) 5. Drain plug
10-118
GD535-5
10 Structure and function
6. Worm wheel (number of teeth: 36) 7. Collar 8. Shim 9. Spring 10. Plate 11. Disc 12. Shim 13. Shaft 14. Floating seal 15. Worm
GD535-5
Circle rotation gear
Outline q The circle rotation gear is driven by circle rotation motor (1) that is connected to worm (15). q Shaft (13) has a clutch mechanism. If abnormal rotation is transmitted from the blade, disc (11) slips to prevent the blade from being damaged. q Clutch pressure of the clutch mechanism can be adjusted by adjusting thickness of shim (8).
10-119
ROPS canopy
10 Structure and function
Cab and its attachments
1
ROPS canopy
1
ROPS Abbreviation for Roll-Over Protective Structure
1. KOMTRAX GPS antenna and communication antenna
10-120
Function q The ROPS canopy protects the operator who uses the s eatbel t fr om be ing c r ushed when the machine tips over.
GD535-5 (03)
10 Structure and function
ROPS cab
1. 2. 3. 4. 5. 6.
Yellow revolving lamp (*1) L.H. door wiper Front windshield wiper Cab mount working lamp KOMTRAX GPS antenna KOMTRAX Communication antenna (ORBCOMM specification) (*2) 7. Radio antenna 8. R.H. door wiper 9. Air conditioner fresh air filter 10. Rear windshield wiper 11. KOMTRAX Communication antenna (3G specification) (*3)
ROPS cab
1
Function ROPS cab is to protect the operator wearing seat belt from being crushed when the machine tips over.
*1: Machines with yellow revolving lamp *2: Machines with KOMTRAX (ORBCOMM specification) *3: Machines with KOMTRAX (3G specification)
GD535-5 (03)
10-121
Machine monitor
10 Structure and function
Electrical system
1
Machine monitor
1
1. Connector (AMP070-12P) 2. Connector (DT-TB-12P) Function q The machine monitor has the monitor display function, mode selection function, and switch function of electrical equipment, and also has a built-in alarm buzzer. q A CPU (central processing unit) installed in it processes information, displays, and outputs a result. q It consists of the display and switch section. LCD (liquid crystal display) is used for the display and flat sheet switches are employed in the switch section. a When there is any defect in the machine monitor itself, any controller, or wiring between the machine monitor and any controller, the machine monitor cannot correct information. a One of the features of the liquid crystal of the display is that there may be black spots (spots that do not light up) or bright spots (spots that stay lit) on the screen. LCD with black spots and bright spots not more than 10 spots is not deemed to be a failed or defective display.
10-122
a At engine start, the battery voltage can drop rapidly depending on ambient temperature or battery condition. In this case, the display may black out temporarily. However, this phenomenon does not indicate a failure. a For the machine monitor being used for the long term, bright blue spots may be seen on the black background. However this phenomenon does not indicate a failure or defect. Bright blue spots do not matter because the normal screen of the display has a blue or white background. (To display white color on the LCD, red, green, and blue spots light up simultaneously.) a For the items below, see "Operation & Maintenance Manual". q Display (screen display) q Switches section q Guidance icon
GD535-5
10 Structure and function
Machine monitor
Input and output signals AMP070-12P [FP1] Pin No.
Signal name
Input/ Output signal
1
Continuous power supply (24 V)
2
GND
4
Starting switch (ACC)
3
Reserved
Output
5
External buzzer output
Output
6
Continuous power supply (24 V)
7
GND
8
Reserved
Input
9
External starting signal
Input
10
System operating lamp
Output
11
CANO_H
Input/ Output
12
CANO_L
Input/ Output
GD535-5
Input Input
Input -
10-123
Machine monitor
10 Structure and function
Gauges and meters Gauge
Display item
Speedometer
Display range and display method
Remarks If a communication error occurs between the monitor controller and the transmission controller, "0" is displayed.
0 to 99 km/h
q
Engine speed meter
0 to 3,500 rpm q
Engine coolant temperature gauge
Torque converter oil temperature gauge
Fuel level gauge
Articulate gauge
10-124
Range
Coolant temperature (°C)
Graduation color
W1
135
Red
W2
102
Red
W3
89
Green
W4
76
Green
W5
63
Green
W6
50
White
Range
Oil temperature (°C)
Graduation color
P1
135
Red
P2
120
Red
P3
93
Green
P4
66
Green
P5
20
White
Range
Fuel level (l)
Graduation color
F1
188
Green
F2
175
Green
F3
122
Green
F4
62
Green
F5
54
Green
F6
51
Red
Range
Articulated angle (degree)
Graduation color
A1
23
Green
A2
5
White
A3
5
White
A4
23
Green
q
q
q
q
q q
If engine speed increases above the specified level, an engine overspeed caution warning lamp lights up. (For details, see "Engine overspeed warning lamp".) If a communication error occurs, the meter reads "0". If the temperature exceeds 102°C, the engine coolant temperature warning lamp lights up. (For details, see "Engine coolant temperature warning lamp".) If a communication error occurs, the gauge reads "0".
If the temperature exceeds 120°C, the torque converter oil temperature warning lamp lights up. If a communication error occurs, the gauge reads "0".
If effective remaining fuel level drops below 100 l, a warning lamp lights up. If sensor error occurs, the gauge reads "0".
This gauge indicates the status of the articulated angle between the front and rear frames.
GD535-5
10 Structure and function
Gauge
Machine monitor
Display item
Display range and display method
Remarks q
Service meter (*1)
0 to 999999.9 h
q
q
Odometer (*1)
0 to 3999999.9 km
Fuel consumption meter (*1)
q q
Daily fuel consumption display Split fuel consumption display
q
Clock (*1)
q
12-hour clock display (AM/PM) 24-hour clock display
This meter integrates travel distances. When the integrated value exceeds 3999999.9 km, the meter reading stops at 3999999.9 km.
This meter displays average fuel consumption.
q q
This meter integrates engine running hours. When the integrated value exceeds 999999.9 h, the meter reading stops at 999999.9 h.
This clock displays time. (12-hour and 24-hour settings can be switched by using Monitor setting → Clock adjustment in User Menu.) )
*1 Each time switch "F2" is pressed, display item changes in the order shown below each time. q Service meter → Odometer → Fuel consumption gauge → Clock
GD535-5
10-125
Machine monitor
10 Structure and function
Warning lamps Display range and display method Symbol
Display item
Action level
Centralized warning lamp
Warning lamp display (backgroun d color)
Action level display
When a defect of action level L04 is detected
Lighting up (red)
L04
When a defect of action level L03 is detected
Lighting up (red)
L03
When a defect of action level L02 is detected
Lighting up (red)
L02
When a defect of action level L01 is detected
Lighting up (yellow)
L01 (*2)
Range
When a defect of action level L02 and above is detected
Lighting up (red)
When a defect is detected while the engine is running (below specified value)
Brake oil pressure
When a defect is detected at the time of starting engine (below specified value) When a defect is detected while the engine is stopped (below specified value)
Engine coolant temperature
Min. 105 °C
Min. 120 °C
Remaining fuel 76 l or below level
10-126
q
-
-
-
Lighting up (red)
Min. 102 °C Torque converter oil temperature
q
L03
Lighting up (red)
Lighting up (red)
Lighting up (red)
Remarks
When any machine defect is detected, a centralized warning lamp lights up. When a warning lamp lights up with red background color, a warning buzzer sounds continuously for a defect related to L04 and sounds intermittently for a defect related of L02 or L03.
When any defect of action level L02 and above is defected or it is requested to give a warning to the operator, a centralized warning lamp lights up and a warning buzzer sounds intermittently. If brake oil pressure drops excessively while the engine is running, a centralized warning lamp lights up and a warning buzzer sounds intermittently. After the engine has been started, if brake oil pressure has not risen sufficiently, a centralized warning lamp lights up and a warning buzzer sounds intermittently. If brake oil pressure drops excessively while the engine is stopped, a warning lamp lights up.
L02
If engine coolant temperature rises above 105 °C, a centralized warning lamp lights up and a warning buzzer sounds intermittently.
-
If engine coolant temperature rises above 102 °C, a warning lamp lights up.
L02
-
If torque converter oil temperature rises above 120 °C, a centralized warning lamp lights up and a warning buzzer sounds intermittently. This lamp lights up when effective remaining fuel level is 76 l or below.
GD535-5 (03)
10 Structure and function
Machine monitor
Display range and display method Symbol
Display item
Hydraulic oil temperature
Differential oil temperature
Maintenance time
Range
100 °C and above
120 °C and above
Lighting up (red)
L02
When maintenance time is over
Lighting up (red)
-
When maintenance reminder time is over
Lighting up (yellow)
-
When a defect of action level L03 is detected
Lighting up (red)
L04 and L03
Lighting up (yellow)
L01 (*2)
Engine overrun Engine speed (*1) exceeds 2550 rpm
Transmission system (*1)
Action level display
Lighting up (red)
Engine system (*1) When a defect of action level L01 is detected
Engine oil pressure (*1)
Warning lamp display (backgroun d color)
Lighting up (red)
L02
L02
Lighting up (red)
L03
When a defect of action level L04, L03 or L02 is detected
Lighting up (red)
L04, L03 and L02
When a defect of action level L01 is detected
Lighting up (yellow)
L01 (*2)
Lighting up (red)
If hydraulic oil temperature rises above 100 °C, a centralized warning lamp lights up and a warning buzzer sounds intermittently. A centralized warning lamp lights up and a warning buzzer sounds intermittently.
q
q
When a defect is detected (below specified value)
When a defect is detected in the Battery charge battery charge level (*1) system while the engine is running
Remarks
L03
q q
This lamp lights up for 30 seconds after starting switch is turned to the "ON" position if maintenance time of any item is over. Maintenance reminder time can be changed by using "Maintenance mode setting" → "Maintenance mode change" → "Maintenance mode reminder time setting" in Service menu. When any defect is detected in the engine system, a warning lamp lights up. When any defect of action level L03 is detected, a centralized warning lamp lights up with a red background color, a centralized warning lamp lights up, and a warning buzzer sounds intermittently.
Centralized warning lamp lights up, and alarm buzzer sounds intermittently.
If any defect is detected while the engine is running, a centralized warning lamp lights up and a warning buzzer sounds intermittently. q q
If any defect is detected in transmission system, a caution lamp lights up. When a caution lamp lights up with a red background color, a centralized warning lamp lights up and a warning buzzer sounds continuously for a defect related to L04 or sounds intermittently for a defect related to L03 and L02.
A caution lamp lights up with a red background color, a centralized warning lamp lights up, and a warning buzzer sounds intermittently.
*1: If 3 or more warning lamps become active at the same time, symbols to be displayed switch every 2 seconds in units of 2 symbols.
*2: After lighting up for 2 seconds, it goes off.
GD535-5 (03)
10-127
Machine monitor
10 Structure and function
Pilot lamp Symbol
Display item
Display range and display method
Parking brake
Lighting up: LOCK Going off: FREE
Turn signal (L.H.)
Flashing: When the L.H. turn signal is indicated or the hazard lamp switch is set to the "ON" position
Headlamp (high beam)
Lighting up: When the headlamp is set to high beam
Turn signal (R.H.)
Flashing: When the R.H. turn signal is indicated on or the hazard lamp switch is set to the "ON" position
Clearance lamp
Lighting up: When the clearance lamp is turned on
Shift indicator
Indication: Gear speed (F1, F2, F3, F4, F5, F6, F7, F8, N, R1, R2, R3, and R4)
Remarks This lamp indicates the state of parking brake lever.
q
Position of gear shift lever
Highlighting: Position of gear shift lever (1, 2, 3, 4, 5, 6, 7, 8, R, N, and F)
q
Message (unread)
Lighting up: There is an unread message. Going off: There are no unread messages.
If the engine starting switch is turned to the "ON" position with gear shift lever set to a position other than "P" and "N", character indicating current travel direction (F or R) flashes and a centralized warning lamp and warning buzzer are activated. (Neutral safety warning) If all signals from gear shift lever turn to "OFF", normal position that were input shortly before is indicated.
This lamp indicates read/unread state of messages.
This lamp indicates read/unread Lighting up: There is a message that is read but Message state of messages. unanswered. (Read or unanswered) Going off: There are no unread messages.
10-128
P mode
Lighting up: When P mode is selected
E mode
Lighting up: When E mode is selected
GD535-5
10 Structure and function
Symbol
Display item
Lock up
Machine monitor
Display range and display method
Remarks
Lighting up: When torque converter lock up is activated Going off: When torque converter lock up is not activated Lighting up: When transmission mode selector switch is set to T/C auto mode ON
Transmission mode Going off: When transmission mode selector switch is set to MANUAL mode ON
Working lamp
Lighting up: When the working lamp is turned on Going off: When the working lamp is turned off
Differential lock (*1)
Lighting up: When the differential lock switch is set to ON Going off: When the differential lock switch is set to OFF
Lifter lock pin
Lighting up: When the lifter lock pin is in the FREE position Going off: When the lifter lock pin is in the LOCK position
RPM set
Lighting up: When the accelerator pedal opening is set Going off: When the accelerator pedal opening is not set
Preheating
Lighting up: When the engine preheat electrical intake airheater is operated Going off: When the engine preheat electrical intake airheater is not operated
Economy operation
Lighting up or off in accordance with accelerator The lamp indicates economic pedal operation.
*1: For machines with differential lock type rear axle
GD535-5 (03)
10-129
Machine monitor
10 Structure and function
Operator mode functions q These functions are displayed normally. An operator can dis play and set them by operating switches. Some functions require special switch operations to display and set them. q The following items can be selected in the operator mode. Group (*1)
A
Display sequence pattern (*2)
Item
W
X
Y
Z
Display of KOMATSU logo
1
1
1
1
Display of password input request
2
-
-
-
Display of results of check before starting
3
2
2
2
Display of warning after check before starting
-
-
3
-
Display of maintenance due time over
-
-
-
3
Display of standard screen
4
3
4
4
Display of end screen
B
C
Setting and display in user menu q ECO Guidance q Machine Setting and Information q Maintenance q Monitor Setting q User Message (including KOMTRAX message for users) Display of caution monitor Display of maintenance due time over Checking function of LCD display
D
Confirmation function of service meter and odometer Function of usage limitation setting/ changing password
*1. Operator mode items are classified as follows. A: Display from the time when the starting switch is turned to the "ON" position to the time when the display changes to the standard screen, and display after the starting switch is turned to the "OFF" position B: Display when machine monitor switch is operated C: Display when condition is satisfied D: Display that requires special operations of switches
*2: Display sequence from the time when the starting switch is turned to the "ON" position to the time when the sta ndar d sc re en appea rs v ar ies depending on the settings and conditions of the machine as follows: W: When the engine start lock is enabled X: When the engine start lock is disabled Y: When any abnormality is detected by the check before starting Z: When any maintenance item that is near the maintenance due time or maintenance due time is over is detected q q
10-130
For the operation method of each operator mode function, see Operation and Maintenance Manual. For the operation method of the engine start lock function, see "Password setting and canceling manual".
GD535-5
10 Structure and function
Machine monitor
Service mode functions q These functions are not displayed normally. A technician can display and set them with special operation of switches. They are used for special settings, inspection, adjustment, and troubleshooting. q The following items can be selected in the service mode. Monitoring /defined Monitoring / Custom Abnormality Record
Mechanical Systems Electrical Systems
Maintenance Time Reset Maintenance Record Maintenance Mode Setting Phone Number Entry Machine Model Select Default
Option Selection Unit Selection
Diagnostic Tests
Cylinder Cut-out ECMV Automatic Compensation T/M Initial Learning T/M Initial Learning Reset
Adjustment
T/C Stall Inching Pedal 0% Adjustment Inching Pedal 100% Adjustment Zero Point Adjustment For Art Angle
No Injection Terminal Status KOMTRAX Settings
GPS & Communication Status Modem Status
Service Message
a For the operation method of each service mode function, see "Service Mode" in the Testing and Adjusting section.
GD535-5
10-131
Machine monitor
10-132
10 Structure and function
GD535-5
10 Structure and function
Automatic gear shift control system
Automatic gear shift control system
1
Outline q In the automatic gear shift control system, the transmission controller receives lever position signals from the gear shift lever, electrical potential signals from the accelerator pedal and inching pedal, speed signals from the transmission, and signals from other switches and sensors, and automatically sets the transmission at an optimum gear speed. q The transmission controller performs torque converter lockup control as well as transmission gear speed control.
GD535-5
10-133
Automatic gear shift control system
10 Structure and function
Gear shift lever position Gear shift lever position and automatic gear shift range q The table below shows the relationship between gear shift lever position and gear speed. q Gear shift and lockup patterns switches according to operation of the transmission mode selector switch. q When the transmission mode selector switch is set to "MANU" (manual mode), the transmission is manually shifted according to the gear shift lever position. Note, however, that the transmission is automatically shifted according to the machine travel speed when the gear shift lever is positioned in R3 or R4. q When the transmission mode selector switch is set to "T/C AUTO" (automatic mode), the transmission is manually shifted when the gear shift lever is positioned in F1 to F4 or R1 to R2. It is automatically shifted according to the machine travel speed when the gear shift lever is positioned in F5 to F8 or R3 and R4. q When the transmission is in manual gear shift condition, to prevent engine overrun, the transmission may not switch to the selected gear speed regardless of operations of the transmission mode selector switch. MANU mode Gear speed
Gear shift lever position
N
N
A
F1
F1
F2
F3
F4
F5
F6
F7
F8
R1
R2
R3
R4
B
F2
B
F3
B
F4
B
F5
B
F6
B
F7
B
F8
B
R1
A
R2
A
R3
A
C
R4
A
C
C
R2
R3
R4
T/C AUTO mode Gear speed
Gear shift lever position
N
N
A
F1
F1
F3
F4
F5
F6
F7
F8
R1
A
F2 F3
A A
F4
A
F5
A
C
F6
A
C
C
F7
A
C
C
C
F8
A
C
C
C
R1
C A
R2
A
R3
A
C
R4
A
C
A: Lockup clutch is not engaged. B: Lockup clutch is engaged.
10-134
F2
C
C: Lockup clutch is automatically engaged.
GD535-5
10 Structure and function
Automatic gear shift control system
Overrun prevention function q When the machine travels downhill or rapid gear shifting is carried out, to prevent engine overrun, the transmission may shift to a gear speed that is different from that indicated by the gear shift lever position. Ultra-low speed travel control q When engine overrun is detected, this function emits a brief warning sound to warn the operator. q When the machine decelerates, the engine overrun prevention function is canceled and the transmission automatically shifts to the gear speed corresponding to the gear shift lever position. VHPC control q The transmission controller and engine controller exchange signals through CAN communication.
q
With gear shift lever at "F1", transmission mode selector switch at "T/C AUTO", and accelerator pedal not pressed, if the travel speed lowers to 1.97 km/h or below, inching pedal is not pressed, and engine speed lowers below 1,000 rpm, the machine enters into the ultra-low speed travel mode and the travel speed is kept at 0.8 km/h.
q
Any change of engine power mode is made after gear shifting is completed.
← CAN communication → (VHPC signal →)
Transmission controller
Engine controller
High ← Priority of judgment → Low Torque converter stall mode Gear speed
ALL
Engine power mode
MID
Table 1: Direct drive mode Engine power mode switch ○: E Mode ●: P Mode
Normal gear shift mode (VHPC control) See the table shown below.
Table 2: Torque converter AUTO mode Engine power mode switch ○: E Mode ●: P Mode
E mode
P mode
F1
○
●
F2
○
F3
Engine power mode E mode
P mode
F1
○
●
●
F2
○
●
○
●
F3
○
●
F4
○
●
F4
○
●
F5
○
●
F5
○
●
F6
○●
F7
○●
F8
F8 mode
○●
P, N
○●
R1
○
R2
○
Gear speed
Gear speed
Engine power mode
F6
○●
F7
○●
F8
F8 mode
○●
P, N
○●
●
R1
○
●
●
R2
○
●
R3
○
●
R3
○
●
R4
○
●
R4
○
●
Engine output value (NET value) at each engine power mode is shown below. E mode: 101 kW {135 HP} P mode: 108 kW {145 HP} F8 mode: 108 kW {145 HP}
GD535-5
10-135
Automatic gear shift control system
10 Structure and function
Schematic diagram of input and output signals Transmission input shaft speed sensor
Po
oA
FL solenoid (ECMV)
Transmission output shaft speed sensor
Po
oA
FH clutch solenoid (ECMV)
Transmission intermediate shaft speed sensor
Ao
oA
R clutch solenoid (ECMV)
Transmission oil temperature sensor
Ao
oA
Lockup clutch solenoid (ECMV)
Torque converter outlet oil temperature sensor:
Do
oA
1st clutch solenoid (ECMV)
FL clutch pressure switch
Do
oA
2nd clutch solenoid (ECMV)
FH clutch pressure switch
Do
oA
3rd clutch solenoid (ECMV)
R clutch pressure switch
Do
oA
4th clutch solenoid (ECMV)
1st clutch pressure switch
Do
2nd clutch pressure switch
Do Do
4th clutch pressure switch
Do
F (forward) signal
Do
R (reverse) signal
Do
Neutral signal
Do
NOT parking signal
Do
oC Transmission controller
3rd clutch pressure switch
Machine monitor Speedometer q Tachometer q Articulate gauge q Transmission oil temperature gauge q Parking signal q Differential oil temperature signal (*1) q
oC
Engine controller VHPC selection signal q Engine speed signal q Error information q Throttle lower limit signal
Do
oD
Parking brake release signal
7 signal
Do
oD
Differential control relay (*1)
8 signal
Do
oD
Backup alarm relay
Inching potentiometer
Ao
oD
RPMset switch 1
Differential selector switch (*1)
Do
oD
RPMset switch 2
q
Parking signal
Do
1 signal
Do
2 signal
Do
3 signal
Do
4 signal
Do
5 signal
Do
6 signal
10-136
GD535-5
10 Structure and function
Automatic gear shift control system
Do
oA
Motor flow controller
Transmission mode switch
Do
oC
Error code
Articulated sensor
Ao
Alternator R
Ao
Starting motor (C)
Do
Brake signal (oil pressure switch)
Do
Hydraulic oil temperature sensor
Ao
Differential oil temperature sensor (*1)
Ao
Manual preheat signal
Do
A: D: P: C:
Transmission controller
Engine power mode switch
Analog signal Digital signal Pulse signal CAN signal
*1: For machines with differential lock type rear axle
GD535-5
10-137
Automatic gear shift control system
10 Structure and function
System circuit diagram
10-138
GD535-5
10 Structure and function
Automatic gear shift control system
*1: For machines with differential lock type rear axle
GD535-5
10-139
Transmission controller
Transmission controller
10 Structure and function
1
Function Real time monitoring function q Input and output signals of the controller can be checked by using the monitoring function of the machine monitor. q For the points of the monitoring function, see Testing and Adjusting, "Special functions of machine monitor". Self-diagnosis function q The transmission controller always monitor state of input and output signals to self-diagnose the system. q If the transmission defects any defect, it send the defect occurrence information to the machine monitor through the network. q If any defect occurs, it can be checked by using machine monitor.
10-140
GD535-5
10 Structure and function
Transmission controller
Input and output signals DEUTSCH-24P [TM39] Pin No.
Signal name
Input and output signals
Pin No.
-
14
Signal name Differential oil temperature sensor
Input and output signals
1
(*1)
Input
2
Transmission L/U pressure sensor
Input
15
Alternator terminal R
Input
3
Transmission oil temperature sensor
Input
16
Sensor power supply
Output
4
GND (SIG)
-
17
Gear shift mode switch
Input
5
Engine preheat signal
Input
18
RPMset MODE-MANU
Input
6
Brake accumulator F oil pressure switch
Input
19
Fuel gauge sensor
Input
7
Inching potentiometer
Input
20
Hydraulic oil temperature sensor
Input
8
Articulated sensor
Input
21
GND (analog GND)
-
9
Torque converter outlet oil temperature sensor:
Input
22
Power supply (5 V)
Output
10
GND (SIG)
-
23
Clearance lamp relay signal
Input
11
Stop lamp signal
Input
24
RPMset MODE-AUTO
Input
12
Engine power mode selector switch
Input
13
(*1)
*1: Be sure not to connect anything to this pin. Doing so can cause a malfunction or failure.
DEUTSCH-40P (1) [TM40] Pin No.
Signal name
Input and output signals
Pin No.
Output
22
CAN0_L
-
23
(*1)
-
Signal name
Input and output signals
1
Power supply (5 V)
2
T/M FILL 3
Input Input
24
Service connector input
Input
-
25
F (forward) signal (shifter)
Input
3
T/M FILL 2
4
(*1)
5
1st signal (shifter)
Input
26
3rd signal (shifter)
Input
6
5th signal (shifter)
Input
27
T/M FILL R
Input
7
T/M FILL FH
Output
8
Differential control relay
9
Input
28
BR DRIVE
Output
29
GND (pulse GND)
Input
(*1)
-
30
Transmission output shaft speed sensor
Input
10
(*1)
-
31
(*1)
-
11
(*1)
-
32
CAN0_H
-
12
Differential lock switch
Input
33
(*1)
-
13
T/M FILL
Input
34
(*1)
-
14
(*1)
-
35
Neutral signal (shifter)
Input
15
R (reverse) signal (shifter)
Input
36
2nd signal (shifter)
Input
16
4th signal (shifter)
Input
37
Brake accumulator R oil pressure switch
Input
17
T/M FILL FL
Input
38
T/M FILL 4
Input
18
Backup lamp relay
Output
39
GND (pulse GND)
Input
19
Centralized warning lamp
Output
40
Transmission input shaft speed sensor
Input
20
Transmission intermediate shaft speed sensor
21
(*1)
GD535-5
Input
*1: Be sure not to connect anything to this pin. Doing so can cause a malfunction or failure.
-
10-141
Transmission controller
10 Structure and function
DEUTSCH-40P (2) [TM41] Pin No.
Signal name
Input and output signals
Pin No.
Signal name
Input and output signals
1
VB (controller PWR)
Input
21
GND (controller GND)
Input
2
VIS (solenoid PWR)
Input
22
VIS (solenoid PWR)
Input
3
SOL_COM (solenoid common GND)
Input
23
SOL_COM (solenoid common GND)
Input
4
(*1)
-
24
KEY_SIG
Input
5
T/M 1
Output
25
T/M 3
Output
6
(*1)
-
26
T/M FL
Output
7
Parking brake solenoid
Output
27
(*1)
-
8
ENG START RELAY
Output
28
(*1)
-
9
6th signal (shifter)
Input
29
8th signal (shifter)
Input
10
Starting motor C terminal signal
Input
30
RPMset-DECEL/RESUME
Input
11
VB (controller PWR)
Input
31
GND (controller GND)
Input
12
VIS (solenoid PWR)
Input
32
GND (controller GND)
Input
13
SOL_COM (solenoid common GND)
Input
33
GND (controller GND)
Input
14
KEY_SIG
Input
34
(*1)
15
T/M 2
Output
35
T/M 4
Output
16
T/M R
Output
36
T/M FH
Output
17
(*1)
-
37
(*1)
18
(*1)
-
38
T/M torque converter L/U
19
7th signal (shifter)
Input
39
Parking signal (shifter)
Input
20
RPMset-ACCEL/SET
Input
40
Not (EXC.) P signal (shifter)
Input
-
Output
*1: Be sure not to connect anything to this pin. Doing so can cause a malfunction or failure.
10-142
GD535-5
10 Structure and function
Engine controller
Engine controller
1
Input and output signals q The symbols in the signal classification column in the Input/output signal table are as follows. A: Power supply B: Input C: Ground/Shield/Return D: Output E: Communication DTP06-4P [EC3] Pin No.
Signal name
Signal classifica tion
1
GND
C
2
GND
C
3
Continuous power supply (+24 V)
A
4
Continuous power supply (+24 V)
A
GD535-5
10-143
Engine controller
10 Structure and function
DRC26-60P [EC1]
Pin No.
Signal name
Input and output signals
Pin No.
Signal name
Input and output signals
1
(*1)
-
31
NC
-
2
IMA power supply
D
32
IMA return
C
3
Ambient pressure sensor
B
33
Sensor power supply (+5 V)
A
4
(*1)
-
34
(*1)
-
5
(*1)
-
35
(*1)
-
6
CAN (-)
E
36
(*1)
-
7
(*1)
-
37
Sensor power supply (+5 V)
A
8
CAN (+)
E
38
GND
C
9
(*1)
-
39
(*1)
-
10
(*1)
-
40
(*1)
-
11
(*1)
-
41
(*1)
-
12
(*1)
-
42
(*1)
-
13
(*1)
-
43
(*1)
-
14
Water-in-fuel sensor
B
44
Boost pressure sensor
B
15
Coolant temperature sensor
B
45
Injector #1 (+)
D
16
Crankshaft speed sensor power supply (+5 V)
A
46
Injector #5 (+)
D
17
(*1)
-
47
G sensor GND
C
18
(*1)
-
48
Ne sensor GND
C
19
(*1)
-
49
(*1)
-
20
(*1)
-
50
(*1)
-
21
(*1)
-
51
Injector #2 (-)
C
22
(*1)
-
52
Injector #3 (-)
C
23
Boost temperature sensor
B
53
Injector #1 (-)
C
24
(*1)
-
54
Injector #2 (+)
D
25
Common rail pressure sensor
B
55
Injector #3 (+)
D
26
G sensor (+)
B
56
Injector #4 (+)
D
27
Ne sensor (+)
B
57
Injector #6 (+)
D
28
(*1)
-
58
Injector #4 (-)
C
29
(*1)
-
59
Injector #6 (-)
C
30
(*1)
-
60
Injector #5 (-)
C
*1: Be sure not to connect anything to this pin. Doing so can cause a malfunction or failure.
10-144
GD535-5
10 Structure and function
Engine controller
DRC26-50P [EC2]
Pin No.
Signal name
Input and output signals
Pin No.
Signal name
Input and output signals
1
Idle validation signal 2
B
26
(*1)
-
2
(*1)
-
27
(*1)
-
3
(*1)
-
28
(*1)
-
4
(*1)
-
29
(*1)
-
5
(*1)
-
30
(*1)
-
6
(*1)
-
31
(*1)
-
7
(*1)
-
32
Idle validation (-)
C
8
(*1)
-
33
GND
C
9
Accelerator pedal potentiometer signal
B
34
(*1)
-
10
(*1)
-
35
(*1)
-
11
Idle validation signal 1
B
36
(*1)
-
12
(*1)
-
37
(*1)
-
13
(*1)
-
38
(*1)
-
14
(*1)
-
39
Starting switch ACC signal
B
15
(*1)
-
40
Grid heater relay drive signal
D
16
(*1)
-
41
(*1)
-
17
(*1)
-
42
(*1)
-
18
(*1)
-
43
(*1)
-
19
(*1)
-
44
(*1)
-
20
(*1)
-
45
(*1)
-
21
(*1)
-
46
CAN_H
E
22
Accelerator pedal potentiometer power supply (+5 V)
A
47
CAN_L
E
23
Accelerator pedal potentiometer
C
48
(*1)
-
24
(*1)
-
49
PWM OUTPUT
D
25
(*1)
-
50
(*1)
-
*1: Be sure not to connect anything to this pin. Doing so can cause a malfunction or failure.
GD535-5
10-145
KOMTRAX system
KOMTRAX system
10 Structure and function
1
Function q The KOMTRAX system transmits various machine information by using the radio communication. KOMTRAX operators can refer to this information in their offices and provide various services to customers. q The KOMTRAX system can transmit the following information. q Position information q Operation information (service meter, odometer, etc.) q Alarm and failure information q Fuel consumption information q Maintenance information q Machine working condition information a To start this service, the radio communication establishment for KOMTRAX system must be performed separately.
10-146
GD535-5
10 Structure and function
KOMTRAX terminal
KOMTRAX terminal
1
Model: TC330/TC630
1. 2. 3. 4. 5.
GPS antenna connection Machine wiring harness connection port (070-18P) Machine wiring harness connection port (070-12P) Communication antenna connection LED lamp display
Function q This terminal uses mobile communication technology. q This is wireless communication equipment that transmits various machine information obtained from the network signals and input signals, as well as the GPS position information. This terminal can send information through the communication antenna. q Conditions of the KOMTRAX terminal can be checked by using "KOMTRAX setting display" in the service mode menu of the machine monitor. q Use of this terminal is not allowed in the countries or regions where legal authorization is not obtained. q The terminal has LED lamps and 7-segment pilot lamp used for testing and troubleshooting on its display section. q Countries where use of the terminal is allowed differ between models TC330 and TC630.
GD535-5
10-147
KOMTRAX terminal
10 Structure and function
Input and output signals 070-18P [L08A] Pin No.
Signal name
070-18P [L08B] Input and output signals
Pin No.
Signal name
Input and output signals
1
(*1)
-
1
GND (continuous power supply)
-
2
(*1)
-
2
GND (continuous power supply)
-
3
(*1)
-
3
Starting switch ACC signal
Input
4
(*1)
-
4
Alternator R signal
Input
5
(*1)
-
5
(*1)
6
(*1)
-
6
Continuous power supply (24 V)
Input
7
(*1)
-
7
Continuous power supply (24 V)
Input
8
(*1)
-
8
(*1)
-
9
(*1)
-
9
(*1)
-
10
CAN2_H
Input/ Output
10
(*1)
-
11
Starting switch C signal
11
CAN2_L
Input/ Output
12
(*1)
12
(*1)
-
13
(*1)
-
14
External starting signal
Input/ Output
15
System operating lamp
Output
16
(*1)
-
17
(*1)
-
18
(*1)
-
-
Input -
*1: Be sure not to covnnect anything to this pin. Doing so can cause a malfunction or failure.
*1: Be sure not to connect anything to this pin. Doing so can cause a malfunction or failure.
10-148
GD535-5
10 Structure and function
Engine starting circuit
Engine starting circuit
1
Function 1. This circuit employs a parking safety circuit to assure safety when the engine is started. q The engine cannot start with the gear shift lever set to a position other than "P (PARK)". 2. The KOMTRAX engine cut-off circuit is employed to prevent the engine from starting when the KOMTRAX terminal receives an engine cut-off command issued via external operation.
GD535-5
10-149
Engine starting circuit
10 Structure and function
Operation 1. When starting switch is in "ON" position q When the starting switch is turned to the "ON" position, starting switch terminals B and BR are connected and a current flows from the battery to the ground through the starting switch and battery relay coil, and the battery relay contacts are closed. This allows electric power to be supplied to each circuit of the machine. At this time, the ACC signal is sent from the starting switch ACC terminal to the engine controller to complete engine start preparations. 2. Parking safety circuit q When the gear shift lever is in "P (PARK)", a current flows from the gear shift lever terminal 6 to safety relay coil to activate safety relay. q When the starting switch is turned to the "START" position while the safety relay is activated, the self hold relay is activated. So, the safety relay can be held even if the P signal from the gear shift lever is interrupted due to a drop in voltage. q When the gear shift lever is in a position other than "P (PARK)", the current from the gear shift lever terminal 6 to safety relay is cut off. As a result, the starting circuit is cut off because no current flows through the safety relay coil. 3. When starting switch is in "START" position q When the starting switch is turned to the "START" position, a current flows from the starting switch C terminal to the starting motor safety relay through the KOMTRAX engine cut-off relay, and safety relay float ENG cancel relay, allowing the engine to start. q When the gear shift lever is set to a position other than "P (PARK)", the parking relay is not activated and the engine cannot be started. q When the KOMTRAX terminal receives an engine cut-off command issued via external operation, the KOMTRAX engine cut-off relay is activated. This breaks the circuit from the starting switch C terminal to the parking relay and the engine cannot be started. 4. After starting the engine q When the starting switch is returned to the "ON" position, the current from the starting switch C terminal is cut off and no current flows from the safety relay to the starting motor.
10-150
GD535-5
10 Structure and function
Engine stop circuit
Engine stop circuit
1
Operation q When the starting switch is turned to the "OFF" position, the ACC signal from the starting switch terminal ACC to the engine controller is cut off and fuel supply to the engine is stopped. q When fuel supply to the engine is stopped, engine speed drops and then stops. q When the engine stops, power generation by the alternator is stopped and voltage feed from the alternator R terminal is cut off. q When the current from the starting switch BR terminal is cut off, battery relay contacts open. So, power supply to each circuit of the machine is stopped.
GD535-5
10-151
Preheating circuit
10 Structure and function
Preheating circuit
Outline q This machine is equipped with an automatic preheating system to improve engine startability in cold districts. q With the automatic preheating system, preheating time is automatically set according to the intake air temperature when the starting switch is turned to the "ON" position. q When the starting switch is turned to the "ON" position, the preheating pilot lamp on the machine monitor lights up and the intake air heater preheats the intake air. q The engine controller detects the engine coolant temperature and sets the preheating time. q While the pilot lamp lights up, the preheating is in progress. So, be sure to keep the starting switch set at "ON" position during the period. If the starting switch is turned to the "START" position during the period, the preheating is canceled. q The automatic preheating system judges the necessity of preheating depending on the engine coolant temperature. Therefore, the engine may not start easily under such special conditions that the engine is warmed with an external heater. q In this case, turn the starting switch to the "R (preheat)" position to enable manual preheating.
1
Operation q When the starting switch is turned to the "ON" position, the engine controller starts. At this time, if the engine coolant temperature is below the set value, the engine controller activates the heater relay just after the starting switch is turned to the "ON" position, and then the intake air heater starts preheating. q The figure below shows the operating time of automatic preheating.
q
10-152
When the starting switch is turned to the "R (preheat)" position, the heater relay is activated and preheating by the intake air heater starts regardless of outside air temperature. The operating time of manual preheating needs to be within 5 to 30 seconds.
GD535-5
10 Structure and function
Sensors
Sensors
1
Engine oil pressure switch
1. Connector 2. Sensor 3. O-ring Coolant temperature sensor Fuel temperature sensor
1. Connector 2. Sensor 3. O-ring
GD535-5
10-153
Sensors
10 Structure and function
Engine speed sensor
1. Connector 2. Sensor 3. O-ring Ambient pressure sensor
1. Connector 2. Pressure introduction hole
10-154
GD535-5
10 Structure and function
Sensors
Charge (Boost) pressure and temperature sensor
1. Connector 2. Sensor 3. O-ring WIF (water-in-fuel) sensor
1. 2. 3. 4.
Connector Tube Sensor O-ring
GD535-5
10-155
Sensors
10 Structure and function
Accelerator pedal sensor
1. Pedal 2. Connector 3. Sensor
Output characteristics
Function q This sensor installed on the top surface of the floor outputs accelerator pedal potentiometer signals and idle validation signals according to the pressing angle of the accelerator pedal. Accelerator pedal potentiometer signal The sensor detects the amount of accelerator pedal displacement with the potentiometer in it and outputs variable voltages from its No. 2 pin.
q
Idle validation signal To detect a failure of the potentiometer, the sensor outputs ON and OFF signals from the No. 5 and No. 6 pins according to the accelerator pedal manipulation.
q
10-156
GD535-5
10 Structure and function
Sensors
Inching pedal potentiometer
1. Pedal 2. Return spring 3. Potentiometer 4. Arm assembly 5. Lever assembly 6. Spring Function q This sensor installed on the top surface of the floor detects the pressing angle of the inching pedal, converts it into an electric signal corresponding to the angle, and outputs the signal Relationship between pedal operation angle and lever stroke (point (a))
GD535-5
Relationship between pedal operation angle and output voltage
10-157
Sensors
10 Structure and function
Potentiometer
1. Shaft 2. Housing 3. Bearing 4. Brush 5. Variable resistor 6. Connector
Output characteristics
Function q This sensor is installed on the front frame side of the joint between the front and rear frames. q This sensor detects the articulation angle between the front and rear frames, converts it into an electric signal corresponding to the angle, and outputs the signal.
10-158
GD535-5
10 Structure and function
Sensors
Torque converter oil temperature sensor Transmission oil temperature sensor Hydraulic oil temperature sensor Differential lock oil temperature sensor (*1) *1: For machines with differential lock type rear axle
1. Connector 2. Plug
3. Thermistor
Function q The torque converter oil temperature sensor is installed on the torque converter outlet port at the top of the transmission front case, and the transmission oil temperature sensor and differential lock oil temperature sensor are installed on the lubrication line at the front face of the transmission rear case and the rear face of the rear axle respectively. q These sensors detect respective hydraulic oil temperatures, converts them into electric signals corresponding to the temperature, and outputs these signals. Brake oil pressure switch
1. Pressure switch 2. cable
3. Connector
Function This switch is installed on the brake accumulator piping. q This switch detects the brake oil pressure (accumulator pressure) and comes ON when the pressure drops below the set pressure. q
GD535-5
10-159
Sensors
10 Structure and function
Transmission input shaft speed sensor Transmission intermediate shaft speed sensor Transmission output shaft speed sensor
1. Wire 2. Magnet 3. Terminal
4. Housing 5. Connector
Function q These sensors are installed on the input shaft section, shaft section, and output shaft section of the transmission case respectively. q These sensors detect gear speeds, converts them into pulse signals corresponding to the speed, and outputs the signals.
10-160
GD535-5
10 Structure and function
Sensors
Fuel level sensor
1. Connector 2. Float 3. Arm 4. Body
5. Spring 6. Contact 7. Spacer
Function q This sensor is installed on the side face of the fuel tank. q This sensor detects the level of remaining fuel, converts it into an electric signal corresponding to the level of remaining fuel, and outputs the signal. q The float rises and falls according to the level of remaining fuel. q The movement of the float activates the variable resistor through the arm.
GD535-5
10-161
Engine power mode selector circuit
Engine power mode selector circuit
10 Structure and function
1
a: Engine power mode selector signal b: Power supply c. CAN signal 1. Battery 2. Battery relay 3. Fuse box 1 4. Power mode selector switch 5. Transmission controller 6. Machine monitor 7. Engine controller Function q Pressing the power mode selector switch switches the power mode between "P mode", in which the engine output is maximized and "E mode", in which the fuel consumption in work is reduced. q The switch signal is input to the transmission controller and an engine output curve that matches the selected engine power mode is selected. Operation When the power mode selector switch, that is a momentary switch, is pressed, the switch signal is input to the transmission controller, and the mode switches to the P mode or E mode. q The transmission controller transmits a CAN signal that corresponds to each mode to the engine controller to switch engine torque performance curves. q The engine power mode pilot lamp is displayed on the machine monitor. q
10-162
GD535-5
20 Standard value table
GD535-5 (01)
20-1
Contents
Contents
20 Standard value table
1
Acronyms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-3 Standard value table- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-8 Standard value table for engine- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-8 Standard value table for machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-10
20-2
GD535-5 (01)
20 Standard value table
Acronyms
Acronyms q q q q
1
The abbreviations of unknown parts, equipment and functions have been extracted from the Shop Manual, and their official names and details are defined in this Acronyms. Abbreviations that are commonly used in society might not be described. Special and rarely used abbreviations are described in the supplementary explanation in the text. The acronyms consist of two parts: the list of abbreviations that are used in the text, and the list of abbreviations that are used in circuit diagrams.
Abbreviations that are used in the text Application (Applicable models (*1) and equipment)
Abbreviations
Official name
ABS
Anti-skid Brake System
AISS
Automatic Idling Setting Engine System
AJSS
Advanced Joystick Steering System
ARAC
Automatic Retarder Accelerator Control
Traveling, brake (HD series, HM series)
Steering (WA series) Traveling, brake (HD series, HM series) Traveling, brake
ARSC
Automatic Retarder Speed Control
ASR
Automatic Spin Regulator
ATT
Attachment
BCV
Brake Cooling oil control Valve
CAN
(HD series, HM series) Traveling, brake (HD series, HM series) Work equipment
Explanation With this function, when the tires skid (wheels stop rotating), the brakes are released, and when the wheels start to rotate, the brakes are applied again. This function automatically sets the idle speed. A lever is used to perform the steering operations instead of a steering wheel. Moreover, it shifts gear and changes direction (FORWARD or REVERSE). When the accelerator pedal is released while the machine is traveling downhill, this function automatically applies the retarder with a constant braking force. When the accelerator pedal is released while the machine is traveling downhill, this function automatically applies the retarder to ensure that the machine speed does not accelerate above the speed set by the operator. When the tires spin on soft ground surfaces, this function automatically uses the optimum braking force to drive both wheels. The function or parts which are attached to the standard model and used
(HD series)
When the retarder is not being used, this valve bypasses part of the brake cooling oil to reduce the load on the hydraulic pump.
Controller Area Network
Communication, electronic control
One of communication standards that is used in the network on the machine
CDR
Crankcase Depression Regulator
Engine
A regulator valve which is installed to KCCV ventilator. It is written as CDR valve and it is not used independently.
CLSS
Closed-center Load Sensing System
Hydraulic system
This system can simultaneously actuate multiple actuators regardless of the load (provides better combined operation than OLSS).
Engine
Engine controller electronically controls supply pump, common rail, and injector. This function maintains optimum fuel injection amount and fuel injection timing.
Electronic control
Electronic control device that receives signals from each sensor of the machine and that specifies the optimum operation to the actuators. (Same as ECU)
CRI
Common Rail Injection
ECM
Electronic Control Module
GD535-5 (01)
Brake
1
20-3
Acronyms
Abbreviations
20 Standard value table
Official name
ECMV
Electronic Control Modulation Valve
ECSS
Electronically Controlled Suspension System
Application (Applicable models (*1) and equipment) Transmission (D series, HD series, WA series and others) Traveling (WA series)
Explanation Proportional solenoid valve that reduces the connection shock by gradually increasing the hydraulic pressure to engage the clutch. This system ensures smooth high-speed travel by absorbing vibration of machine during travel with hydraulic spring effect of accumulator.
ECU
Electronic Control Unit
Electronic control
Electronic control device that receives signals from each sensor of the machine and that specifies the optimum operation to the actuators. (Same as ECM)
EGR
Exhaust Gas Recirculation
Engine
This function recirculates part of exhaust gas to the combustion chamber in order to reduce combustion temperature and control the emission of NOx.
Equipment Management Monitoring System
Machine monitor
This system allows data (filter, oil replacement interval, malfunctions on machine, failure code, and failure history) from each sensor on the machine to be checked on the monitor.
EPC
Electromagnetic Proportional Control
Hydraulic system
Electromagnetic proportional control This mechanism allows actuators to be operated in proportion to the current supplied.
FOPS
Falling Object Protective Structure
Operator's cab, canopy
F-N-R
Forward-NeutralReverse
Operation
Forward-Neutral-Reverse
Communication
GPS
Global Positioning System
Global positioning system The satellite positioning system to determine the current position on the earth
GNSS
Global Navigation Satellite System
EMMS
This performance is standardized as ISO 3449.
(KOMTRAX, KOMTRAX Plus) Communication (KOMTRAX, KOMTRAX Plus) Steering
20-4
This structure protects the operator's head from falling objects. (Falling Object Protective Structure)
Global navigation satellite system A general term for positioning system using satellites such as GPS, GALILEO, etc. This function uses a combination of hydraulic motor and bevel shaft to control difference in travel speed of right and left tracks. Accordingly machine can turn without using steering clutch.
HSS
Hydrostatic Steering System
HST
Hydro Static Transmission
ICT
Information and Communication Technology
Communication, electronic control
A general term for the engineering and its socially applied technology of information processing and communication.
IMA
Inlet Metering Actuator
Engine
Valve that adjusts fuel intake amount at inlet port of pump in order to control fuel discharged volume of supply pump. (Same as IMV)
IMU
Inertial Measurement Unit
Engine
This is a device to detect the angle (or angular velocity) and acceleration of the 3 axes that control motions.
IMV
Inlet Metering Valve
Engine
Valve adjusting fuel intake amount at inlet port of pump in order to control fuel discharged volume of supply pump. (Same as IMA)
(D series) Transmission (D series, WA series)
This function uses a combination of hydraulic pump and hydraulic motor to shift the speed range steplessly without using gears.
GD535-5 (01)
20 Standard value table
Abbreviations
Official name
Acronyms
Application (Applicable models (*1) and equipment)
KCCV
KOMATSU Closed Crankcase Ventilation
Engine
KCSF
KOMATSU Catalyzed Soot Filter
Engine
KDOC
KOMATSU Diesel Oxidation Catalyst
Engine
KDPF
KOMATSU Diesel Particulate Filter
Explanation The mechanism for oil separation from gas in order to re-burn the blow-by gas and for oil return to the intake system. It is mainly composed of filters. The filter to capture the soot from exhaust gas. It is built in the KDPF. The catalyst for exhaust gas purification.
Engine
It may be built in the KDPF or combined with the muffler. This component is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it. It is used instead of the conventional muffler.
Traveling, brake
This function recovers the drive force of the wheels by braking automatically with the optimum force and at the same time activates the inter-axle differential lock when the wheels idle while the machine travels on the soft ground road.
KOMATSU Traction Control System
(HM series)
LCD
Liquid Crystal Display
Machine monitor
The liquid crystal display panel. Image display device such as a monitor which assembles in the liquid crystal element.
LED
Light Emitting Diode
Electronic components
Light emitting diode It refers to semiconductor element that emits light when the voltage is applied in forward direction.
LIN
Local Interconnect Network
Communication, electronic control
One of communication standards that is used in the network on the machine
LS
Load Sensing
Hydraulic system
Function that detects differential pressure of pump and controls discharged volume corresponding to load.
KTCS
Low Voltage Differential Communication, electronic Signaling control
One of communication standards that is used in the network on the machine
MAF
Mass Air Flow
Engine
The intake airflow rate of the engine. It is not used alone, but used in combination with sensors. The intake airflow sensor may be called the MAF sensor.
MMS
Multimedia Messaging Service
Communication
The service to allow transmission and reception of short messages such as characters, voice and images between mobile phones.
Normally Closed
Electric system, hydraulic system
The characteristics of an electric or hydraulic circuit that is normally closed when the system is not operating, and that is normally opened when the system is operating.
Normally Open
Electric system, hydraulic system
The characteristics of an electric or hydraulic circuit that is normally opened when the system is not operating, and that is normally closed when the system is operating.
Open-center Load Sensing System
Hydraulic system
The hydraulic system that can simultaneously operate multiple actuators regardless of the load.
Pressure Compensation
Hydraulic system
The function to compensate for the hydraulic pressure.
LVDS
NC
NO
OLSS PC
GD535-5 (01)
20-5
Acronyms
Abbreviations
20 Standard value table
Official name
Application (Applicable models (*1) and equipment)
Explanation
Steering Palm Command Control System (D series)
The function to make the controller analyze the lever, pedal, and dial data instantaneously, and to allow the electronic control of engine, transmission and others appropriately.
PCV
Pre-stroke Control Valve
Engine
This valve is installed at inlet port of pump and it adjusts fuel intake amount in order to control fuel discharged volume of supply pump.
PPC
Proportional Pressure Control
Hydraulic system
Used for controlling proportional pressure. This system moves actuators in proportion to the hydraulic pressure.
PPM
Piston Pump and Motor
PTO
Power Take Off
Power transmission
Power take-off mechanism
PTP
Power Tilt and power Pitch dozer
Work equipment (D series)
This function performs hydraulic control of the tilt and pitch of the bulldozer blade.
Operator's cab, canopy
The structure to protect the operator (fastened with seat belt) if the machine falls. (Roll-over protective structure for operator)
PCCS
ROPS
Roll-Over Protective Structure
Hydraulic system (D series, PC series, others)
Piston hydraulic pump and motor.
This performance is standardized as ISO 3471.
SCR
Selective Catalytic Reduction
Urea SCR system
The exhaust gas purification device, that uses urea water and converts the nitrogen oxides (NOx) into harmless nitrogen and water (by reduction reaction). It may be called part of the exhaust gas purifying catalyst or the related device name.
SI
Le SystЮme International d‚Äô UnitЩs
Unit
Abbreviated for the "International System of Units". It is the universal unit system and "A single unit for a single quantity" is the basic principle applied.
SOL
Solenoid
Electrical system
It refers to an actuator consisting of a solenoid and an iron core that is moved by the magnetic force when the solenoid is energized.
TWV
2-Way Valve
Hydraulic system
Solenoid valve that switches over direction of flow.
VGT
Variable Geometry Turbocharger
Engine
Turbocharger having the variable geometry of exhaust passage
*1: Applicable model codes D: Bulldozer HD: Dump truck HM: Articulated dump truck PC: Hydraulic excavator WA: Wheel loader
20-6
GD535-5 (01)
20 Standard value table
Acronyms
Abbreviations used in circuit diagrams Abbreviations
Official name
A/C
Air Conditioner
A/D
Analogue-to-Digital
A/M
Air Mix damper
ACC
Accessory
ADD
Additional
AUX
Auxiliary
BR
Battery Relay
CW
Clockwise
CCW
Counter Clockwise
ECU
Electronic Control Unit
ECM
Electronic Control Module
ENG
Engine
EXGND
External Ground
F.G.
Frame Ground
GND
Ground
IMA
Inlet Metering Actuator
NC
No Connection
S/T STRG
Steering
SIG
Signal
SOL
Solenoid
STD
Standard
OPT OP PRESS SPEC SW TEMP
Option Pressure Specification Switch Temperature
T/C
Torque Converter
T/M
Transmission
GD535-5 (01)
1
20-7
Standard value table for engine
20 Standard value table
1
Standard value table for engine
1
Classification
Standard value table
Item
q
Engine speed q
q q q q q
Engine
Exhaust temperature (Temperature at turbocharger inlet)
Exhaust gas color
Valve clearance Compression pressure
q q q q q q
q
q
q q
q
Blowby pressure
q q q q
Engine oil pressure
Oil temperature
GD535-5
Engine
SAA6D107E-1
Measurement condition
q
Boost Pressure
Machine model
q
q
E mode Coolant tempera- At High idle P mode ture: 80 to 90°C Low idle Hydraulic oil temperature: 45 to 55°C Torque converter Rated speed oil temperature: 60 to 80°C
Unit
Standard value for new machine
Repair limit
rpm
1875 ± 50
1875 ± 50
rpm
2150 ± 50
2150 ± 50
rpm
800 ± 50
800 ± 50
In E mode / In P mode with a gear speed other than F7 and F8
In P mode with gear speed F7 or F8
2000
2100
rpm
Coolant temperature: 60 to 100°C Torque converter oil temperature: 60 to 80°C Hydraulic oil temperature: 45 to 55°C At rated horsepower At aftercooler outlet
kPa {mmHg}
Min. 127 {Min. 950}
Min. 100 {Min. 750}
Coolant temperature: 60 to 100°C Torque converter oil temperature: 60 to 80°C Hydraulic oil temperature: 45 to 55°C Whole speed range Ambient temperature: 20°C At turbocharger inlet
°C
Max. 650
Max. 700
At sudden acceleration (LooHi)
% (Opacity)
Max. 25
35
At high idle
% (Opacity)
-
-
Intake valve
mm
0.25 ± 0.05
0.152 to 0.381
Exhaust valve
mm
0.51 ± 0.05
0.381 to 0.762
Engine oil temperature: 40 to 60°C MPa At cranking (engine speed: 250 to 280 rpm {kg/cm2} (reference))
Min. 2.41 {Min. 24.6}
Min. 1.69 {Min. 17.2}
Coolant temperature: 60 to 100°C Torque converter oil temperature: 60 to 80°C kPa {mmH2O} Hydraulic oil temperature: 45 to 55°C At rated horsepower
Max. 1.17 {Max. 120}
Max. 1.96 {Max. 200}
Engine coolant temperature: 60 to 100°C
Normal temperature
Coolant temperature:60 to 100°C Engine Oil (*1) EO10W30-LA EO15W40-LA EOS5W30-LA EOS5W40-LA
At high idle
MPa {kg/cm2}
Min. 0.29 {Min. 3.0}
Min. 0.25 {Min. 2.5}
At low idle
MPa {kg/cm2}
Min. 0.10 {Min. 1.0}
Min. 0.07 {Min. 0.7}
°C
80 to 110
Max. 120
Whole speed range (inside oil pan)
*1: KES diesel engine oil
20-8
GD535-5 (01)
20 Standard value table
Standard value table for engine
a When using the standard value table for checking, adjusting, and troubleshooting, the following cautions are required. 1. The standard values for new machine in the table are based on the values at factory shipment. Use them for estimating wear and tear after operation and as targets of repair. 2. The repair limits in the table are estimated based on the results of various tests at factory shipment. Use them for reference for troubleshooting according to the situations such as degree of repair and operation history. 3. This standard value table is not used as criteria for claims.
GD535-5 (01)
20-9
Standard value table for machine
20 Standard value table
Standard value table for machine
1
Classification
Machine model
Item
GD535-5
Measurement condition
Unit
NEUTRAL a For details, see Fig. A in "Machine posture (α1) Depressing and procedure for meaAccelerator pedal angle suring performance". Travel q With engine started (α) q α = α1 - α2 q q q
Inching pedal
q
Travel of levers, pedals, and steering wheel
q
Gear shift lever
20-10
q q
With engine stopped Tip of pedal Traveling: Between released and fully depressed positions Play: At released position Height: Released position and fully depressed position from floor top surface
With engine stopped At 24 mm below top of lever
Standard value for new machine
Repair limit
45 ± 2
45 ± 2
17 ± 2
17 ± 2
deg.
Traveling
mm
84 ± 4.2
84 ± 4.2
Play
mm
Max. 5
Max. 5
Height (Released)
mm
175 ± 5
175 ± 5
Height (Fully depressed)
mm
90 ± 5
90 ± 5
PoN
mm
28.5 ± 5
28.5 ± 5
NoF1
mm
28.5 ± 5
28.5 ± 5
F1oF2
mm
28.5 ± 5
28.5 ± 5
F2oF3
mm
28.5 ± 5
28.5 ± 5
F3oF4
mm
28.5 ± 5
28.5 ± 5
F4oF5
mm
28.5 ± 5
28.5 ± 5
F5oF6
mm
28.5 ± 5
28.5 ± 5
F6oF7
mm
28.5 ± 5
28.5 ± 5
F7oF8
mm
28.5 ± 5
28.5 ± 5
NoR1
mm
28.5 ± 5
28.5 ± 5
R1oR2
mm
28.5 ± 5
28.5 ± 5
R2oR3
mm
28.5 ± 5
28.5 ± 5
R3oMAX
mm
28.5 ± 5
28.5 ± 5
GD535-5 (01)
20 Standard value table
Standard value table for machine
Classification
Machine model
Unit
Standard value for new machine
Repair limit
Rotation
6.0 to 7.0
6.0 to 7.0
mm
0 to 25
0 to 25
Travel
mm
39 ± 3.9
39 ± 3.9
Play
mm
Max. 5
Max. 5
L.H. blade lift cylinder control lever
N o FORWARD No REARWARD
mm
26 ± 5
26 ± 5
Attachment control lever
N o FORWARD No REARWARD
mm
29 ± 5
29 ± 5
Blade rotation control lever
N o FORWARD No REARWARD
mm
26 ± 5
26 ± 5
Articulate control lever
N o FORWARD No REARWARD
mm
29 ± 5
29 ± 5
N o FORWARD No REARWARD
mm
26 ± 5
26 ± 5
Power tilt control lever
N o FORWARD No REARWARD
mm
29 ± 5
29 ± 5
Leaning control lever
N o FORWARD No REARWARD
mm
26 ± 5
26 ± 5
Blade side shift control lever
N o FORWARD No REARWARD
mm
26 ± 5
26 ± 5
R.H. blade lift cylinder control lever
N o FORWARD No REARWARD
mm
26 ± 5
26 ± 5
Item
Measurement condition
q q
Steering wheel
q q
q q
Brake pedal
Travel of levers, pedals, and steering wheel
GD535-5
q
q
Drawbar side shift control lever
GD535-5 (01)
q q
With engine running at Low No. of rotations idle Front wheels raised off the ground No. of rotations: Between steering stroke ends Play: Between rotation startPlay ing point of steering wheel and point where machine starts steering With engine stopped Tip of pedal Travel: Between released position and position where brake starts to work Play: At released position
With engine stopped Center of lever knob
20-11
Standard value table for machine
20 Standard value table
Classification
Machine model
Item
Standard value for new machine
Repair limit
24.5 to 37.8 {2.5 to 3.9}
24.5 to 37.8 {2.5 to 3.9}
45.1 to 58.8 {4.6 to 6.0}
45.1 to 58.8 {4.6 to 6.0}
N {kg}
Max. 142 {Max. 14.5}
Max. 142 {Max. 14.5}
PoN
N {kg}
Max. 29.4 {Max. 3.0}
Max. 29.4 {Max. 3.0}
NoF1
N {kg}
Max. 29.4 {Max. 3.0}
Max. 29.4 {Max. 3.0}
F1oF2
N {kg}
Max. 29.4 {Max. 3.0}
Max. 29.4 {Max. 3.0}
F2oF3
N {kg}
Max. 29.4 {Max. 3.0}
Max. 29.4 {Max. 3.0}
F3oF4
N {kg}
Max. 29.4 {Max. 3.0}
Max. 29.4 {Max. 3.0}
F4oF5
N {kg}
Max. 29.4 {Max. 3.0}
Max. 29.4 {Max. 3.0}
F5oF6
N {kg}
Max. 29.4 {Max. 3.0}
Max. 29.4 {Max. 3.0}
F6oF7
N {kg}
Max. 29.4 {Max. 3.0}
Max. 29.4 {Max. 3.0}
F7oF8
N {kg}
Max. 29.4 {Max. 3.0}
Max. 29.4 {Max. 3.0}
NoR1
N {kg}
Max. 29.4 {Max. 3.0}
Max. 29.4 {Max. 3.0}
R1oR2
N {kg}
Max. 29.4 {Max. 3.0}
Max. 29.4 {Max. 3.0}
R2oR3
N {kg}
Max. 29.4 {Max. 3.0}
Max. 29.4 {Max. 3.0}
R3oMAX
N {kg}
Max. 29.4 {Max. 3.0}
Max. 29.4 {Max. 3.0}
With engine running at low idle During travel in F1
N {kg}
Max. 29.0 {Max. 3}
Max. 49.0 {Max. 5}
With engine running at high idle At position 150 mm from center of rotation Max. value read until machine stops completely
N {kg}
276 ± 28 {28.1 ± 2.8}
276 ± 28 {28.1 ± 2.8}
Measurement condition
At start of depressing
Accelerator pedal
Depressing At fully effort depressed position q
Inching pedal
q
Control effort of levers, pedals, and steering wheel
q
q q
Gear shift lever q
Steering wheel
q q q
Brake pedal
q q
20-12
GD535-5
q q
Unit
With engine started Measure at 150 mm away from pedal fulcrum
With engine stopped Measure at 150 mm away from pedal fulcrum Read values through travel end
With engine stopped Measure at 24 mm below tip of lever knob Max. value to just before finish of gear shifting
N {kg}
GD535-5 (01)
20 Standard value table
Standard value table for machine
Rotation speed
Control effort of levers, pedals, and steering wheel
Classification
Machine model
Item
GD535-5
Measurement condition
Unit
Standard value for new machine
Repair limit
L.H. blade lift cylinder control lever
N o FORWARD No REARWARD
N {kg}
20 to 35 {2.04 to 3.57}
20 to 35 {2.04 to 3.57}
Attachment control lever
N o FORWARD No REARWARD
N {kg}
20 to 35 {2.04 to 3.57}
20 to 35 {2.04 to 3.57}
Blade rotation control lever
N o FORWARD No REARWARD
N {kg}
20 to 45 {2.04 to 4.59}
20 to 45 {2.04 to 4.59}
Articulate control lever
N o FORWARD No REARWARD
N {kg}
20 to 35 {2.04 to 3.57}
20 to 35 {2.04 to 3.57}
With engine stopped N o FORWARD Read values through travel N o end REARWARD
N {kg}
20 to 35 {2.04 to 3.57}
20 to 35 {2.04 to 3.57}
Power tilt control lever
N o FORWARD No REARWARD
N {kg}
20 to 35 {2.04 to 3.57}
20 to 35 {2.04 to 3.57}
Leaning control lever
N o FORWARD No REARWARD
N {kg}
20 to 35 {2.04 to 3.57}
20 to 35 {2.04 to 3.57}
Blade side shift control lever
N o FORWARD No REARWARD
N {kg}
20 to 35 {2.04 to 3.57}
20 to 35 {2.04 to 3.57}
R.H. blade lift cylinder control lever
N o FORWARD No REARWARD
N {kg}
20 to 35 {2.04 to 3.57}
20 to 35 {2.04 to 3.57}
rpm
1890 ± 100
1890 ± 100
Drawbar side shift control lever
Torque converter stall speed
GD535-5 (01)
q q
q q q
Torque converter stall function Torque converter oil temperature: 60 to 80 °C With engine running at high idle
20-13
Standard value table for machine
20 Standard value table
Classification
Machine model
Standard value for new machine
Repair limit
Low idle
2.55 ± 0.2 {26.0 ± 2.0}
2.55 ± 0.2 {26.0 ± 2.0}
Rated speed (2,000 rpm)
2.73 ± 0.2 {27.9 ± 2.0}
2.73 ± 0.2 {27.9 ± 2.0}
Torque converter inlet pressure
Rated speed (2,000 rpm)
Max. 0.9 {Max. 9.2}
Max. 0.9 {Max. 9.2}
Torque converter outlet pressure
Rated speed (2,000 rpm)
0.58 ± 0.1 {5.9 ± 1.0}
0.58 ± 0.1 {5.9 ± 1.0}
Rated speed (2,000 rpm)
1.76 ± 0.2 {18.0 ± 2.0}
1.76 ± 0.2 {18.0 ± 2.0}
2.21 ± 0.25 {22.5 ± 2.5}
2.21 ± 0.25 {22.5 ± 2.5}
2.21 ± 0.25 {22.5 ± 2.5}
2.21 ± 0.25 {22.5 ± 2.5}
Rated speed (2,000 rpm)
2.21 ± 0.25 {22.5 ± 2.5}
2.21 ± 0.25 {22.5 ± 2.5}
Transmission 1st clutch pressure
Rated speed (2,000 rpm)
2.21 ± 0.25 {22.5 ± 2.5}
2.21 ± 0.25 {22.5 ± 2.5}
Transmission 2nd clutch pressure
Rated speed (2,000 rpm)
2.21 ± 0.25 {22.5 ± 2.5}
2.21 ± 0.25 {22.5 ± 2.5}
Transmission 3rd clutch pressure
Rated speed (2,000 rpm)
2.21 ± 0.25 {22.5 ± 2.5}
2.21 ± 0.25 {22.5 ± 2.5}
Transmission 4th clutch pressure
Rated speed (2,000 rpm)
2.21 ± 0.25 {22.5 ± 2.5}
2.21 ± 0.25 {22.5 ± 2.5}
l/min
210
-
F1
km/h
4.2 ± 0.2
4.2 ± 0.2
F2
km/h
5.9 ± 0.3
5.9 ± 0.3
F3
km/h
8.0 ± 0.4
8.0 ± 0.4
F4
km/h
11.3 ± 0.5
11.3 ± 0.5
F5
km/h
15.7 ± 0.8
15.7 ± 0.8
F6
km/h
22.0 ± 1.1
22.0 ± 1.1
F7
km/h
30.1 ± 1.5
30.1 ± 1.5
F8
km/h
42.0 ± 2.1
42.0 ± 2.1
R1
km/h
4.7 ± 0.2
4.7 ± 0.2
R2
km/h
9.1 ± 0.5
9.1 ± 0.5
R3
km/h
17.8 ± 0.9
17.8 ± 0.9
R4
km/h
34.1 ± 1.7
34.1 ± 1.7
MPa {kg/cm2}
3.05 (+0.2 / 0) {31.2 (+1 / 0)}
3.05 (+0.1 / 0.294) {31.2 (+1 / -3)}
Item
Measurement condition
Power train oil pressure and pump performance
Transmission main relief pressure
Torque converter lockup clutch pressure Transmission FL clutch pressure Transmission R clutch pressure
Power train performance
q q q
q
Transmission FH clutch pressure
Power train pump discharged volume
Differential
GD535-5
q q
q q q
Travel speed q
Differential lock pressure [Differential lock specification]
20-14
q q q
Torque converter oil temperature: 60 to 80 °C Transmission oil temperature: 60 to 80 °C With engine running at Low idle, or at rated speed (2,000 rpm) During running wheels idle off ground with gear shift lever in P position or each speed range
Unit
Rated speed (2,000 rpm) Rated speed (2,000 rpm)
Torque converter oil temperature: 60 to 80 °C With engine running at High idle
In manual mode In P-mode Torque converter oil temperature: 60 to 80 °C While machine is traveling with engine at rated speed (2,000 rpm)
Final drive oil temperature: 60 to 80 °C With engine running at high idle When differential lock is operated
MPa {kg/cm2}
GD535-5 (01)
20 Standard value table
Standard value table for machine
Classification
Machine model
Steering system and tires
Unit
Standard value for new machine
Repair limit
Hydraulic oil temperature: 45 to 55 °C With engine running at high idle With steering cylinder relieved
MPa {kg/cm2}
17.6 ± 1.0 {180 ± 9.8}
17.6 ± 1.0 {180 ± 9.8}
Hydraulic oil temperature: 45 to 55 °C With engine running at high idle With steering cylinder relieved
cc/min
Max. 10
Max. 10
On flat paved surface Camber: Kingpin inclination angle
deg.
0
0
On flat paved surface Toe-in: Difference between front center distance and rear center distance of tires
mm
-5 ± 5
-5 ± 5
Measure the face runout by putting a dial gauge at tire side walls (both front and rear tires)
mm
Max. 7
Max. 7
13.00-24-12PR
kPa {kg/cm2}
260 ± 20 {2.6 ± 0.2}
260 ± 20 {2.6 ± 0.2}
14.00-24-12PR
kPa {kg/cm2}
260 ± 20 {2.6 ± 0.2}
260 ± 20 {2.6 ± 0.2}
Item
Steering oil pressure Oil leak from steering cylinder Camber
Measurement condition
q q q q q q q q q
Toe-in Face runout of tire
Tire inflation pressure
GD535-5 (01)
GD535-5
q
q
20-15
Standard value table for machine
20 Standard value table
Classification
Machine model
Item
Brake accumulator charge pressure Wheel brake operating pressure Pressure drop of wheel brake operating pressure
Brake
Wheel brake braking distance Disc wear of wheel brake
q q
q q q q q q
q q
q q
q q q q q
Thickness of parking brake pad
q
q q
Clearance at parking brake pad
q
Travel and operating effort of control valve
q
Travel of control valve spool
q q
q
Control valve spool operating effort
20-16
Unit
Standard value for new machine
Repair limit
kPa {kg/cm2}
9.36 (0 / -0.5) {95.5 (0 / -5)}
9.36 (0 / -0.5) {95.5 (0 / -5)}
kPa {kg/cm2}
13.8 (0 / -0.5) {140 (0 / -5)}
13.8 (0 / -0.5) {140 (0 / -5)}
Hydraulic oil temperature: 45 to 55 °C With engine stopped (after accumulator is charged) When brake pedal is depressed
MPa {kg/cm2}
4.4 ± 0.4 {45 ± 4.1}
4.4 ± 0.4 {45 ± 4.1}
Hydraulic oil temperature: 45 to 55 °C With engine stopped (after accumulator is charged) Pressure drop in 5 minutes after wating 1 minite with brake pedal depressed
kPa {kg/cm2}
Max. 98 {Max. 1.0}
Max. 98 {Max. 1.0}
Hydraulic oil temperature: 45 to 55 °C With engine stopped (after accumulator is charged) Starting switch at ON position and gear shift lever in N position
MPa {kg/cm2}
Min. 8.2 {Min. 83.6}
Min. 8.2 {Min. 83.6}
Hydraulic oil temperature: 45 to 55 °C Braking distance when machine is traveling at 35 km/h
m
Max. 15.8
Max. 15.8
mm
1.5 (0/-0.2)
0
12.5 ± 0.5
Min. 9.5
6.5 ± 0.5
Min. 3.5
mm
1.5 to 1.8
Min. 2.5
Blade rotation only
mm
5 ± 0.5
5 ± 0.5
Other than blade rotation
mm
5.5 ± 0.5
5.5 ± 0.5
Blade rotation only
N {kg}
Max. 110 {Max. 11.2}
Max. 110 {Max. 11.2}
Other than blade rotation
N {kg}
Max. 102.5 {Max. 10.5}
Max. 102.5 {Max. 10.5}
Measurement condition
q
Parking brake releasing pressure
GD535-5
q q
Hydraulic oil temperature: Cut-in pressure 45 to 55 °C With engine running at high Cut-out idle pressure
Brake pedal: Depress to the stroke end. Protrusion of shaft Check with shaft of disc wear gauge Engine: Stopped Thickness (a) and (b) of pad (1) For details, see Fig. B in "Machine posture and procedure for measuring performance".
Thickness (a) mm Thickness (b)
Engine: Stopped Sum of clearances (c) and (d) between pad (1) and disc (2) Use manual hand hydraulic pump to apply parking brake. (Specified pressure: 8.2 MPa) For details, see Fig. B in "Machine posture and procedure for measuring performance". With engine stopped N o RAISE side, N o LOWER side
With engine stopped N o RAISE side, N o LOWER side Read values through travel end
GD535-5 (01)
20 Standard value table
Standard value table for machine
Work equipment oil pressure and performance of hydraulic pump Classification
Machine model
Item
Work equipment oil pressure
Steering pump discharge
q q
q q q
Discharge of work equipment pump
q
Brake pump discharge
q
Blade lift speed
q
q
q q
Blade side shift speed
q
Drawbar side shift speed Work equipment speed
q
Blade rotation speed
Power tilt speed
q
q
Articulate speed q
Leaning speed
q
q
Scarifier lift speed q
GD535-5 (01)
Unit
Standard value for new machine
Repair limit
MPa {kg/cm2}
19.1 (+0.5/0) {195 (+5/0)}
19.1 ± 0.5 {195 ± 5}
Hydraulic oil temperature: 45 to 55 °C With engine running at Low idle
l/min
13.5 ± 2.5
13.5 ± 2.5
Hydraulic oil temperature: 45 to 55 °C With engine running at Low idle Blade rotation control (measure during operation)
l/min
29 ± 4.5
29 ± 4.5
Hydraulic oil temperature: 45 to 55 °C With engine running at Low idle
l/min
13 ± 2
13 ± 2
2.0 ± 0.3
Max. 4.0
3.0 ± 0.4
Max. 5.0
8.2 ± 1.3
Max. 10.0
5.3 ± 0.8
Max. 7.0
2.3 ± 0.4
Max. 4.0
3.3 ± 0.5
Max. 5.0
8.1 ± 1.3
Max. 10.0
8.1 ± 1.3
Max. 10.0
2.0 ± 0.3
Max. 3.0
1.7 ± 0.3
Max. 3.0
4.2 ± 0.6
Max. 6.0
4.2 ± 0.7
Max. 6.0
0.7 ± 0.1
Max. 2.0
1.0 ± 0.1
Max. 2.0
1.0 ± 0.2
Max. 2.0
1.4 ± 0.3
Max. 3.0
Measurement condition
q
GD535-5
Hydraulic oil temperature: 45 to 55 °C Work With engine running at high equipment relief idle pressure Work equipment relief pressure: With leaning cylinder relieved
Hydraulic oil temperature: RAISE 45 to 55 °C LOWER With engine running at High Left shifting idle Blade lift: Move cylinder full Right shifting stroke over full travel and operLeft shifting ate both cylinders independently. Right shifting Blade side shift: Move cylinder Left rotation between stroke ends. Drawbar side shift: Set blade Right rotation with its bottom at a height of With large 100 mm and move cylinder becutting angle tween stroke ends. Blade rotation Measure time With small required for blade to rotate cutting angle from start to 90-degree rotaLeft turn tion. Right turn Power tilt: Move cylinder between stroke ends. Leaning to left Articulate: Move cylinder beLeaning to right tween stroke ends. (During traveling) RAISE Leaning: Move cylinder between stroke ends. LOWER Scarifier lift: Move cylinder between stroke ends.
Sec.
20-17
Standard value table for machine
20 Standard value table
Hydraulic drift and oil leak of work equipment Classification
Machine model
Item
Blade hydraulic drift (No load on cylinder)
q q q q
Blade hydraulic drift (machine lifted)
q q q
Oil leak from work equipment cylinder
Unit
Standard value for new machine
Repair limit
R.H. and L.H. blade lift cylinders: RAISE stroke end Hydraulic oil temperature: 45 to 55 °C With engine stopped Cylinder extension in 10 minutes after setting
mm
Max. 10
Max. 20
R.H. and L.H. blade lift cylinders: LOWER stroke end (to raise machine off ground) Hydraulic oil temperature: 45 to 55 °C With engine stopped Cylinder retraction in 10 minutes after setting
mm
Max. 20
Max. 35
cc/min
Max. 3
Max. 3
Measurement condition
q
q q q
GD535-5
Hydraulic oil temperature: 45 to 55 °C With engine running at High idle With cylinder relieved
a When using the standard value table for checking, adjusting, and troubleshooting, the following cautions are required. 1. The standard values for new machine in the table are based on the values at factory shipment. Use them for estimating wear and tear after operation and as targets of repair. 2. The repair limits in the table are estimated based on the results of various tests at factory shipment. Use them for reference for troubleshooting according to the situations such as degree of repair and operation history. 3. This standard value table is not used as criteria for claims.
20-18
GD535-5 (01)
20 Standard value table
Standard value table for machine
Machine posture and procedure for measuring performance a Fig. A
a Fig. B
GD535-5 (01)
20-19
Standard value table for machine
20-20
20 Standard value table
GD535-5 (01)
30 Testing and adjusting
GD535-5 (01)
30-1
Contents
Contents
30 Testing and adjusting
1
Acronyms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-4 Tools for testing, adjusting, and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-9 Tools for testing, adjusting, and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-9 Engine and cooling system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-16 Testing engine speed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-16 Testing boost pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-18 Testing exhaust gas temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-20 Testing exhaust gas color - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-22 Adjusting valve clearance- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-24 Testing compression pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-26 Testing blowby pressure- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-29 Testing engine oil pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-30 Handling fuel system devices - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-31 Releasing remaining pressure from fuel system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-32 Testing fuel pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-33 Bleeding air from fuel circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-34 Testing fuel circuit for leakage- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-35 Handling cylinder cutout mode operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-36 Handling no-injection cranking operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-37 Handling voltage circuit of engine controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-38 Testing muffler (main body) and stacked muffler for looseness and damage - - - - - - - - - - - - - - - - - - - - 30-39 Testing muffler function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-40 Testing installed condition of cylinder heads and manifolds - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-41 Testing of engine piping for damage and looseness - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-42 Testing fuel discharge, return rate, and leakage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-43 Checking and replacing alternator belt- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-47 Checking and replacing auto-tensioner - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-47-2 Power train - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-48 Testing power train oil pressure- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-48 Adjusting transmission speed sensor- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-62 Retrieval of disabled machine due to transmission valve failure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-65 Flushing procedure for torque converter and transmission circuits - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-68 Testing and adjusting toe-in - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-70 Testing and adjusting differential lock oil pressure (differential lock specification)- - - - - - - - - - - - - - - - - 30-72 Steering system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-74 Testing and adjusting steering oil pressure- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-74 Testing oil leakage of steering cylinder- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-75 Bleeding air from steering circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-76 Brake system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-77 Releasing remaining pressure from brake circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-77 Testing and adjusting brake oil pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-78 Bleeding air from brake circuit- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-81 Testing wear of wheel brake disc- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-82 Testing and adjusting parking brake pad - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-83 Releasing parking brake manually- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-86 Charging brake accumulator with gas - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-87 Hydraulic system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-89 Testing work equipment oil pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-89 Testing lifter lock pin circuit pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-91 Testing oil leakage of work equipment cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-93 Bleeding air from work equipment circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-96 Work equipment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-97 Adjusting drawbar ball joint clearance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-97
30-2
GD535-5 (02)
30 Testing and adjusting
Testing and adjusting circle guide clearance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing and adjusting slip clutch type circle drive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Procedure for testing diodes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Special functions of machine monitor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Handling high-voltage circuit of engine controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - KOMTRAX terminal start-up procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Preparatory work for troubleshooting of electrical system failure - - - - - - - - - - - - - - - - - - - - - - - - - - - Pm Clinic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Pm Clinic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
GD535-5 (02)
Contents
30-98 30-100 30-102 30-102 30-104 30-151 30-152 30-156 30-158 30-158
30-3
Acronyms
30 Testing and adjusting
Acronyms q q q q
1
The abbreviations of unknown parts, equipment and functions have been extracted from the Shop Manual, and their official names and details are defined in this Acronyms. Abbreviations that are commonly used in society might not be described. Special and rarely used abbreviations are described in the supplementary explanation in the text. The acronyms consist of two parts: the list of abbreviations that are used in the text, and the list of abbreviations that are used in circuit diagrams.
Abbreviations that are used in the text Application (Applicable models (*1) and equipment)
Abbreviations
Official name
ABS
Anti-skid Brake System
AISS
Automatic Idling Setting Engine System
AJSS
Advanced Joystick Steering System
ARAC
Automatic Retarder Accelerator Control
Traveling, brake (HD series, HM series)
Steering (WA series) Traveling, brake (HD series, HM series) Traveling, brake
ARSC
Automatic Retarder Speed Control
ASR
Automatic Spin Regulator
ATT
Attachment
BCV
Brake Cooling oil control Valve
CAN
(HD series, HM series) Traveling, brake (HD series, HM series) Work equipment
Explanation With this function, when the tires skid (wheels stop rotating), the brakes are released, and when the wheels start to rotate, the brakes are applied again. This function automatically sets the idle speed. A lever is used to perform the steering operations instead of a steering wheel. Moreover, it shifts gear and changes direction (FORWARD or REVERSE). When the accelerator pedal is released while the machine is traveling downhill, this function automatically applies the retarder with a constant braking force. When the accelerator pedal is released while the machine is traveling downhill, this function automatically applies the retarder to ensure that the machine speed does not accelerate above the speed set by the operator. When the tires spin on soft ground surfaces, this function automatically uses the optimum braking force to drive both wheels. The function or parts which are attached to the standard model and used
(HD series)
When the retarder is not being used, this valve bypasses part of the brake cooling oil to reduce the load on the hydraulic pump.
Controller Area Network
Communication, electronic control
One of communication standards that is used in the network on the machine
CDR
Crankcase Depression Regulator
Engine
A regulator valve which is installed to KCCV ventilator. It is written as CDR valve and it is not used independently.
CLSS
Closed-center Load Sensing System
Hydraulic system
This system can simultaneously actuate multiple actuators regardless of the load (provides better combined operation than OLSS).
Engine
Engine controller electronically controls supply pump, common rail, and injector. This function maintains optimum fuel injection amount and fuel injection timing.
Electronic control
Electronic control device that receives signals from each sensor of the machine and that specifies the optimum operation to the actuators. (Same as ECU)
30-4
CRI
Common Rail Injection
ECM
Electronic Control Module
Brake
1
GD535-5 (01)
30 Testing and adjusting
Abbreviations
Official name
ECMV
Electronic Control Modulation Valve
ECSS
Electronically Controlled Suspension System
Acronyms
Application (Applicable models (*1) and equipment) Transmission (D series, HD series, WA series and others) Traveling (WA series)
Explanation Proportional solenoid valve that reduces the connection shock by gradually increasing the hydraulic pressure to engage the clutch. This system ensures smooth high-speed travel by absorbing vibration of machine during travel with hydraulic spring effect of accumulator.
ECU
Electronic Control Unit
Electronic control
Electronic control device that receives signals from each sensor of the machine and that specifies the optimum operation to the actuators. (Same as ECM)
EGR
Exhaust Gas Recirculation
Engine
This function recirculates part of exhaust gas to the combustion chamber in order to reduce combustion temperature and control the emission of NOx.
Equipment Management Monitoring System
Machine monitor
This system allows data (filter, oil replacement interval, malfunctions on machine, failure code, and failure history) from each sensor on the machine to be checked on the monitor.
EPC
Electromagnetic Proportional Control
Hydraulic system
Electromagnetic proportional control This mechanism allows actuators to be operated in proportion to the current supplied.
FOPS
Falling Object Protective Structure
Operator's cab, canopy
F-N-R
Forward-NeutralReverse
Operation
Forward-Neutral-Reverse
Communication
GPS
Global Positioning System
Global positioning system The satellite positioning system to determine the current position on the earth
GNSS
Global Navigation Satellite System
EMMS
This structure protects the operator's head from falling objects. (Falling Object Protective Structure) This performance is standardized as ISO 3449.
(KOMTRAX, KOMTRAX Plus) Communication (KOMTRAX, KOMTRAX Plus) Steering
Global navigation satellite system A general term for positioning system using satellites such as GPS, GALILEO, etc. This function uses a combination of hydraulic motor and bevel shaft to control difference in travel speed of right and left tracks. Accordingly machine can turn without using steering clutch.
HSS
Hydrostatic Steering System
HST
Hydro Static Transmission
ICT
Information and Communication Technology
Communication, electronic control
A general term for the engineering and its socially applied technology of information processing and communication.
IMA
Inlet Metering Actuator
Engine
Valve that adjusts fuel intake amount at inlet port of pump in order to control fuel discharged volume of supply pump. (Same as IMV)
IMU
Inertial Measurement Unit
Engine
This is a device to detect the angle (or angular velocity) and acceleration of the 3 axes that control motions.
IMV
Inlet Metering Valve
Engine
Valve adjusting fuel intake amount at inlet port of pump in order to control fuel discharged volume of supply pump. (Same as IMA)
GD535-5 (01)
(D series) Transmission (D series, WA series)
This function uses a combination of hydraulic pump and hydraulic motor to shift the speed range steplessly without using gears.
30-5
Acronyms
Abbreviations
30 Testing and adjusting
Official name
Application (Applicable models (*1) and equipment)
KCCV
KOMATSU Closed Crankcase Ventilation
Engine
KCSF
KOMATSU Catalyzed Soot Filter
Engine
KDOC
KOMATSU Diesel Oxidation Catalyst
Engine
KDPF
KOMATSU Diesel Particulate Filter
Explanation The mechanism for oil separation from gas in order to re-burn the blow-by gas and for oil return to the intake system. It is mainly composed of filters. The filter to capture the soot from exhaust gas. It is built in the KDPF. The catalyst for exhaust gas purification.
Engine
It may be built in the KDPF or combined with the muffler. This component is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it. It is used instead of the conventional muffler.
Traveling, brake KOMATSU Traction Control System
(HM series)
LCD
Liquid Crystal Display
Machine monitor
The liquid crystal display panel. Image display device such as a monitor which assembles in the liquid crystal element.
LED
Light Emitting Diode
Electronic components
Light emitting diode It refers to semiconductor element that emits light when the voltage is applied in forward direction.
LIN
Local Interconnect Network
Communication, electronic control
One of communication standards that is used in the network on the machine
LS
Load Sensing
Hydraulic system
Function that detects differential pressure of pump and controls discharged volume corresponding to load.
KTCS
Low Voltage Differential Communication, electronic Signaling control
One of communication standards that is used in the network on the machine
MAF
Mass Air Flow
Engine
The intake airflow rate of the engine. It is not used alone, but used in combination with sensors. The intake airflow sensor may be called the MAF sensor.
MMS
Multimedia Messaging Service
Communication
The service to allow transmission and reception of short messages such as characters, voice and images between mobile phones.
Normally Closed
Electric system, hydraulic system
The characteristics of an electric or hydraulic circuit that is normally closed when the system is not operating, and that is normally opened when the system is operating.
Normally Open
Electric system, hydraulic system
The characteristics of an electric or hydraulic circuit that is normally opened when the system is not operating, and that is normally closed when the system is operating.
Open-center Load Sensing System
Hydraulic system
The hydraulic system that can simultaneously operate multiple actuators regardless of the load.
Pressure Compensation
Hydraulic system
The function to compensate for the hydraulic pressure.
LVDS
NC
NO
OLSS PC
30-6
This function recovers the drive force of the wheels by braking automatically with the optimum force and at the same time activates the inter-axle differential lock when the wheels idle while the machine travels on the soft ground road.
GD535-5 (01)
30 Testing and adjusting
Abbreviations
Official name
Acronyms
Application (Applicable models (*1) and equipment)
Explanation
Steering Palm Command Control System (D series)
The function to make the controller analyze the lever, pedal, and dial data instantaneously, and to allow the electronic control of engine, transmission and others appropriately.
PCV
Pre-stroke Control Valve
Engine
This valve is installed at inlet port of pump and it adjusts fuel intake amount in order to control fuel discharged volume of supply pump.
PPC
Proportional Pressure Control
Hydraulic system
Used for controlling proportional pressure. This system moves actuators in proportion to the hydraulic pressure.
PPM
Piston Pump and Motor
PTO
Power Take Off
Power transmission
Power take-off mechanism
PTP
Power Tilt and power Pitch dozer
Work equipment (D series)
This function performs hydraulic control of the tilt and pitch of the bulldozer blade.
Operator's cab, canopy
The structure to protect the operator (fastened with seat belt) if the machine falls. (Roll-over protective structure for operator)
PCCS
ROPS
Roll-Over Protective Structure
Hydraulic system (D series, PC series, others)
Piston hydraulic pump and motor.
This performance is standardized as ISO 3471.
SCR
Selective Catalytic Reduction
Urea SCR system
The exhaust gas purification device, that uses urea water and converts the nitrogen oxides (NOx) into harmless nitrogen and water (by reduction reaction). It may be called part of the exhaust gas purifying catalyst or the related device name.
SI
Le SystЮme International d‚Äô UnitЩs
Unit
Abbreviated for the "International System of Units". It is the universal unit system and "A single unit for a single quantity" is the basic principle applied.
SOL
Solenoid
Electrical system
It refers to an actuator consisting of a solenoid and an iron core that is moved by the magnetic force when the solenoid is energized.
TWV
2-Way Valve
Hydraulic system
Solenoid valve that switches over direction of flow.
VGT
Variable Geometry Turbocharger
Engine
Turbocharger having the variable geometry of exhaust passage
*1: Applicable model codes D: Bulldozer HD: Dump truck HM: Articulated dump truck PC: Hydraulic excavator WA: Wheel loader
GD535-5 (01)
30-7
Acronyms
30 Testing and adjusting
Abbreviations used in circuit diagrams Abbreviations Air Conditioner
A/D
Analogue-to-Digital
A/M
Air Mix damper
ACC
Accessory
ADD
Additional
AUX
Auxiliary
BR
Battery Relay
CW
Clockwise
CCW
Counter Clockwise
ECU
Electronic Control Unit
ECM
Electronic Control Module
ENG
Engine External Ground
F.G.
Frame Ground
GND
Ground
IMA
Inlet Metering Actuator
NC
No Connection
S/T STRG
Steering
SIG
Signal
SOL
Solenoid
STD
Standard
OPT OP PRESS SPEC SW TEMP
30-8
Official name
A/C
EXGND
1
Option Pressure Specification Switch Temperature
T/C
Torque Converter
T/M
Transmission
GD535-5 (01)
30 Testing and adjusting
Tools for testing, adjusting, and troubleshooting
Tools for testing, adjusting, and troubleshooting
1
Tools for testing, adjusting, and troubleshooting
1
Testing/Adjusting item
Testing boost pressure
Symbol
B
Testing exhaust gas temperature Testing exhaust gas color
Adjusting valve clearance
Testing compression pressure
E
F
Testing blowby pressure
Part name
Q'ty
799-201-2202 Boost gauge kit
1
-101 to 200 kPa {-760 to 1500 mmHg}
2
790-301-1530 Elbow
1
R1/8×R1/8, 90°
799-101-1502 Digital thermometer
1
-99.9 to 1299 °C
1
799-201-9002 Handy smoke checker
1
2
Commercially available
1
1
795-799-1131 Gear
1
2
Commercially available
1
1
795-799-6700 Puller
1
2
795-502-1590 Gauge assembly
1
0 to 7 MPa {0 to 70 kg/cm2}
3
795-790-4411 Adapter
1
For 107E-1 engine
4
6754-11-3130 Gasket
1
For 107E-1 engine
799-201-1506 Blowby checker
1
0 to 5 kPa {0 to 500 mmH2O}
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
790-261-1205 Digital hydraulic tester
1
Pressure gauge: 70 MPa {700 kg/ cm2}
2
799-401-2320 Gauge
1
Pressure gauge: 1 MPa {10 kg/cm2}
3
790-301-1220 Nipple
1
PT1/8
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
790-261-1205 Digital hydraulic tester
1
Pressure gauge: 70 MPa {700 kg/ cm2}
799-401-2320 Gauge
1
Pressure gauge: 1 MPa {10 kg/cm2}
799-101-5220 Nipple
1
07002-11023
1
G
Smoke meter
Feeler gauge
1 Testing engine oil pressure
H
1 Testing fuel pressure
J 2 3
O-ring
K
2 3
4
GD535-5 (01)
Bosch index: 0 to 9
Intake: 0.33 mm, exhaust: 0.71 mm
Size: 10 x 1.25 mm
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
790-261-1205 Digital hydraulic tester
1
Pressure gauge: 70 MPa {700 kg/ cm2}
799-401-2320 Gauge
1
Pressure gauge: 1 MPa {10 kg/cm2}
799-101-5220 Nipple
1
07002-11023
O-ring
1
Commercially available
Block
2
1
Testing power train oil pressure
Remarks
1
C
D
Part No.
Size: 10 x 1.25 mm
30-9
Tools for testing, adjusting, and troubleshooting
Testing/Adjusting item
Symbol
Retrieval of disabled machine due to transmission valve failure
L
30 Testing and adjusting
Part No.
Part name
Q'ty
794-423-1190 Plug
3
07002-22034
3
O-ring
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
790-261-1205 Digital hydraulic tester
1
Pressure gauge: 70 MPa {700 kg/ cm2}
799-401-2320 Gauge
1
Pressure gauge: 1 MPa {10 kg/cm2}
790-301-1271 Joint
1
07002-11023
1
1 Testing differential lock pressure [differential lock specification]
2 M 3 4 5
O-ring
799-401-3200 Adapter 791T-6012220
Elbow
1
2 Testing oil leakage of steering cylinder
P
Q
1
Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
790-261-1205 Digital hydraulic tester
1
Pressure gauge: 70 MPa {700 kg/ cm2}
790-301-1271 Joint
1
07002-11023
O-ring
1
Commercially available
Measuring cylinder
1
Testing and adjusting parking brake pad
1
Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
790-261-1205 Digital hydraulic tester
1
Pressure gauge: 70 MPa {700 kg/ cm2}
2
793-520-1805 Brake test kit
1
0 to 20 MPa {0 to 200 kg/cm2}
3
799-401-3100 Adapter
1
Size: 02
790-301-1271 Joint
1
07002-11023
O-ring
1
5 791T-601-2220 Elbow
1
30-10
Commercially available
Size: 10 x 1.25 mm
Vernier calipers
1
1
792-454-1100 Pump assembly
1
2
792-454-1120 Valve
1
3
792-454-1110
Pump
1
4
790-425-1240 Nipple
1
5
416-62-11480 O-ring
1
6
790-612-5110 Adapter
1
Size: R1/8-Rc1/4
7
790-190-2310 Hose
1
Size: R1/4-Rc1/4
8
Commercially available
Hose
1
9
Commercially available
Oil container
1
R
S
Size: 10 x 1.25 mm
799-101-5002 Hydraulic tester
4
Testing wear of wheel brake disc
Size: 03
799-101-5002 Hydraulic tester
1
Testing and adjusting brake oil pressure
Size: 10 x 1.25 mm
1
1 Testing steering oil pressure N
Remarks
Size: 7/16-20UNF-2A-Rc1/8
GD535-5 (01)
30 Testing and adjusting
Tools for testing, adjusting, and troubleshooting
Testing/Adjusting item
Symbol
Charging brake accumulator with gas
T
Part No.
Part name
Q'ty
792-610-1702 Charging tool
1
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
790-261-1205 Digital hydraulic tester
1
Pressure gauge: 70 MPa {700 kg/ cm2}
790-301-1530 Elbow
1
R1/8×R1/8, 90°
790-301-1271 Joint
1
07002-11023
1
1 Testing and adjusting work equipment oil pressure
U 2 3
Testing lifter lock pin circuit pressure
2 Testing oil leakage of work equipment cylinder
W
1
Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
790-261-1205 Digital hydraulic tester
1
Pressure gauge: 70 MPa {700 kg/ cm2}
799-401-3100 Adapter
2
Size: 02
Commercially available
1
Measuring cylinder
1
6754-71-5340 Connector
1
6754-71-5350 Washer
1
4
Commercially available
Measuring cylinder
1
5
Commercially available
Stopwatch
1
6
Commercially available
Hose (inside diameter: 14 mm)
1
7
Commercially available
Hose (inside diameter: 8 mm)
1
3
Y
Size: 10 x 1.25 mm
799-101-5002 Hydraulic tester
795-790-4700 Tester kit
1
Testing fuel return rate and leakage
O-ring
1
V
Remarks
79A-264-0021 Push-pull scale
1
0 to 294 N {0 to 30 kg}
79A-264-0091 Push-pull scale
1
0 to 490 N {0 to 50 kg}
－
Commercially available
Ruler
1
Testing work equipment speed
－
Commercially available
Stopwatch
1
Testing voltage and resistance
－
Commercially available
Multimeter
1
Testing operating effort and depressing effort
－
Testing travel and hydraulic drift
GD535-5 (01)
30-11
Tools for testing, adjusting, and troubleshooting
Testing/Adjusting item
Diagnosing controllers, sensors, and actuators
30-12
Symbol
－
Part No.
30 Testing and adjusting
Part name
Q'ty
Remarks
799-601-4130 T-adapter
－
For NE sensor
799-601-4130 T-adapter
－
For oil pressure sensor
799-601-4240 Socket
－
For ambient pressure sensor
799-601-4250 Socket
－
For boost pressure sensor
799-601-4330 Socket
－
For G sensor
799-601-9020 T-adapter
－
For injector
799-601-9030 T-adapter
－
For CAN
799-601-9040 T-adapter
－
For EGR valve position sensor
799-601-9430 Socket
－
For supply pump
795-799-5530 Socket
－
For coolant temperature sensor and fuel temperature sensor
795-799-5540 Socket
－
For boost temperature sensor
799-601-4211 T-adapter
－
For controller (50 poles)
799-601-4220 T-adapter
－
For controller (60 poles)
GD535-5 (01)
30 Testing and adjusting
Testing/Adjusting item
Tools for testing, adjusting, and troubleshooting
Symbol
Part No.
Part name
799-601-4101, or 799-6014201, or 799- T-adapter assembly 601-9000, or 799-601-9200
Diagnosing sensors and wiring harnesses for machine
－
Remarks
1
Adapter for DT
799-601-9020
q
Adapter for DT
1
For DT2P
799-601-9030
q
Adapter for DT
1
For DT3P (parts 799-601-4100 and 799-601-4200 are not contained.)
799-601-9040
q
Adapter for DT
1
For DT4P
799-601-9050
q
Adapter for DT
1
For DT6 (parts 799-601-4100 and 799-601-4200 are not contained.)
799-601-9110
q
Adapter for DT
1
For DT12GR (parts 799-601-4100 and 799-601-4200 are not contained.)
799-601-9120
q
Adapter for DT
1
For DT12B (parts 799-601-4100 and 799-601-4200 are not contained.)
799-601-9130
q
Adapter for DT
1
For DT12G (parts 799-601-4100 and 799-601-4200 are not contained.)
799-601-9140
q
Adapter for DT
1
For DT12BR (parts 799-601-4100 and 799-601-4200 are not contained.)
1
Adapter for X, SWP, and M
799-601-7000, or 799-6017100, or 799- T-adapter assembly 601-7400, or 799-601-8000 799-601-7010
q
Adapter for X
1
For X1P (parts 799-601-7000 and 799-601-7100 are not contained.)
799-601-7020
q
Adapter for X
1
For X2P
799-601-7050
q
Adapter for SWP
1
For SW6P (part 799-601-8000 is not contained.)
799-601-7070
q
Adapter for SWP
1
For SW14P (parts 799-601-7000 and 799-601-7100 are not contained.)
799-601-7080
q
Adapter for M
1
For M1P (parts 799-601-7000 and 799-601-7100 are not contained.)
799-601-7090
q
Adapter for M 1
1
For M2P
799-601-7110
q
Adapter for M 1
1
For M3P
799-601-7120
q
Adapter for M 1
1
For M4P
799-601-7130
q
Adapter for M 1
1
For M6P
799-601-7310
q
Adapter for SWP
1
For SW12P
799-601-7500 T-adapter assembly
1
Adapter for 070
799-601-7520
q
Adapter for 070
1
For 070-12P
799-601-7550
q
Adapter for 070
1
For 070-20P
799-601-9300 T-adapter assembly
1
Adapter for DRC
Adapter for DRC
1
For DRC-40P
799-601-9350
GD535-5 (01)
Q'ty
q
30-13
Tools for testing, adjusting, and troubleshooting
Symbol
Part No.
Diagnosing sensors and wiring harnesses for machine
－
799-601-9360
Removing and installing coolant temperature sensor
－
795T-9811010
Testing/Adjusting item
30 Testing and adjusting
Part name
q
Adapter for DRC
Socket
Q'ty
1
Remarks
For DRC-24P
1
a For types and part numbers for T-adapters and boxes for troubleshooting for machine monitor, controller, sensor, actuator, and wiring harness, see Troubleshooting, "T-box and T-adapter list".
30-14
GD535-5 (01)
30 Testing and adjusting
Tools for testing, adjusting, and troubleshooting
Note) Komatsu does not take any responsibility for special tools manufactured according to these sketches. Elbow
Socket
GD535-5 (01)
30-15
Testing engine speed
30 Testing and adjusting
Engine and cooling system
1
Testing engine speed
1
k Park
the machine on flat ground, place the work equipment on the ground surely, set the gear shift lever to P (PARK) position, and then stop the engine. k Chock the tires to prevent the machine from moving. a Perform the testing of the engine speed under the following conditions. q Coolant temperature: 80 to 90°C q Hydraulic oil temperature: 45 to 55°C q Torque converter oil temperature: 60 to 80°C 1. Preparation (For the testing of low and high idle speeds) Turn the starting switch to ON position, and switch the machine monitor to "Monitoring" display to prepare for testing the engine speed. a For the operating method, see "Special functions of machine monitor". q Monitoring code: 01002 "Engine Speed" q Monitoring code: 04107 "Coolant Temperature" q Monitoring code: 30100 "T/C Oil Temperature" q Monitoring code: 04401 "Hydraulic Oil Temperature"
2. Testing low idle speed 1) Start the engine, and hold the gear shift lever at P position. 2) Check the engine speed when the accelerator pedal is not depressed. a For standard values, see the Standard value table, "Standard value table for engine". 3. Testing high idle speed 1) Start the engine, and hold the gear shift lever at P position. 2) Check the engine speed when the accelerator pedal is depressed to the stroke end.
30-16
a For standard values, see the Standard value table, "Standard value table for engine". 4. Testing torque converter stall speed 1) Start the engine, and hold the gear shift lever at P position. 2) Switch the machine monitor to "T/C Stall" display to prepare for stalling the torque converter. a For the operating method, see "Special functions of machine monitor".
3) While depressing the brake pedal completely, operate the gear shift lever to F8 position. k Keep the brake pedal firmly depressed. 4) Depress the accelerator pedal gradually to stall the torque converter with the engine at high idle. 5) When the torque converter oil temperature reaches 90°C, release the accelerator pedal to the low idle position immediately, and return the gear shift lever to P position. k Do not operate the gear shift lever while the accelerator pedal is depressed. Otherwise internal damage may be induced in the transmission. 6) While holding the gear shift lever at P position, run the engine at medium speeds. When the torque converter oil temperature decreases to approximately 80°C, release the accelerator pedal to the low idle position. 7) Repeat steps 3) to 6) to equalize the oil temperature of the torque converter and transmission. 8) While repeating steps 3) to 6), check the torque converter stall speed when the torque converter oil temperature is 80°C. a Check the torque converter stall speed 2 to 3 times in the same procedure. a For standard values, see the Standard value table, "Standard value table for engine".
GD535-5 (01)
30 Testing and adjusting
Testing engine speed
Be sure to check the torque converter stall speed before delivery since the variation in speed is generated under the following conditions. q Variation unique to each engine q Variation due to differences in ambient pressure and temperature q Variation due to differences in consumption of torque by auxiliaries q Variation due to differences in characteristics among torque converters q Variation due to differences in testing methods
GD535-5 (01)
30-17
Testing boost pressure
30 Testing and adjusting
Testing boost pressure
1
a Tools for testing boost pressure Sym bol B
Part No.
Part name
1 799-201-2202
Boost gauge kit
2 790-301-1530
Elbow (R1/8 x R1/8, 90°)
k Park
the machine on flat ground, place the work equipment on the ground surely, set the gear shift lever to P (PARK) position, and then stop the engine. k Chock the tires to prevent the machine from moving. k When installing and removing testing tools, take care not to touch a hot part of the engine. a Perform the testing of the boost pressure under the following conditions. q Coolant temperature: 60 to 100°C q Hydraulic oil temperature: 45 to 55°C q Torque converter oil temperature: 60 to 80°C 1. Open the R.H. engine side cover, and remove boost pressure pickup plug (1) from the air intake connector.
3. Run the engine at middle or higher speed and drain oil from the hose. a Repeat opening the self-sealing portion on the hose to drain oil with the gauge and hose being connected approximately half at their connection part. a When the Pm kit is available, you can use air bleeding coupling (790-261-1130) in the kit. a If oil is left in the hose, the gauge does not work. Accordingly, be sure to drain the oil. 4. Set the gear shift lever to P position and keep the engine running at low idle. 5. Switch the machine monitor to "T/C Stall" display to prepare for stalling the torque converter. a For the operating method, see "Special functions of machine monitor".
2. Install elbow B2 and nipple [1] in boost gauge kit B1, and then connect gauge [2].
30-18
GD535-5 (01)
30 Testing and adjusting
Testing boost pressure
6. While depressing the brake pedal completely, operate the gear shift lever to F8 position. k Keep the brake pedal firmly depressed. 7. Depress the accelerator pedal gradually, then measure the boost pressure when the torque converter stalls with the engine at high idle. a For standard values, see the Standard value table, "Standard value table for engine". 8. After the test is finished, release and return the accelerator pedal to the low idle position immediately, and return the gear shift lever to P position. k Do not operate the gear shift lever while the accelerator pedal is depressed. Otherwise internal damage may be induced in the transmission. 9. After finishing the test, remove the testing tools, and restore the machine.
GD535-5 (01)
30-19
Testing exhaust gas temperature
30 Testing and adjusting
Testing exhaust gas temperature
1
a Tools for testing exhaust gas temperature Sym bol C
Part No.
a Clamp the wiring harness of the digital thermometer so that it does not touch a hot part during measurement.
Part name
799-101-1502 Digital thermometer
k Park
the machine on flat ground, place the work equipment on the ground surely, set the gear shift lever to P (PARK) position, and then stop the engine. k Chock the tires to prevent the machine from moving. k Install or remove the testing tools after the exhaust manifold temperature has lowered. a Perform the testing of the exhaust gas temperature under the following conditions. q Coolant temperature: 60 to 100°C q Hydraulic oil temperature: 45 to 55°C q Torque converter oil temperature: 60 to 80°C 1. Open the L.H. engine side cover and remove bracket (1) of the turbocharger.
2. Remove exhaust gas temperature pickup port plug (2) from the exhaust manifold.
4. Procedure for testing periodically in Pm clinic a In order to prevent overheating of the torque converter, stabilize exhaust gas temperature with full stall (torque converter stall + hydraulic relief) once. Then stall the torque converter only for the measurement. 1) Start the engine, and hold the gear shift lever at P position. 2) Hold the accelerator pedal at the low idle position. 3) Operate the right and left blade lift control levers to move the right and left blade lift cylinders to the RAISE stroke ends. 4) Switch the machine monitor to "T/C Stall" display to prepare for stalling the torque converter. a For the operating method, see "Special functions of machine monitor".
3. Install sensor [1] of digital thermometer C and connect it to meter [2].
30-20
GD535-5 (01)
30 Testing and adjusting
Testing exhaust gas temperature
6. After finishing the test, remove the testing tools, and restore the machine.
5) While depressing the brake pedal completely, operate the gear shift lever to F8 position. k Keep the brake pedal firmly depressed. 6) Depress the accelerator pedal gradually to stall the torque converter at engine high idle. At the same time, operate the right and left blade lift control levers to RAISE position to relieve oil pressure in the work equipment circuit (full stall state). a Continue the above operations until the exhaust gas temperature reaches near 670°C, which is the standard value. 7) After the exhaust gas temperature is stabilized at around the targeted temperature, return the right and left blade lift control levers to NEUTRAL position, and check the exhaust gas temperature when the torque converter alone is stalled. a For standard values, see the Standard value table, "Standard value table for engine". 8) After the check is finished, release the accelerator pedal immediately, and return the gear shift lever to P position. k Do not operate the gear shift lever while the accelerator pedal is depressed. Otherwise internal damage may be induced in the transmission. 5. Procedure for measuring maximum value in troubleshooting Measure the maximum exhaust gas temperature when the actual operations are performed. a Use the digital temperature gauge in the PEAK mode (the maximum temperature is automatically recorded when it is set to the PEAK mode). a As the exhaust gas temperature differs greatly depending on the ambient temperature (intake air temperature of the engine), correct the value by using the following formula if an abnormal value is recorded. q Compensation value [°C] = Measured value + 2 x (20 - Ambient temperature)
GD535-5 (01)
30-21
Testing exhaust gas color
30 Testing and adjusting
Testing exhaust gas color
1
a Tools for testing exhaust gas color Sym bol D
Part No.
Part name
1
799-201-9002 Handy smoke checker
2
Commercially Smoke meter available
a For standard values, see the Standard value table, "Standard value table for engine". 6) After finishing the test, remove the testing tools, and restore the machine. 2. Testing by using smoke meter D2 1) Insert probe [1] of smoke meter D2 into the outlet of exhaust pipe (1), and fix it to the exhaust pipe with clip.
k Park
the machine on flat ground, place the work equipment on the ground surely, set the gear shift lever to P (PARK) position, and then stop the engine. k Chock the tires to prevent the machine from moving. k Be careful not to touch any hot part when installing or removing the testing tools. a Perform the testing of the exhaust gas color under the following conditions. q Coolant temperature: 60 to 100°C a If an air source and an electric power source are not available in the field, use handy smoke checker D1. When recording official data, etc., use smoke meter D2. 1. Measuring by using handy smoke checker D1 1) Place a sheet of filter paper to smoke checker D1. 2) Insert the exhaust gas intake pipe into exhaust pipe (1). 3) Start the engine, and hold the gear shift lever at P position. 4) Accelerate the engine suddenly or run it at high idle and operate the handle of smoke checker D1 to collect exhaust gas on the filter paper. a Suction time: 1.4 ± 0.2 seconds
2) Connect the probe hose, accelerator switch outlet, and air hose to smoke meter D2. a The supplied air pressure must be 1.5 MPa {15 kg/cm2} or below. 3) Connect the power cable to an 100 VAC receptacle. a Check that the smoke meter power switch is in OFF position before connecting the power cable to the receptacle. 4) Loosen the cap nut of the suction pump, and place the filter paper. a Fit the filter paper securely so that the exhaust gas does not leak. 5) Turn on the power switch of D2.
5) Remove the filter paper and compare it with the attached scale for judgment.
30-22
GD535-5 (01)
30 Testing and adjusting
Testing exhaust gas color
6) Start the engine and leave the gear shift lever set in P position. 7) Accelerate the engine quickly or run it at high idle, and depress the accelerator pedal of smoke meter D2 to collect exhaust gas on the filter paper. 8) Place the contaminated filter paper on the clean filter paper (at least 10 sheets) in the filter paper holder and read the indicated value. a For standard values, see the Standard value table, "Standard value table for engine". 9) After finishing the test, remove the testing tools, and restore the machine.
GD535-5 (01)
30-23
Adjusting valve clearance
30 Testing and adjusting
Adjusting valve clearance
1
a Tools for adjusting valve clearance Sym bol E
Part No.
Part name
1
795-799-1131 Gear
2
Commercially Feeler gauge available
1. Remove hood assembly and air cleaner assembly (1). For removal and installation procedure, see "Removal and installation of engine hood assembly" in disassembly and assembly. 2. Remove muffler assembly (2). 3. Remove cylinder head cover (3).
5. Rotate the crankshaft forward by using gear E1 to align the wide slit (b) (1 place) of the disc for detecting rotation at the rear of the crankshaft pulley to the top surface (a) of protruding part of front cover. a Positioning is accepted if the top surface (a) of the protruding part is within the range of wide slit (b) when viewed from intake manifold side.
4. Remove plug (4) at the top of the starting motor, and install gear E1. k
30-24
Note that this positioning does not set No. 1 and No. 6 cylinders at their top dead centers. (They are positioned 76 to 88 degrees before their top dead centers.)
GD535-5 (01)
30 Testing and adjusting
6. Adjust the valve clearance according to the following procedure. a If the rocker arm of exhaust valve (EX side) of No. 1 cylinder cannot be moved by hand, adjust the valves marked with Q in the valve arrangement drawing. q If the rocker arm of exhaust valve (EX side) of No. 1 cylinder can be moved by hand by the distance of the valve clearance, adjust the valves marked with q in the valve arrangement drawing.
Adjusting valve clearance
7. Similarly to step 5, rotate the crankshaft forward one turn by using gear E1 to align the wide slit (b) to the top surface (a) of the protruding part. 8. Adjust the clearances of the other valves according to steps 6. a If the valves marked with Q in the valve arrangement drawing are adjusted in step 4, adjust the rest of the valves marked with q. (If the valves marked with q have been already adjusted, adjust those marked with Q.) 9. After finishing the adjustment, remove the adjusting tools, and restore the machine. k Be sure to remove gear E1. 3 Cylinder head cover mounting bolt: 20 to 28 Nm {2.04 to 2.86 kgm}
1) Insert feeler gauge E2 into the clearance between rocker arm (5) and crosshead (6). 2) Loosen lock nut (7) and adjust valve clearance by using adjustment screw (8). a With feeler gauge inserted, turn the adjustment screw so that the feeler gauge can move lightly. a For standard values, see the Standard value table, "Standard value table for engine". 3) Fix adjustment screw (8) and tighten lock nut (7). 3 Lock nut: 20 to 28 Nm {2.04 to 2.86 kgm} a After tightening the lock nut, check the valve clearance again.
GD535-5 (01)
30-25
Testing compression pressure
30 Testing and adjusting
Testing compression pressure
1
a Tools for testing compression pressure Sym bol
F
Part No.
Part name
1
795-799-6700 Puller
2
795-502-1590 Gauge assembly
3
795-790-4411 Adapter
4
6754-11-3130 Gasket
k When
testing the compression pressure, take care not to get yourself burned by touching the exhaust manifold or muffler, or get caught in a rotating part. a Test the compression pressure with the engine being warmed up. a Perform the testing of the compression pressure under the following conditions. q Engine oil temperature: 40 to 60°C q At cranking (engine speed): 250 to 280 rpm (for reference) 1. Remove cylinder head cover (1).
7. Remove retainer (6), and remove fuel inlet connector (7). 8. Remove injector holder (8). 9. Remove injector (9). a Use puller F1 to remove the injector with the impacts of the slide hammer. a Do not pry the top of the injector to remove.
2. Disconnect clamp (2) of the injector wiring harness connector and move the wiring harness out of the way. 3. Disconnect fuel high-pressure tube (3).
4. Loosen injector terminal nuts (4) and remove the terminals from the injector. 5. Set the cylinder to be checked to the compression top dead center. a See "Adjusting valve clearance". 6. Remove rocker arm assembly (5).
30-26
10. Install adapter F3 with gasket F4 fitted at its tip into the injector mounting bore.
GD535-5 (01)
30 Testing and adjusting
Testing compression pressure
11. Fix adapter F3 with injector holder (8). a Tighten mounting bolts of the injector holder alternately. 3 Injector holder mounting bolt: 8±0.8 Nm {0.8 ± 0.08 kgm} 12. Connect gauge assembly F2 to adapter F3. a Apply a small amount of engine oil to the contact faces of the adapter and gauge to prevent air leakage. 13. Install rocker arm assembly (5). 3 Rocker arm assembly mounting bolt: 36 ± 5 Nm {3.67 ± 0.51 kgm} 14. Adjust the valve clearance. a See "Adjusting valve clearance".
2) Tighten injector holder mounting bolt (10) by approximately 3 to 4 threads. 3) Set fuel inlet connector (7). a Press it in until you feel the O-ring clicks in. 4) Tighten fuel inlet connector (7) lightly with retainer (6). 3 Retainer: 15 ± 5.0 Nm {1.5 ± 0.5 kgm} 5) Tighten injector holder mounting bolts (10) alternately. 3 Holder mounting bolt: 8 ± 0.8 Nm {0.8 ± 0.08 kgm} 6) Tighten retainer (6) of the fuel inlet connector lightly. 3 Retainer: 50 ± 5 Nm {5.1 ± 0.5 kgm}
15. Select the no-injection cranking mode by operating the machine monitor. a For the operating method, see "Special functions of machine monitor". k Be sure to select the no-injection cranking mode, otherwise the engine may start during measurement creating a dangerous situation. 16. Measure the compression pressure when the engine is cranked by the starting motor. a Read the pressure gauge pointer when it is stabilized. a For standard values, see the Standard value table, "Standard value table for engine".
7) Tighten the sleeve nuts of fuel high-pressure pipe (3) in the order of nuts on the head side and those on the common rail side. 3 Sleeve nut: 35 ± 3.5 Nm {3.6 ± 0.4 kgm}
17. After finishing the test, remove the testing tools, and restore the machine. a Install the injector and fuel high-pressure tube according to the following procedure. 1) Align protrusion (a) of the injector with notch (b) of the injector holder, and set the injector to the cylinder head. a Set the injector with the mating position facing the fuel inlet connector insertion side.
GD535-5 (01)
30-27
Testing compression pressure
30 Testing and adjusting
18. After installing the rocker arm assembly, adjust the valve clearance. For details of the procedure, see "Adjusting valve clearance". 3 Rocker arm assembly mounting bolt: 36 ± 5 Nm {3.67 ± 0.51 kgm} 19. Install the injector wiring harness. 3 Terminal nut: 1.5 ± 0.25 Nm {0.15 ± 0.025 kgm} a Check that the injector wiring harness does not interfere with the rocker arm. 20. Install the cylinder head cover. 3 Head cover mounting nut: 24 ± 4 Nm {2.45 ± 0.41 kgm}
30-28
GD535-5 (01)
30 Testing and adjusting
Testing blowby pressure
Testing blowby pressure
1
a Tools for testing blowby pressure Sym bol
Part No.
G
799-201-1506
Part name Blowby checker
k Park
the machine on flat ground, place the work equipment on the ground surely, set the gear shift lever to P (PARK) position, and then stop the engine. k Chock the tires to prevent the machine from moving. a Perform the testing of the boost pressure under the following conditions. q Coolant temperature: 60 to 100°C q Hydraulic oil temperature: 45 to 55°C q Torque converter oil temperature: 60 to 80°C 1. Install nozzle [1] of blowby checker G to the tip of blowby hose (1), and connect it to gauge [2].
4. While depressing the brake pedal completely, operate the gear shift lever to F8 position. k Keep the brake pedal firmly depressed. 5. Depress the accelerator pedal gradually, then measure the boost pressure when the torque converter stalls with the engine at high idle. a For standard values, see the Standard value table, "Standard value table for engine". a Normally, the blowby pressure should be measured while the engine is operated at the rated horsepower. In the field, however, an approximate value can be obtained by stalling the torque converter. a If rated horsepower operation or torque converter stalling is not possible, measure the blowby pressure while the engine is running at high idle. In this case, the measured value of blowby pressure comes to approximately 80 % of that obtained at rated horsepower operation. a Blowby pressure varies greatly with the condition of the engine. Therefore, if the measured value obtained by the test is considered unusual, check for excessive oil consumption, bad color of exhaust gas, early oil deterioration, early oil contamination, etc., which are related to improper blowby pressure. 6. After the test is finished, release the accelerator pedal to the low idle position immediately, and return the gear shift lever to P position. k Do not operate the gear shift lever while the accelerator pedal is depressed. Otherwise internal damage may be induced in the transmission.
2. Start the engine, set the gear shift lever to P position, and keep the engine running at low idle.
7. After finishing the test, remove the testing tools, and restore the machine.
3. Switch the machine monitor to "T/C Stall" display to prepare for stalling the torque converter. a For the operating method, see "Special functions of machine monitor".
GD535-5 (01)
30-29
Testing engine oil pressure
30 Testing and adjusting
Testing engine oil pressure
1
a Tools for testing engine oil pressure Sym bol 1 H
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1205
Digital hydraulic tester
2 799-401-2320
Gauge
3 790-301-1220
Nipple
k Park
the machine on flat ground, place the work equipment on the ground surely, set the gear shift lever to P (PARK) position, and then stop the engine. k Chock the tires to prevent the machine from moving. a Perform the testing of the engine oil pressure under the following conditions. q Coolant temperature: 60 to 100°C
4. Start the engine and measure the engine oil pressure when the engine is running at low idle and at high idle. a For standard values, see the Standard value table, "Standard value table for engine".
1. Open R.H. engine side cover (1).
5. After finishing the test, remove the testing tools, and restore the machine.
2. Remove oil pressure pickup plug (2) of the cylinder block.
3. Install nipple H3 and connect it to gauge H2.
30-30
GD535-5 (01)
30 Testing and adjusting
Handling fuel system devices
Handling fuel system devices
1
a Precautions when testing and servicing fuel system The common rail fuel injection system (CRI) consists of more precise parts than the parts used in the conventional fuel injection pump and nozzle. If foreign material enters this system, it may cause a failure. Use extreme care more strictly than ever to prevent entry of foreign material when servicing the fuel system. If any dust or other material sticks to any part, wash the part thoroughly with clean fuel. a Precautions for replacing fuel filter cartridge Be sure to use the Komatsu genuine fuel filter cartridge. The common rail fuel injection system (CRI) consists of more precise parts than the parts used in the conventional fuel injection pump and nozzle. To prevent the entry of foreign material, this system uses a special filter with high-efficiency filtering performance. Therefore, use of filters other than Komatsu genuine filters can cause a failure in the fuel system. Be sure not to use filters other than Komatsu genuine ones.
GD535-5 (01)
30-31
Releasing remaining pressure from fuel system
30 Testing and adjusting
Releasing remaining pressure from 1 fuel system a While the engine is running, pressure is generated in the low-pressure and high-pressure circuits of the fuel circuit. Low-pressure circuit: Between feed pump and fuel filter, between fuel filter and fuel supply pump High-pressure circuit: Between fuel supply pump and common rail, between common rail and fuel injector a The pressure in both low-pressure circuit and high-pressure circuit lowers to a safety level automatically 30 seconds after the engine is stopped. a Before the fuel circuit is tested and its parts are removed or installed, the remaining pressure in the fuel circuit must be released completely. Accordingly, observe the following. k Before testing the fuel system or removing/ installing the tools, wait at least 30 seconds after stopping the engine until the remaining pressure in the fuel circuit is released. (Do not start the work immediately after the engine is stopped since remaining pressure is still in the circuit.)
30-32
GD535-5 (01)
30 Testing and adjusting
Testing fuel pressure
Testing fuel pressure
1
a Tools for testing fuel pressure Sym bol 1 J
2 3
Part No.
Part name
799-101-5002 Hydraulic tester 790-261-1205 Digital hydraulic tester 799-401-2320 Gauge 799-101-5220 Nipple 07002-11023
O-ring
k Park
the machine on flat ground, place the work equipment on the ground surely, set the gear shift lever to P (PARK) position, and then stop the engine. k Chock the tires to prevent the machine from moving. a Measure the fuel pressure only in the low-pressure circuit from the feed pump through the fuel filter to the supply pump. k Check of the high-pressure circuit from the supply pump through the common rail to the injector cannot be performed because extremely high pressure is generated there.
3. Start the engine, run it at low idle, and measure the fuel pressure. a The fuel pressure is normal when it is within the following range. 0.5 to 1.3 MPa {5.1 to 13.3 kg/cm2} 4. After finishing the test, remove the testing tools, and restore the machine. 3 Fuel pressure pickup plug: 10 ± 2 Nm {1 ± 0.2 kgm}
1. Open the R.H. engine side cover, and remove fuel pressure pickup plug (1) from the fuel filter.
2. Install nipple J3 and connect it to gauge J2.
GD535-5 (01)
30-33
Bleeding air from fuel circuit
Bleeding air from fuel circuit
30 Testing and adjusting
1
a If fuel is used up or if a fuel circuit component is removed and installed, bleed air from the fuel circuit according to the following procedure. 1. Loosen knob (1) of the priming pump and move it back and forth.
a Move the knob until its motion becomes heavy. (If the main filter is empty, moving the knob 60 to 70 times bleeds air from the circuit. ) 2. Start the engine by cranking it with the starting motor. a The air in the high-pressure circuit is bled automatically by cranking the engine. a If the engine does not start, there still may be air in the low-pressure circuit. In this case, repeat from step 2.
30-34
GD535-5 (01)
30 Testing and adjusting
Testing fuel circuit for leakage
Testing fuel circuit for leakage
1
k Park
the machine on flat ground, place the work equipment on the ground surely, set the gear shift lever to P (PARK) position, and then stop the engine. k Chock the tires to prevent the machine from moving. k Very high pressure is generated in the highpressure circuit of the fuel system. If fuel leaks while the engine is running, it presents a serious danger such as fire, etc. a Clean the engine and the parts around it, and degrease them in advance so that you can check it easily for fuel leakage. 1. Spray color checker (developer) to the fuel supply pump, common rail, fuel injectors, and joints of the high-pressure piping. 2. Start the engine, keep its speed at 1000 rpm or below, and stop it when the speed is stabilized. 3. Check the fuel piping and devices for fuel leakage. a Check the high-pressure circuit for fuel leakage focusing on the area where the color checker is sprayed. a If any fuel leakage is detected, repair it and perform the checks from step 1 again. 4. Start the engine, and keep it running at low idle. 5. Check the fuel piping and devices for fuel leakage. a Check the high-pressure circuit for fuel leakage focusing on the area where the color checker is sprayed. a If any fuel leakage is detected, repair it and perform the checks from step 2 again. 6. Start the engine, and keep it running at high idle. 7. Check the fuel piping and devices for fuel leakage. a Check the high-pressure circuit for fuel leakage focusing on the area where the color checker is sprayed. a If any fuel leakage is detected, repair it and perform the checks from step 1 again. 8. Start the engine and keep it running at high idle, and apply a load to the engine. a Perform blade RAISE relief for right and left. 9. Check the fuel piping and devices for fuel leakage. a Check the high-pressure circuit for fuel leakage focusing on the area where the color checker is sprayed. a If any fuel leakage is detected, repair it and perform the checks from step 1 again. a If no fuel leakage is detected, this check is completed.
GD535-5 (01)
30-35
Handling cylinder cutout mode operation
Handling cylinder cutout mode operation
30 Testing and adjusting
1
a The cylinder cutout mode operation means to run the engine with the fuel injectors of one or more cylinders disabled electrically to reduce the number of active cylinders. The purposes and effects of this operation are as follows. 1. This operation is used to find out a cylinder which does not output power normally (or, combustion in it is abnormal). 2. When a cylinder is selected for the cylinder cutout mode operation, if the engine speed and output do not change from the normal operation (all-cylinder operation), that cylinder has a failure. q The possible failures are as follows. q Compression gas leakage from cylinder head gasket area q Defective injection q Defective piston, piston ring or cylinder liner q Defective valve mechanism (valve operating system) q Defective electrical system 3. The injector of each cylinder is separately controlled electronically in the common rail fuel injection system, so the cylinder cutout test can be performed more easily by the simple operations of the switches compared with the mechanical fuel injection system. So, the defective cylinder can be found out easily. a Cylinder cutout mode operation is set in the service mode of the machine monitor. For details, see "Diagnostic Tests (Cylinder Cut-out)" of "Special functions of machine monitor".
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GD535-5 (01)
30 Testing and adjusting
Handling no-injection cranking operation
Handling no-injection cranking operation
1
a No-injection cranking operation means to crank the engine by using the starting motor while disabling injection in every cylinder electrically. The purpose and effect of this operation are as follows. a No-injection cranking is performed to lubricate the engine parts and to protect them from seizure. It is performed before the engine is started after the machine or engine has been stored for a long period. a No-injection cranking operation is set in the service mode of the machine monitor. For details, see "No Injection" of "Special functions of machine monitor".
GD535-5 (01)
30-37
Handling voltage circuit of engine controller
Handling voltage circuit of engine controller
30 Testing and adjusting
1
1. Be sure to turn the starting switch to OFF position before disconnecting or connecting the connectors between the engine controller and engine. 2. When you perform troubleshooting, do not start the engine while a T-adapter is inserted into or connected to the connector between the engine controller and engine. a You may turn the starting switch to OFF or ON position but must not turn it to START position.
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GD535-5 (01)
30 Testing and adjusting
Testing muffler (main body) and stacked muffler for looseness and damage
Testing muffler (main body) and stacked muffler for looseness and damage
1
1. Visually check the muffler and stacked muffler for cracks and damage. If damage is found on them, replace it with new one. 2. Check the mounting bolts and nuts of the muffler and stacked muffler for looseness. If any part is loosened, retighten it.
GD535-5 (01)
30-39
Testing muffler function
Testing muffler function q
30 Testing and adjusting
1
Check for an unusual noise or abnormal noise compared to that when the machine was new. If an unusual noise is heard, make repairs.
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GD535-5 (01)
30 Testing and adjusting
Testing installed condition of cylinder heads and manifolds
Testing installed condition of cylinder heads and manifolds
1
Check the mounting state of the cylinder head and intake and exhaust manifolds. If any part is loosened, retighten it. a For the tightening torques, see the "Disassembly and assembly".
GD535-5 (01)
30-41
Testing of engine piping for damage and looseness
Testing of engine piping for damage and looseness
30 Testing and adjusting
1
Intake and exhaust system: Check the piping for damage, mounting bolts and nuts for looseness, and the joints for air suction and exhaust gas leakage. If any part is loosened or damaged, retighten or repair it. Cooling system: Check the piping for damage, mounting bolts and nuts for looseness, and the joints for water leakage. If any part is loosened or damaged, retighten or repair it. Fuel system: Check the piping for damage, mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it.
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GD535-5 (01)
30 Testing and adjusting
Testing fuel discharge, return rate, and leakage
Testing fuel discharge, return rate, and leakage
1
a Tools for testing fuel discharge, return and leakage Sym bol 1 3
Part No.
Part name
795-790-4700 Tester kit 6754-71-5340 Connector 6754-71-5350 Washer
4
Commercially Measuring cylinder available
5
Commercially Stopwatch available
6
Commercially Hose (inside diameter: 14 mm) available
7
Commercially Hose (inside diameter: 8 mm) available
Y
a Prepare a container of approximately 20 l to receive fuel that leaks out during the testing. 1. Testing supply pump discharge 1) Loosen clamp (2) of tube (1) on the discharge side of the supply pump and disconnect tube (1) .
2) Connect test hose Y6 to the nipple on the discharge side of the supply pump. a Clamp the hose with a wire, etc. so that the hose is not disconnected. a Arrange the route of the test hose so that it does not sag, and put its end in a container.
GD535-5 (01)
3) Crank the engine for 30 seconds and measure the discharge by using measuring cylinder Y4. a Arrange the route of the test hose so that it does not sag, and put its end in a container. a To protect the starting motor, do not continue cranking for more than 30 seconds except for this test. a When the supply pump discharge is in the following standard range, it is normal. At cranking (125 rpm)
Min. 75 cc
At cranking (150 rpm)
Min. 90 cc
4) After finishing the test, remove the testing tools, and restore the machine. 3 Sleeve nut of tube: 35 ± 4 Nm {3.6 ± 0.4 kgm} 3 Clamp mounting bolt: 10 ± 2 Nm {1.0 ± 0.2 kgm}
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Testing fuel discharge, return rate, and leakage
2. Testing supply pump return rate 1) Disconnect return hose (3) of the supply pump.
30 Testing and adjusting
4) Start the engine, run it at low idle, and measure the fuel return rate of the supply pump for 25 seconds by using measuring cylinder Y4. a When the return rate from the supply pump is in the following standard range, it is normal. At low idle
2) Install connector Y3 and cap nut [1] of tester kit Y1 to the return hose to prevent the fuel from flowing out. 3) Connect test hose [2] of tester kit Y1 to the supply pump. a Arrange the route of the test hose so that it does not sag, and put its end in a container.
400 cc
5) After finishing the test, remove the testing tools, and restore the machine. 3. Testing leakage from pressure limiter 1) Disconnect return hose (4) from the pressure limiter. a Leave the seal washer fitted to the connector bolt.
2) Install the removed connector bolt and cap nut [1] of tester kit Y1 to the return hose side to prevent the fuel from flowing out. 3) Install connector Y3 to the common rail side and connect test hose [2] of tester kit Y1 to the connector. a Arrange the route of the test hose so that it does not sag, and put its end in a container.
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GD535-5 (01)
30 Testing and adjusting
Testing fuel discharge, return rate, and leakage
4. Testing fuel return rate from injector 1) Disconnect return hose (6) from the cylinder head. a Leave the seal washer fitted to the connector bolt side.
4) Start the engine, run it at low idle, and measure the fuel leakage rate for 1 minute by using measuring cylinder Y4. a When the leakage from the pressure limiter is in the following standard range, it is normal. At low idle
0 cc (No leakage)
2) Install connector Y3 to the cylinder head rail, connect test hose [2] of tester kit Y1 to the connector, and put its end in a container. 3) Install removed connector bolt (7) and cap nut [1] of tester kit Y1 to block the return hose so that fuel does not flow out. 4) Start the engine, run it at low idle, and measure the return rate from the injector for 1 minute by using measuring cylinder Y4. a When the return rate from the injector is in the following standard range, it is normal. At low idle
Max. 180 cc/min
At cranking
Max. 90 cc/min
5) After finishing the test, remove the testing tools, and restore the machine. 3 Joint bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}
k
GD535-5 (01)
If the engine cannot be started, you may perform the measurement while rotating the engine by using the starting motor. However, to protect the starting motor, do not rotate the engine for more than 20 seconds continuously.
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Testing fuel discharge, return rate, and leakage
30 Testing and adjusting
5) After finishing the test, remove the testing tools, and restore the machine. 3 Joint bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}
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GD535-5 (01)
30 Testing and adjusting
Checking and replacing alternator belt
Checking and replacing alternator belt
1
a Testing tools Symbol K
Part No.
Part name
Commercially Wrench available
k Park
the machine on flat ground, set the gear shift lever to the P position, and lower the work equipment to the ground. k Stop the engine and chock the wheels. k Disconnect the cable from the negative (-) terminal of the battery. a When replacing the alternator belt, remove the air conditioner compressor belt beforehand. a The auto-tensioner is provided for the alternator belt. Thus, checking and adjusting the belt is usually not necessary. Testing 1. Open cover (1a). 2. Remove cover (1b).
5. Check the alternator belt (3). a Replace the alternator belt (3) in the following cases. q The alternator belt has a vertical scratch (b) which crosses the horizontal scratch (a). q The alternator belt has tears (c). Need not to be replaced if it has only a horizontal scratch (d). a Possible causes of the damage on the belt Improper tension has been applied. Part whose size or length is wrong has been used. q Pulley is out of the position. q Pulley is damaged. q Auto-tensioner is damaged. q Installation state is improper. q Severe operating environment q Oil and grease are attached to the side of the belt. a If the belt is obviously worn, there is a possibility that the auto-tensioner is also worn and the surface of the pulley is rough. In that case, the newly replaced belt may be worn early if the pulley is continuously used. Therefore, replacement of the belt and autotensioner as a set is recommended.
3. Remove cover (2a). 4. Remove cover (2b).
GD535-5 (02)
30-47
Checkng and replacing alternator belt
30 Testing and adjusting
a
Replacing 1. Install the wrench (K) to the (g) part (width across flats: 12.7 mm) of the auto-tensioner (4). a Check that the wrench (K) is securely installed. If the wrench (K) is loosely installed and rotated, it can accidentally come off and this is extremely dangerous because the spring force of the auto-tensioner (4) is strong. 2. Turn the wrench (K) in the direction of the arrow, and loosen the tension of the alternator belt (3).
3.
4.
5.
6.
Be careful not to get your fingers caught between the pulley and alternator belt (3) during work.
7.
After installing the alternator belt (3), return the auto-tensioner (4) slowly and carefully.
8.
Check that the groove of the alternator belt (3) fits in the each pulley groove (5) without any displacement.
Remove the alternator belt (3). a Be careful not to get your fingers caught between the pulley and alternator belt (3) during work. After removing the alternator belt (3), return the auto-tensioner (4) slowly and carefully.
Install the wrench (K) to the (g) part (width across flats: 12.7 mm) of the auto-tensioner (4). a Check that the wrench (K) is securely installed. If the wrench (K) is loosely installed and rotated, it can accidentally come off and this is extremely dangerous because the spring force of the auto-tensioner (4) is strong. Turn the wrench (K) in the direction of the arrow, and install the alternator belt (3).
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GD535-5 (02)
30 Testing and adjusting
Checkng auto-tensioner and replacing alternator belt Checking and replacing
Checking and replacing auto-tensioner a Testing tools Symbol K
Part No.
1
5. Part name
Commercially Wrench available
6.
k Park
the machine on flat ground, set the gear shift lever to the P position, and lower the work equipment to the ground. k Stop the engine and chock the wheels. k Disconnect the cable from the negative (-) terminal of the battery. a When replacing the alternator belt, remove the air conditioner compressor belt beforehand. a The auto-tensioner is provided for the alternator belt. Thus, checking and adjusting the belt is usually not necessary.
Check that there is no crack on the arm (a), pulley (b), arm stop part (c), and spring case stop parts (d) and (e) of the auto-tensioner (4). a Replace the auto-tensioner (3) if there is any crack or damage. Check with the alternator belt installed that the arm stop part (c) of the auto-tensioner does not contact with the spring case stop parts (d) or (e). a Replace the alternator belt if the arm stop part (c) contacts with the spring case stop parts (d) or (e).
Testing 1. Open cover (1a). 2. Remove cover (1b).
3. 4.
Remove cover (2a). Remove cover (2b).
7.
GD535-5 (02)
Install the wrench (K) to the (g) part (width across flats: 12.7 mm) of the auto-tensioner (4). a Check that the wrench (K) is securely installed. If the wrench (K) is loosely installed and rotated, it can accidentally come off and this is extremely dangerous because the spring force of the auto-tensioner (4) is strong.
30-47-2
Checkng replacing alternator belt Checking and auto-tensioner and replacing
8.
Turn the wrench (K) in the direction of the arrow, and loosen the tension of the alternator belt (3).
9.
Remove the alternator belt (3). a Be careful not to get your fingers caught between the pulley and alternator belt (3) during work. After removing the alternator belt (3), return the auto-tensioner (4) slowly and carefully. Check that the arm stop part (c) of the auto-tensioner (4) does contact with the spring case stop part (e). a Replace the auto-tensioner (4) if it does not. Check that the arm (a) of the auto-tensioner (4) is not moved by hand. a Replace the auto-tensioner (4) if the arm (a) is moved by hand. Check that the arm stop part (c) contacts with the spring case stop part (d) by using the wrench (K). a If the arm stop part (c) does not contact with the spring case stop part (d), replace the auto-tensioner (4). a The auto-tensioner (4) is not needed to be replaced if there is no abnormality in steps 11, 12, and 13.
10. 11.
12.
13.
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30 Testing and adjusting
GD535-5 (02)
30 Testing and adjusting
Checkng and replacing alternator belt
Replacing 1. Remove the bolt (5), and remove the auto-tensioner (4).
2.
Set the dowel pin (6) of the new auto-tensioner (4) to be aligned with the groove (7) of the cylinder block.
3.
Install the bolt (5). 3 Bolt (5) :43 ± 6 Nm {4.4 ± 0.6 kgm}
GD535-5 (02)
30-47-4
Testing power train oil pressure
30 Testing and adjusting
Power train
1
Testing power train oil pressure
1
a Tools for testing power train oil pressure Sym bol 1 2 K 3 4
Part No.
Part name
799-101-5002 Hydraulic tester 790-261-1205 Digital hydraulic tester 799-401-2320 Gauge 799-101-5220 Nipple 07002-11023
O-ring
Commercially Block available
k Park
the machine on flat ground, place the work equipment on the ground surely, set the gear shift lever to P (PARK) position, and then stop the engine. k Chock the tires to prevent the machine from moving. a Check this testing under the following conditions. q Transmission oil temperature: 60 to 80°C q Torque converter oil temperature: 60 to 80°C a The following figure shows the measuring positions of each oil pressure on the transmission.
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GD535-5 (01)
30 Testing and adjusting
Testing power train oil pressure
a Oil pressure to be measured and measuring range of oil pressure gauge No .
Oil pressure to be measured
a Combination of gear speed and clutch used Operating clutch pack No.
Oil pressure gauge (MPa {kg/cm2})
F1
FL
1
Main relief pressure of power train
6.0 {60}
F2
2
Torque converter inlet pressure
2.5 {25}
F3
3
Torque converter outlet pressure
1.0 {10}
F4
4
Torque converter lockup clutch pressure
6.0 {60}
5
Transmission FL clutch pressure
6.0 {60}
6
Transmission FH clutch pressure
6.0 {60}
7
Transmission R clutch pressure
6.0 {60}
8
Transmission 1st clutch pressure
6.0 {60}
9
Transmission 2nd clutch pressure
6.0 {60}
10 Transmission 3rd clutch pressure
6.0 {60}
11 Transmission 4th clutch pressure
6.0 {60}
Gear speed
F5
F8
R
q
1st
2nd
3rd
4th
q q
q
q
q q
q
q
q q
F6 F7
FH
q
q
q q
q
N R1
q
R2
q
R3
q
R4
q
q q q q
Gear shift lever and transmission gear speed q To protect the transmission, for gear shifting among forward gears, the machine has a function to prevent transmission gear shift from skipping 2 gear speeds even when the gear shift lever is operated by skipping 2 gear speeds. For gear shifting among reverse gears, there is a function to prevent transmission gear shift from skipping one gear speed even when the gear shift lever is operated by skipping one gear speed. a) Example of gear shift lever operation: F1 - > F4 b) Operation of transmission: F1 -> F3 -> F4 q The transmission shifts directly to the target gear speed only when the gear shift lever is operated from N position to the target gear speed (F1 to F4). a) Example of gear shift lever operation: N - > F4 b) Operation of transmission: N -> F4
GD535-5 (01)
30-49
Testing power train oil pressure
Preparatory work (preparation for running wheel idle off ground) a Among measurement items of oil pressure, when measuring the lockup clutch pressure of the torque converter and each clutch pressure of the transmission, raise the rear wheels off the ground according to the following procedure to prepare for running the wheels idle off ground. a When operating the gear shift lever with wheels running idle off ground, restrict the engine speed to 1,300 rpm or below. When the gear shift lever is positioned in F5 to F8, R3, and R4 in "T/C AUTO" mode or R3 and R4 in "MANUAL" mode, the transmission shifts automatically. So, be sure not to increase the engine speed to 1,300 rpm and above when running wheel idle off ground. 1. Chock the right and left front wheels backward and forward to prevent the machine from moving. 2. Start the engine, and operate the right and left blade lift cylinder control levers to lower the blade horizontally to the ground.
30 Testing and adjusting
Testing method Testing main relief pressure of power train k Install or remove testing tools while the engine is stopped. 1. Remove cover (1) on the right side of the machine.
2. Connect gauge K2 to pickup nipple (2) for the power train main relief pressure. q For the position of the pickup plug, see "measuring positions of each oil pressure" above. a Use a 6-MPa {60-kg/cm2} gauge for gauge K2.
3. Operate the left blade lift cylinder control lever in LOWER direction to raise the left rear wheel off the ground, and install a block or stand under the left tandem case. 4. Operate the right blade lift cylinder control lever in LOWER direction to raise the right rear wheel off the ground, and install a block or stand under the right tandem case. 5. Raise the blade off the ground to check that the rear wheels are completely off the ground, and lower the blade to the ground again and stop the engine. k After raising the rear wheels off the ground, install safety poles to keep people away from the tires.
3. Start the engine and hold the gear shift lever at P position to increase the torque converter oil temperature to 60 to 80°C.
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GD535-5 (01)
30 Testing and adjusting
4. While holding the gear shift lever, measure the power train main relief pressure when the accelerator pedal is not depressed (at low idle) and when the engine is running at the rated speed (2000 rpm). a Use "RPM set switch" to set the engine rated speed. For "RPM set switch", see the Operation and Maintenance Manual. a For standard values, see the Standard value table, "Standard value table for machine".
Testing power train oil pressure
Testing torque converter inlet pressure k Install or remove testing tools while the engine is stopped. 1. Remove cover (1) on the right side of the machine.
5. After finishing the measurement, remove the testing tools, and restore the machine.
2. Connect gauge K2 to oil pressure pickup nipple (3) for the torque converter inlet pressure. a Use a 2.5-MPa {25-kg/cm2} gauge for gauge K2.
3. Start the engine and hold the gear shift lever at P position to increase the torque converter oil temperature to 60 to 80°C. 4. While holding the gear shift lever, measure the torque converter inlet pressure with the engine running at the rated speed (2,000 rpm). a Use "RPM set switch" to set the engine rated speed. For "RPM set switch", see the Operation and Maintenance Manual.
GD535-5 (01)
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Testing power train oil pressure
a For standard values, see the Standard value table, "Standard value table for machine". 5. After finishing the measurement, remove the testing tools, and restore the machine.
30 Testing and adjusting
Torque converter outlet pressure k Install or remove testing tools while the engine is stopped. 1. Remove cover (4) on the left side of the machine.
2. Remove pickup plug (5) for the torque converter outlet pressure. 3. Install nipple K3 and connect gauge K2 to it. a Use a 1-MPa {10 kg/cm2} gauge for gauge K2.
4. Start the engine and hold the gear shift lever at P position to increase the torque converter oil temperature to 60 to 80°C. 5. While holding the gear shift lever, measure the torque converter outlet pressure with the engine running at the rated speed (2,000 rpm). a Use "RPM set switch" to set the engine rated speed. For "RPM set switch", see the Operation and Maintenance Manual.
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GD535-5 (01)
30 Testing and adjusting
a For standard values, see the Standard value table, "Standard value table for machine". 6. After finishing the measurement, remove the testing tools, and restore the machine.
Testing power train oil pressure
Testing torque converter lockup clutch pressure (L/C) k Install or remove testing tools while the engine is stopped. 1. Remove covers (6) above the transmission valve.
2. Remove pickup plug (7) of the lockup clutch valve (ECMV). 3. Install nipple K3 and connect gauge K2 to it. a Use a 6-MPa {60 kg/cm2} gauge for gauge K2.
4. Start the engine and hold the gear shift lever at P position to increase the torque converter oil temperature to 60 to 80°C. 5. Set the transmission mode selector switch to MANUAL mode.
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Testing power train oil pressure
30 Testing and adjusting
Testing transmission FL clutch pressure k Install or remove testing tools while the engine is stopped. 1. Remove covers (8) above the transmission valve.
6. Operate the gear shift lever to run the rear wheels idle. k Before starting the engine, check that the rear wheels are completely off ground. k Check that the engine side cover is closed before running the rear wheels idle off ground. k If the brake pedal is depressed with the rear wheels running, the tandem may turn due to the reaction force of the brake. So, do not depress the brake pedal strongly. a Be sure to operate the gear shift lever while the engine is running at 1,300 rpm or below. a In MANUAL mode, because the drive mode changes to the torque converter drive mode just before the engine stops, do not depress the brake pedal. a The gear shift lever may be in any position other than N or R1 through R4.
2. Remove pickup plug (9) of FL clutch valve (ECMV). 3. Install nipple K3 and connect gauge K2 to it. a Use a 6-MPa {60 kg/cm2} gauge for gauge K2.
7. Run the rear wheels idle with the engine running at the rated speed (2,000 rpm), and measure the lockup clutch pressure. a Use "RPM set switch" to set the engine rated speed. For "RPM set switch", see the Operation and Maintenance Manual. a For standard values, see the Standard value table, "Standard value table for machine". 8. After finishing the measurement, remove the testing tools, and restore the machine.
4. Start the engine and hold the gear shift lever at P position to increase the torque converter oil temperature to 60 to 80°C. 5. Set the transmission mode selector switch to MANUAL mode.
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GD535-5 (01)
30 Testing and adjusting
Testing power train oil pressure
Testing transmission FH clutch pressure k Install or remove testing tools while the engine is stopped. 1. Remove covers (8) above the transmission valve.
6. Operate the gear shift lever to F1 position to run the rear wheels idle. k Before starting the engine, check that the rear wheels are completely raised off ground. k Check that the engine side cover is closed before running the rear wheels idle off ground. k If the brake pedal is depressed with the rear wheels running, the tandem may turn due to the reaction force of the brake. So, do not depress the brake pedal strongly. a Be sure to operate the gear shift lever while the engine is running at 1,300 rpm or below. a In MANUAL mode, because the drive mode changes to the torque converter drive mode just before the engine stops, do not depress the brake pedal.
2. Remove pickup plug (10) of FH clutch valve (ECMV). 3. Install nipple K3 and connect gauge K2 to it. a Use a 6-MPa {60 kg/cm2} gauge for gauge K2.
7. Run the rear wheels idle off ground with the engine running at the rated speed (2,000 rpm), and measure the FL clutch pressure. a Use "RPM set switch" to set the engine rated speed. For "RPM set switch", see the Operation and Maintenance Manual. a For standard values, see the Standard value table, "Standard value table for machine". 8. After finishing the measurement, remove the testing tools, and restore the machine.
4. Start the engine and hold the gear shift lever at P position to increase the torque converter oil temperature to 60 to 80°C. 5. Set the transmission mode selector switch to MANUAL mode.
GD535-5 (01)
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Testing power train oil pressure
30 Testing and adjusting
Testing transmission R clutch pressure (R) k Install or remove testing tools while the engine is stopped. 1. Remove covers (8) above the transmission valve.
6. Operate the gear shift lever to F2 position to run the rear wheels idle. k Before starting the engine, check that the rear wheels are completely off the ground. k Check that the engine side cover is closed before running the rear wheels idle off ground. k If the brake pedal is depressed with the rear wheels running, the tandem may turn due to the reaction force of the brake. So, do not depress the brake pedal strongly. a Be sure to operate the gear shift lever while the engine is running at 1,300 rpm or below. a In MANUAL mode, because the drive mode changes to the torque converter drive mode just before the engine stops, do not depress the brake pedal.
2. Remove pickup plug (11) of R clutch valve (ECMV). 3. Install nipple K3 and connect gauge K2 to it. q Use a 6-MPa {60 kg/cm2} gauge for gauge K2.
7. Run the rear wheels idle off ground with the engine running at the rated speed (2,000 rpm), and measure the FH clutch pressure. a Use "RPM set switch" to set the engine rated speed. For "RPM set switch", see the Operation and Maintenance Manual. a For standard values, see the Standard value table, "Standard value table for machine". 8. After finishing the measurement, remove the testing tools, and restore the machine.
4. Start the engine and hold the gear shift lever at P position to increase the torque converter oil temperature to 60 to 80°C. 5. Set the transmission mode selector switch to MANUAL mode.
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GD535-5 (01)
30 Testing and adjusting
Testing power train oil pressure
Testing transmission 1st clutch pressure k Install or remove testing tools while the engine is stopped. 1. Remove covers (8) above the transmission valve.
6. Operate the gear shift lever to R1 position to run the rear wheels idle. k Before starting the engine, check that the rear wheels are completely off the ground. k Check that the engine side cover is closed before running the rear wheels idle off ground. k If the brake pedal is depressed with the rear wheels running, the tandem may turn due to the reaction force of the brake. So, do not depress the brake pedal strongly. a Be sure to operate the gear shift lever while the engine is running at 1,300 rpm or below. a In MANUAL mode, because the drive mode changes to the torque converter drive mode just before the engine stops, do not depress the brake pedal.
2. Remove pickup plug (12) of the 1st clutch valve (ECMV). 3. Install nipple K3 and connect gauge K2 to it. q Use a 6-MPa {60 kg/cm2} gauge for gauge K2.
7. Run the rear wheels idle with the engine running at the rated speed (2,000 rpm), and measure the R clutch pressure. a Use "RPM set switch" to set the engine rated speed. For "RPM set switch", see the Operation and Maintenance Manual. a For standard values, see the Standard value table, "Standard value table for machine". 8. After finishing the measurement, remove the testing tools, and restore the machine.
4. Start the engine and hold the gear shift lever at P position to increase the torque converter oil temperature to 60 to 80°C. 5. Set the transmission mode selector switch to MANUAL mode.
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Testing power train oil pressure
30 Testing and adjusting
Testing transmission 2nd clutch pressure k Install or remove testing tools while the engine is stopped. 1. Remove covers (6) above the transmission valve.
6. Operate the gear shift lever to F1 position to run the rear wheels idle. k Before starting the engine, check that the rear wheels are completely raised off ground. k Check that the engine side cover is closed before running the rear wheels idle off ground. k If the brake pedal is depressed with the rear wheels running, the tandem may turn due to the reaction force of the brake. So, do not depress the brake pedal strongly. a Be sure to operate the gear shift lever while the engine is running at 1,300 rpm or below. a In MANUAL mode, because the drive mode changes to the torque converter drive mode just before the engine stops, do not depress the brake pedal.
2. Remove pickup plug (13) of 2nd clutch valve (ECMV). 3. Install nipple K3 and connect gauge K2 to it. q Use a 6-MPa {60 kg/cm2} gauge for gauge K2.
7. Run the rear wheels idle with the engine running at the rated speed (2,000 rpm), and measure the 1st clutch pressure. a Use "RPM set switch" to set the engine rated speed. For "RPM set switch", see the Operation and Maintenance Manual. a For standard values, see the Standard value table, "Standard value table for machine". 8. After finishing the measurement, remove the testing tools, and restore the machine.
4. Start the engine and hold the gear shift lever at P position to increase the torque converter oil temperature to 60 to 80°C. 5. Set the transmission mode selector switch to MANUAL mode.
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GD535-5 (01)
30 Testing and adjusting
Testing power train oil pressure
Testing transmission 3rd clutch pressure k Install or remove testing tools while the engine is stopped. 1. Remove covers (6) above the transmission valve.
6. Operate the gear shift lever to F3 position to run the rear wheels idle. k Before starting the engine, check that the rear wheels are completely off the ground. k Check that the engine side cover is closed before running the rear wheels idle off ground. k If the brake pedal is depressed with the rear wheels running, the tandem may turn due to the reaction force of the brake. So, do not depress the brake pedal strongly. a Be sure to operate the gear shift lever while the engine is running at 1,300 rpm or below. a In MANUAL mode, because the drive mode changes to the torque converter drive mode just before the engine stops, do not depress the brake pedal.
2. Remove pickup plug (14) of 3rd clutch valve (ECMV). 3. Install nipple K3 and connect gauge K2 to it. q Use a 6-MPa {60 kg/cm2} gauge for gauge K2.
7. Run the rear wheels idle with the engine running at the rated speed (2,000 rpm), and measure the 2nd clutch pressure. a Use "RPM set switch" to set the engine rated speed. For "RPM set switch", see the Operation and Maintenance Manual. a For standard values, see the Standard value table, "Standard value table for machine". 8. After finishing the measurement, remove the testing tools, and restore the machine.
4. Start the engine and hold the gear shift lever at P position to increase the torque converter oil temperature to 60 to 80°C. 5. Set the transmission mode selector switch to MANUAL mode.
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Testing power train oil pressure
30 Testing and adjusting
Testing transmission 4th clutch pressure k Install or remove testing tools while the engine is stopped. 1. Remove covers (6) above the transmission valve.
6. Operate the gear shift lever to F5 position to run the rear wheels idle. k Before starting the engine, check that the rear wheels are completely off the ground. k Check that the engine side cover is closed before running the rear wheels idle off ground. k If the brake pedal is depressed with the rear wheels running, the tandem may turn due to the reaction force of the brake. So, do not depress the brake pedal strongly. a Be sure to operate the gear shift lever while the engine is running at 1,300 rpm or below. a In MANUAL mode, because the drive mode changes to the torque converter drive mode just before the engine stops, do not depress the brake pedal.
2. Remove pickup plug (15) of 4th clutch valve (ECMV). 3. Install nipple K3 and connect gauge K2 to it. q Use a 6-MPa {60 kg/cm2} gauge for gauge K2.
7. Run the rear wheels idle with the engine running at the rated speed (2000 rpm), and measure the 3rd clutch pressure. a Use "RPM set switch" to set the engine rated speed. For "RPM set switch", see the Operation and Maintenance Manual. a For standard values, see the Standard value table, "Standard value table for machine". 8. After finishing the measurement, remove the testing tools, and restore the machine.
4. Start the engine and hold the gear shift lever at P position to increase the torque converter oil temperature to 60 to 80°C. 5. Set the transmission mode selector switch to MANUAL mode.
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GD535-5 (01)
30 Testing and adjusting
Testing power train oil pressure
6. Operate the gear shift lever to F7 position to run the rear wheels idle. k Before starting the engine, check that the rear wheels are completely off the ground. k Check that the engine side cover is closed before running the rear wheels idle off ground. k If the brake pedal is depressed with the rear wheels running, the tandem may turn due to the reaction force of the brake. So, do not depress the brake pedal strongly. a Be sure to operate the gear shift lever while the engine is running at 1,300 rpm or below. a In MANUAL mode, because the drive mode changes to the torque converter drive mode just before the engine stops, do not depress the brake pedal. 7. Run the rear wheels idle with the engine running at the rated speed (2000 rpm), and measure the 4th clutch pressure. a Use "RPM set switch" to set the engine rated speed. For "RPM set switch", see the Operation and Maintenance Manual. a For standard values, see the Standard value table, "Standard value table for machine". 8. After finishing the measurement, remove the testing tools, and restore the machine.
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Adjusting transmission speed sensor
Adjusting transmission speed sensor
30 Testing and adjusting
1
k Park
the machine on flat ground, place the work equipment on the ground surely, set the gear shift lever to P (PARK) position, and then stop the engine. k Chock the tires to prevent the machine from moving. a If a transmission speed sensor is removed and installed or the transmission is disassembled and assembled, adjust each of the speed sensors according to the following procedure. a The following figure shows the installed position of each speed sensor on the transmission.
1. Transmission input shaft speed sensor (connector: TM20) 2. Intermediate shaft speed sensor (connector: TM21)
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3. Transmission output (connector: TM22)
shaft
speed
sensor
GD535-5 (01)
30 Testing and adjusting
Adjustment method Adjusting transmission input shaft speed sensor 1. Remove transmission input shaft speed sensor (1) to check there is no adherence of iron particles or scratches on its tip. Then reinstall the sensor temporarily to its original position. 2 Sensor threaded part: Liquid gasket (LG-5) 2. Tighten it until the end of sensor (1) lightly touches tooth tip of gear (4). 3. Loosen sensor (1) from the current position by a half to 1 turn. a Clearance (a) of 0.75 to 1.5 mm is made between the sensor end and gear tooth tip. a Adjust the installation angle of sensor (1) so that the harness is in installation angle adjustment range (d). Installation angle adjustment range (d): 180 deg. a Adjust lead wire (10) so that it will not be stretched too tight. 4. With sensor (1) fixed, tighten nut (5). 3 Nut (5): 49.0 to 68.6 Nm {5 to 7 kgm}
GD535-5 (01)
Adjusting transmission speed sensor
Adjusting intermediate shaft speed sensor 1. Remove intermediate shaft speed sensor (2) to check there is no adherence of iron particles or the scratches on its tip. Then reinstall the sensor temporarily to its original position. 2 Sensor threaded part: Liquid gasket (LG-5) 2. Tighten it until the end of sensor (2) lightly touches tooth tip of gear (6). 3. Loosen sensor (2) from the current position by a half to 1 turn. a Clearance (b) of 0.75 to 1.5 mm is made between the sensor end and gear tooth tip. a Adjust the installation angle of sensor (2) so that the harness is in installation angle adjustment range (e). Installation angle adjustment range (e): 180 deg. a Adjust lead wire (10) so that it will not be stretched too tight. 4. With sensor (2) fixed, tighten nut (7). 3 Nut (7): 49.0 to 68.6 Nm {5 to 7 kgm}
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Adjusting transmission speed sensor
Adjusting transmission output shaft speed sensor 1. Remove transmission output shaft speed sensor (3) to check there is no adherence of iron particles or scratches on its tip. Then reinstall the sensor temporarily to its original position. 2 Sensor threaded part: Liquid gasket (LG-5) 2. Tighten it until the end of sensor (3) lightly touches tooth tip of gear (8). 3. Loosen sensor (3) from the current position by a half to 1 turn. a Clearance (c) of 0.75 to 1.5 mm is made between the sensor end and gear tooth tip. a Adjust the installation angle of sensor (3) so that the harness is in installation angle adjustment range (f). Installation angle adjustment range (f): 180 deg. a Adjust lead wire (10) so that it will not be stretched too tight. 4. With sensor (3) fixed, tighten nut (9). 3 Nut (9): 49.0 to 68.6 Nm {5 to 7 kgm}
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30 Testing and adjusting
Checking sensor input signal Check that the signal from each speed sensor is inputted normally by using the "Monitoring" function of the machine monitor. a For the operating method, see "Special functions of machine monitor". q Monitoring code: 31200 "T/M input shaft speed" q Monitoring code: 31300 "T/M intermediate shaft speed" q Monitoring code: 31400 "T/M output shaft speed" k You cannot check the speed of other shafts than the input shaft unless actually driving the machine or running wheels idle off ground. a For the method for running wheel idle off ground, see "Testing power train oil pressure".
GD535-5 (01)
30 Testing and adjusting
Retrieval of disabled machine due to transmission valve failure
Retrieval of disabled machine due to transmission valve failure
1
a Testing tools Sym bol L
Part No.
Part name
1
794-423-1190 Plug
2
07002-22034
O-ring
k Park
the machine on flat ground, place the work equipment on the ground surely, set the gear shift lever to P (PARK) position, and then stop the engine. k Chock the tires to prevent the machine from moving. k Use this clutch engaging method only when the machine is disabled due to a failure of transmission valve (ECMV). Be sure to restore the machine immediately after the machine is moved. a If the machine does not move because of failure of the clutch valve (ECMV) of the transmission, move the machine by engaging the transmission clutch according to the following procedure. a The following figure shows the installed positions of the clutch valves (ECMV) on the transmission.
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Retrieval of disabled machine due to transmission valve failure
Retrieving method 1. Remove covers (6) and (8) above the transmission valve, and clean the periphery of the clutch valve. a Remove mud and dirt completely so that foreign materials do not enter the clutch valve during operation.
30 Testing and adjusting
a Travel direction and clutch to be engaged Directional clutch
Gear speed clutch
Gear speed
When traveling forward
FL
2nd
F3
When traveling reverse
R
2nd
R2
a Because the lockup clutch of the torque converter is not engaged, the torque converter is in the torque converter drive mode regardless of the selection of the transmission mode selector switch.
2. Disconnect 8 connectors on the solenoid side of the torque converter and transmission clutch valve. k All the connectors need to be disconnected so that the clutch does not engage unexpectedly during traveling. a Solenoid connector No. q TM4: FL clutch q TM2: FH clutch q TM13: R clutch q TM11: 1st clutch q TM6: 2nd clutch q TM8: 3rd clutch q TM15: 4th clutch q TM16: Lockup clutch 3. Remove 2 solenoids (1) of the clutch valve to be engaged. a Remove the solenoid by turning the solenoid main body at the hexagonal part (width across flats: 33 mm).
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4. Install plug L1 to the mounting bore of the solenoid. a Clean the plug and check that the O-ring is fitted so that no foreign material enters before installation. a Tighten the plug until the stepped portion of the plug touches the valve body even though it may become slightly heavy because the plug pushes the internal spool spring. 3 Plug L1: 49.0 ± 5.0 Nm {5.0 ± 0.5 kgm}
5. Remove the chocks and start the engine. k When the engine is started, the transmission is left engaged at F3 or R2. If the gear shift lever is moved from P position unnecessarily, the parking brake is released and the machine moves off.
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30 Testing and adjusting
Retrieval of disabled machine due to transmission valve failure
6. Operate the gear shift lever to N position while depressing the brake pedal, and release the brake pedal gradually to move the machine to a safe place. a If you cannot release the parking brake, see "Parking brake manual releasing procedure". k After moving the machine, return the gear shift lever to P position, stop the engine, and chock the tires. 7. After the operation is finished, restore the clutch valve immediately.
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Flushing procedure for torque converter and transmission circuits
Flushing procedure for torque converter and transmission circuits 1
30 Testing and adjusting
2. Replacing transmission oil filter 1) Open cover (4) on the left side of the machine.
k Park
the machine on flat ground, place the work equipment on the ground surely, set the gear shift lever to P (PARK) position, and then stop the engine. k Chock the tires to prevent the machine from moving. a Dust such as metal powder, etc. in the hydraulic circuits of the torque converter and transmission shortens the life of the torque converter and transmission and causes internal breakage. To remove dust in the hydraulic circuit, perform flushing according to the following procedure. a Perform flushing in the following cases. q When metal powder flows into the circuit because of damage to the torque converter, transmission and hydraulic components. q When the torque converter and transmission are overhauled or modified. Flushing procedures 1. Draining oil from transmission case Drain the oil from the transmission case if any oil is remaining. 1) Loosen drain plug (1) and then loosen drain plug (2) to drain the oil. 6 Transmission case: 45 l (refill capacity) a After draining is complete, tighten the drain plug. 3 Drain plug (1): 58.8 to 78.4 Nm {6.0 to 8.0 kgm} 3 Drain plug (2): 49.0 to 78.4 Nm {5.0 to 8.0 kgm} 2) Loosen drain plug (3) to drain the remaining oil. a After draining is complete, tighten the drain plug. 3 Drain plug (3): 9.8 to 12.7 Nm {1.0 to 1.3 kgm}
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2) Loosen center bolt (5), and remove filter case (6). 3) Install a new filter case (6) again for flushing. a Filter case (6) is integrated with an element.
3. Refilling transmission case with oil 1) Refill the transmission case with new oil to the specified level from oil filler port (7). 6 Transmission case: 45 l 2) Start the engine to circulate the oil through the system. Then, check the oil level again.
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30 Testing and adjusting
4. Flushing 1) Start the engine, and run it for approximately 20 minutes for warm-up without depressing the accelerator pedal (at low idle). a Increase the engine speed to approximately 1,500 rpm occasionally. a If the engine coolant temperature gauge does not rise to the operating range (green range) because of low ambient temperature, continue the operation further. 2) Drive the machine or run the drive wheels idle off ground for approximately 20 minutes. a For the method for running the wheels idle off ground, see "Testing power train oil pressure". a Use all the gear speeds of F1 through F8 and R1 through R4. 3) Repeat the same operation as step 1 for approximately 20 minutes.
Flushing procedure for torque converter and transmission circuits
7. Checking oil level of transmission case Start the engine to circulate the oil through the system. Then, check the oil level again.
5. Replacing transmission oil filter Replace the filter case of the transmission oil filter with a new one in the same procedure as step 2. a The filter case is integrated with an element. 6. Replacing transmission last chance filter 1) Turn and remove filter case (8), and remove element (9).
2) Replace element (9) with a new one, and install filter case (8). a Clean the filter case if there is any dust or the like inside. a Apply a small amount of grease on the outside perimeter of the O-ring. 3 Filter case (8): 34.3 to 44.1 Nm {3.5 to 4.5 kgm}
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Testing and adjusting toe-in
Testing and adjusting toe-in
30 Testing and adjusting
1
If the front axle is disassembled and assembled, or straight-travel stability is low, test and adjust toe-in according to the following procedure.
6. Stop the machine when the mark is positioned at a height equal to that between road surface and the center of the axle. Be sure to perform this operation while moving the machine forward.
Testing Adjust toe-in so that a sideslip tester reads 0. If the sideslip tester is unavailable, adjust it according to the following procedure. 1. Park the machine on a flat road surface with the steering and leaning controls set at their center positions. When parking the machine, be sure to move it forward several meters and then stop it. 2. Measure height (h) from the road surface to the center of the front axle. 7. Measure the distance between the two marks put on both tires. Let this dimension be (B). When the value of (B) - (A) is -5 ± 1 mm, the toein meets the standard. The sideslip tester reads 0 in this case. If the value is out of this range, perform the following adjustment
3. Put a mark on the tire at the nearly center of the tire width and at a height equal to the dimension obtained in step 2. Put the mark on both tires in a similar manner. 4. Measure the distance between the two marks put on both tires. Let this dimension be (A).
5. Move the machine forward slowly so that the mark put on the tire is positioned at the back.
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30 Testing and adjusting
Testing and adjusting toe-in
Adjusting a When adjusting it, keep the front axle horizontal and set leaning angle to 0. 1. Loosen clamp nuts (1), apply a wrench to square part (2) of the tie rod, and then turn tie rods on both sides to adjust toe-in. Turning th em in the dir ection of the arr ow increases toe-in and turning in the opposite direction reduces toe-in. For the extension amount, turning both tie rods 1/3 turn in the extension direction extends them by 6 mm. 2. After the adjustment, tighten clamp nuts (1).
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Testing and adjusting differential lock oil pressure (differential lock specification)
Testing and adjusting differential lock oil pressure (differential lock specification)
30 Testing and adjusting
1
a Tools for testing and adjusting differential lock oil pressure Sym bol 1 2 M
3 4
Part No.
Part name
799-101-5002 Hydraulic tester 790-261-1205 Digital hydraulic tester 799-401-2320 Gauge 790-301-1271 Joint 07002-11023
O-ring
4) Start the engine and set the differential lock switch to ON position.
799-401-3200 Adapter
5 791T-601-2220 Elbow k Park
the machine on flat ground, place the work equipment on the ground surely, set the gear shift lever to P (PARK) position, and then stop the engine. k Chock the tires to prevent the machine from moving. a Perform testing and adjusting of differential lock oil pressure under the following conditions. q Final drive case oil temperature: 60 to 80°C Testing 1. Testing differential lock pump discharge pressure 1) Disconnect differential lock valve hose (1) on the inlet side.
a When the differential lock is activated, the differential lock pilot lamp lights up. 5) Measure the differential lock pump discharge pressure with the engine running at high idle. a For standard values, see the Standard value table, "Standard value table for machine". 6) After finishing the test, remove the testing tools, and restore the machine. 2. Testing differential lock valve outlet pressure 1) Remove oil pressure pickup plug (2) on the outlet side of the differential lock valve.
2) Install adapter M4 and connect disconnected hose (1) again. 3) Install nipple [1] of hydraulic tester M1 and connect gauge M2 to it. a Use a 6-MPa {60-kg/cm2} gauge.
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30 Testing and adjusting
Testing and adjusting differential lock oil pressure (differential lock specification)
2) Install joint M3, elbow M5, and nipple [1] of hydraulic tester M1, and connect gauge M2 to it. a Use a 6-MPa {60 kg/cm2} gauge.
Adjusting Adjusting differential lock oil pressure a If both the differential lock pump discharge pressure and valve outlet pressure are not normal, adjust differential lock relief valve (3) according to the following procedure.
1. Loosen lock nut (5) with adjustment screw (4) fixed.
3) Start the engine and set the differential lock switch to ON position.
2. Turn adjustment screw (4) to adjust the oil pressure. a Rotate the adjustment screw: q clockwise to increase the pressure. q counterclockwise to decrease the pressure. a Quantity of pressure adjustment per turn of adjustment screw (4): 3.7 MPa {37.8 kg/ cm2} 3. Tighten lock nut (5) with adjustment screw (4) fixed. 3 Lock nut (5): 10 to 15 Nm {1.0 to 1.5 kgm}
a When the differential lock is activated, the differential lock pilot lamp lights up. 4) Measure the differential lock valve outlet pressure with the engine running at high idle. a For standard values, see the Standard value table, "Standard value table for machine". 5) After finishing the test, remove the testing tools, and restore the machine.
GD535-5 (01)
4. After the adjustment, check that the pump discharge pressure and valve outlet pressure are normal referring to "Testing".
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Testing and adjusting steering oil pressure
30 Testing and adjusting
Steering system
1
Testing and adjusting steering oil pressure
1
a Tools for testing and adjusting steering oil pressure Sym bol 1 N 2
Part No.
Part name
799-101-5002 Hydraulic tester
2. Install nipple [1] of hydraulic tester N1 and connect gauge [2] to it. a Use a 40-MPa {400-kg/cm2} gauge. 3. Start the engine and operate the steering cylinder to the stroke end. 4. While running the engine at high idle, relieve the steering cylinder and measure the oil pressure. a For standard values, see the Standard value table, "Standard value table for machine".
790-261-1205 Digital hydraulic tester 790-301-1271 Joint 07002-11023
O-ring
k Park
the machine on flat ground, place the work equipment on the ground surely, set the gear shift lever to P (PARK) position, and then stop the engine. k Chock the tires to prevent the machine from moving. a Perform the testing and adjusting of the steering oil pressure under the following conditions. q Hydraulic oil temperature: 45 to 55°C Testing 1. Remove steering oil pressure pickup plugs (1) or (2), and install joint N2.
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5. After finishing the test, remove the testing tools, and restore the machine. Adjusting a You cannot adjust the steering oil pressure (the relief valve of the priority valve).
GD535-5 (01)
30 Testing and adjusting
Testing oil leakage of steering cylinder
Testing oil leakage of steering cylinder
1
5. After finishing the measurement, restore the machine.
a Tools for testing oil leakage of steering cylinder Sym bol P
Part No.
Part name
Commercially Measuring cylinder available
k Park
the machine on flat ground, place the work equipment on the ground surely, set the gear shift lever to P (PARK) position, and then stop the engine. k Chock the tires to prevent the machine from moving. a Perform the testing and adjusting of the steering oil pressure under the following conditions. q Hydraulic oil temperature: 45 to 55°C 1. Start the engine, and extend the cylinder to measure to the stroke end. 2. Disconnect hose (1) on the cylinder head side and block the hose by using a plug. k Be careful not to disconnect the hose on the cylinder bottom side. a Use the following parts to block the hose. 07376-70422 (Plug #04)
3. Start the engine, run it at high idle, and relieve the steering cylinder. k Operate the cylinder to measure to extension side to relieve it hydraulically. Be careful not to operate it to the opposite direction. 4. Measure the amount of oil leakage by using measuring cylinder P for a minute after a lapse of 30 seconds from starting relief. a For standard values, see the Standard value table, "Standard value table for machine".
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Bleeding air from steering circuit
Bleeding air from steering circuit
30 Testing and adjusting
1
a If the steering cylinder has been removed and installed or its cylinder piping has been disconnected and connected, bleed air according to the following procedure. a While bleeding air, make sure that the oil level in the hydraulic tank does not decrease below the specified level. 1. While running the engine at low idle, extend and retract the cylinder 4 to 5 times. k Stop the piston rod at approximately 50 mm before stroke end to avoid relieving. 2. While running the engine at low idle, move the piston rod to the stroke end to relieve the circuit.
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30 Testing and adjusting
Brake system
Releasing remaining pressure from brake circuit
1
Releasing remaining pressure from 1 brake circuit k Park
the machine on flat ground, place the work equipment on the ground surely, set the gear shift lever to P (PARK) position, and then stop the engine. k Chock the tires to prevent the machine from moving. k High pressure in the accumulator is normally applied to the circuit from the charge valve, through accumulator to brake valve as well as parking brake valve of the brake circuit. Before disconnecting or connecting piping, or removing or installing tools, release the remaining pressure according to the following procedures. k The pressurized oil in the accumulator is applied to the circuit between the brake valve and wheel brake only when the brake pedal is depressed. k The pressurized oil in the accumulator is applied to the circuit between the parking brake valve and parking brake only when the gear shift lever is operated to a position other than P with the starting switch set to ON position. 1. Depress and release the brake pedal repeatedly until no brake operation sound is heard. 2. When there is no brake operation sound, depress and release the brake pedal repeatedly for several tens of times. a Bleeding of remaining pressure is complete. To check if there is no remaining pressure, disconnect pipings slowly.
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Testing and adjusting brake oil pressure
Testing and adjusting brake oil pressure
30 Testing and adjusting
1
3) Remove oil pressure pickup plug (2) of the charge valve.
a Tools for testing and adjusting brake oil pressure Sym bol 1 2 Q 3 4
Part No.
Part name
799-101-5002 Hydraulic tester 790-261-1205 Digital hydraulic tester 793-520-1805 Brake test kit 799-401-3100 Adapter 790-301-1271 Joint 07002-11023
O-ring
5 791T-601-2220 Elbow k Park
the machine on flat ground, place the work equipment on the ground surely, set the gear shift lever to P (PARK) position, and then stop the engine. k Chock the tires to prevent the machine from moving. a Perform the testing and adjusting of the brake oil pressure under the following conditions. q Hydraulic oil temperature: 45 to 55°C
4) Install joint Q4 and elbow Q5, and then connect gauge [2] of hydraulic tester Q1 to it. a Use a 40-MPa {400-kg/cm2} gauge.
Testing 1. Measuring charge valve cut-in pressure and cut-out pressure 1) Release the remaining pressure in the wheel brake circuit. For details, see "Releasing remaining pressure from wheel brake circuit". k Do not perform measurement preparation without releasing the remaining pressure because high pressure is accumulated in the accumulator. 2) Open the cover on the right side of the machine and remove cover (1).
5) Start the engine and run it at low idle to accumulate pressure in the accumulator. a Run the engine at low idle for further 1 to 2 minutes because the pressure is below the cut-in pressure when the brake oil pressure caution lamp of the machine monitor goes out. 6) Measure the cut-in pressure with the engine running at high idle. 1] Repeat depressing and releasing of the brake pedal to gradually decrease the oil pressure in the accumulator.
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GD535-5 (01)
30 Testing and adjusting
2] Measure the oil pressure at the time that the pointer of gauge [2] turns from descent to ascent. a For standard values, see the Standard value table, "Standard value table for machine". 7) Measure the cut-out pressure with the engine running at high idle. 1] Stop the brake pedal operation when the oil pressure starts rising from the cut-in pressure. 2] Measure the oil pressure at the time that the pointer of gauge [2] stops rising. a For standard values, see the Standard value table, "Standard value table for machine". 8) After finishing the test, remove the testing tools, and restore the machine. 2. Testing wheel brake operating pressure and amount of pressure drop k Do not operate the brake pedal when installing or removing the testing tools because high pressure is accumulated in the accumulator. a Test the front, rear, right, and left brakes according to the same procedure. 1) Release the remaining pressure in the wheel brake circuit. For details, see "Releasing remaining pressure from wheel brake circuit". 2) Remove the brake piping cover of the tandem case, and remove air bleeder (1).
Testing and adjusting brake oil pressure
5) Measure the operating pressure of the wheel brake. 1] Run the engine at low idle for several minutes to accumulate pressure in the accumulator, and stop the engine. 2] Measure the operating pressure when the brake pedal is depressed to the stroke end. a For standard values, see the Standard value table, "Standard value table for machine". 6) Measure the drop in the wheel brake operating pressure. a Check that the operating pressure of the wheel brake is normal before measurement. 1] Run the engine at low idle for several minutes to accumulate pressure in the accumulator, and stop the engine. 2] Depress the brake pedal to the stroke end and wait for 1 minute. Then, measure the pressure drop in 5 minutes. a Keep on depressing the brake pedal for 5 minutes. a For standard values, see the Standard value table, "Standard value table for machine". 7) After finishing the test, remove the testing tools, and restore the machine. k After removing the testing tools, make sure to bleed air from the wheel brake circuit.
3) Install brake test kit Q2. 4) Bleed air from the wheel brake circuit. For details, see "Bleeding air from brake circuit". a Use the air bleeder of brake test kit Q2 for bleeding air.
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Testing and adjusting brake oil pressure
3. Testing parking brake operating pressure k Do not operate the gear shift lever to a position other than P position when installing or removing the testing tools because high pressure is accumulated in the accumulator. 1) Release the remaining pressure in the wheel brake circuit. For details, see "Releasing remaining pressure from wheel brake circuit". 2) Disconnect hose (1) of the parking brake calipers.
3) Install adapter Q3 and connect the disconnected hose again. 4) Install nipple [1] of hydraulic tester Q1 and connect gauge [2] to it. a Use a 40-MPa {400-kg/cm2} gauge.
30 Testing and adjusting
k
After removing the testing tools, make sure to bleed air from the parking brake circuit.
Adjusting Adjusting charge valve cut-out pressure a If the cut-out pressure of the charge valve is not normal, adjust relief valve (R2) of the charge valve according to the following procedure. a The cut-out pressure varies according to adjustment of relief valve (R2).
1. Loosen lock nut (1) with adjustment screw (2) fixed. 2. Turn adjustment screw (2) to adjust oil pressure. a Rotate the adjustment screw: q clockwise to increase the pressure. q counterclockwise to decrease the pressure. a Quantity of pressure adjustment per turn of adjustment screw: 2.49 MPa {25.4 kg/cm2} 3. Tighten lock nut (1) with adjustment screw (2) fixed. 3 Lock nut: 11.8 to 16.7 Nm {1.2 to 1.7 kgm} 4. After the adjustment, be sure to test the charge valve cut-in pressure and cut-out pressure again. For details, see "Testing".
5) Run the engine at low idle for several minutes to accumulate pressure in the accumulator. 6) While running the engine at low idle, depress the brake pedal to the stroke end and hold it there surely. 7) Move the gear shift lever to N position and measure the oil pressure at that moment. a For standard values, see the Standard value table, "Standard value table for machine". 8) After finishing the test, remove the testing tools, and restore the machine.
30-80
GD535-5 (01)
30 Testing and adjusting
Bleeding air from brake circuit
Bleeding air from brake circuit
1
k Park
the machine on flat ground, place the work equipment on the ground surely, set the gear shift lever to P (PARK) position, and then stop the engine. k Chock the tires to prevent the machine from moving. a When brake circuit equipment is removed or installed, bleed air from the brake circuit according to the following procedure. 1. Bleeding air from wheel brake part of wheel brake circuit a Bleed air from the front, rear, right, and left brakes according to the same procedure. 1) Remove the brake piping cover of the tandem case, and install air bleeding hose [1] to air bleeder (1).
2. Bleeding air from parking brake circuit 1) Connect air bleeding hose [1] to air bleeder (2) of the parking brake calipers.
2) Start the engine, and run it at low idle. 3) Set the gear shift lever to N position, and hold it there. 4) Loosen air bleeder (2) by approximately 1/2 turn to drain oil mixed with air. 5) When oil without air starts to flow out, tighten air bleeder (2). 3 Air bleeder: 22.6 to 28.3 Nm {2.3 to 2.9 kgm} (Target: 25.5 Nm {2.6 kgm}) 6) After bleeding air, restore the machine.
2) Start the engine, and run it at low idle. 3) Depress the brake pedal to the stroke end, and keep it. 4) Loosen air bleeder (1) by approximately 1/2 turn to drain oil mixed with air. 5) When oil without air starts to flow out, tighten air bleeder (1). 6) After bleeding air, restore the machine.
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30-81
Testing wear of wheel brake disc
30 Testing and adjusting
Testing wear of wheel brake disc
1
a Tools for testing wear of wheel brake disc Sym bol R
Part No.
Part name
Commercially Vernier calipers available
k Park
the machine on a flat ground, place the work equipment on the ground surely, set the gear shift lever to P (PARK) position, and then stop the engine. k Chock the tires to prevent the machine from moving. a Each wheel brake has a testing gauge. Be sure to perform the check at the 4 places in a similar manner.
Restore the machine after finishing the test. 3 Cap (1): 29.4 to 39.2 Nm {3 to 4 kgm}
1. Remove cap (1). a Do not loosen nut (3) on the tandem case side because it is for fixing the wear gauge.
2. Start the engine. 3. Run the engine for several minutes without depressing the accelerator pedal (at low idle) to accumulate pressure in the accumulator, and stop the engine. 4. Depress the brake pedal to the stroke end, and keep it for a while. 5. Push in shaft (2) of the wear gauge to the tandem case, and measure protrusion (a). a If protrusion (a) comes to 0 mm, the brake disc has reached its wear limit. Replace it with a new one in this case. For standard values, see Standard value table, "Standard value table for machine".
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GD535-5 (01)
30 Testing and adjusting
Testing and adjusting parking brake pad
Testing and adjusting parking brake pad
1
a Tools for testing and adjusting parking brake pad Sym bol
S
Part No.
Part name
1
792-454-1100 Pump assembly
2
792-454-1120 Valve
3
792-454-1110 Pump
4
790-425-1240 Nipple
5
416-62-11480 O-ring
6
790-612-5110 Adapter
7
790-190-2310 Hose
8
Commercially Hose available
9
Commercially Oil container available
k Park
the machine on flat ground, place the work equipment on the ground surely, set the gear shift lever to P (PARK) position, and then stop the engine. k Chock the tires to prevent the machine from moving. k Take extra care to prevent adhesion of oil and grease to the surface of brake pads and discs. Testing wear of parking brake pad
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30-83
Testing and adjusting parking brake pad
30 Testing and adjusting
Measuring pad thickness Measure thicknesses (a) and (b) of pad (1) with the engine stopped. For standard values, see "Standard value table for machine" of Standard value table. Measuring pad clearance 1. Start the engine. 2. Run the engine for several minutes without depressing the accelerator pedal (at low idle) to accumulate pressure in the accumulator. 3. Depress the brake pedal to the stroke end, and keep it there. 4. Move the gear shift lever to N position and hold it there, and then measure clearances (c) and (d) between pad (1) and disc (2). For standard values, see Standard value table, "Standard value table for machine". Adjusting parking brake pad clearance When the parking brake does not work properly or the pad is replaced with a new one, the clearance must be adjusted.
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GD535-5 (01)
30 Testing and adjusting
1. Disconnect hose (13) from the parking brake calipers. 2. Remove nipple (14) from the parking brake calipers.
3. Install nipple S4 to the parking brake calipers, and connect adapter S6 and hose S7 to it. a When installing nipple S4, be sure to install Oring S5. 4. Connect hose S7 to valve S2 in pump assembly S1. 5. Connect hose S8 to air bleeder (12) and put the other end of hose S8 into oil container S9.
Testing and adjusting parking brake pad
12. Tighten bolt (8) until it touches urethane spring (10), and then tighten it further by 1/2 turn. 13. Tighten lock nut (7) to mount bracket side. 3 Lock nut (7): 242 to 302 Nm {24.7 to 30.8 kgm} 14. Loosen adjustment bolt (9) and adjust the clearances between front and rear pads (1) and disc (2). a The adjusted clearance value is 1.5 to 1.8 mm for the total of clearances (c) and (d). 15. With the tip of bolt (6) touching bracket (11), adjust clearances (c) and (d) between front and rear pads (1) and disc (2) to make the clearances equal by using double nut (5), and secure double nut (5). 3 Double nut (5): 24.1 to 30.1 Nm {2.46 to 3.07 kgm} 16. Secure adjustment bolt (9) with lock nut (4). 3 Lock nut (4): 102.8 to 128.2 Nm {10.5 to 13.1 kgm} 17. Measure clearances (c) and (d) between front and rear pads (1) and disc (2). 18. Operate pump S3 to release the pressure. 19. Check that the clearances (c) and (d) between front and rear pads (1) and disc (2) come to 0. 20. Install cover plug (3). 3 Cover plug (3): 59.0 to 128.2 Nm {10.5 to 13.1 kgm} After finishing the adjustment, remove the tools used, and restore the machine. k After connecting hose (13) to the parking brake calipers, be sure to bleed air from the parking brake circuit. For details, see "Bleeding air from brake circuit".
6. Operate pump S3 to raise the pressure up to 8.2 MPa. 7. Loosen air bleeder (12) by approximately 1/2 turn to drain oil mixed with air. 8. When oil without air starts to flow out, tighten air bleeder (12). 3 Air bleeder (12): 22.6 to 28.3 Nm {2.3 to 2.9 kgm} 9. Remove cover plug (3) and loosen lock nut (4). 10. Release the fixed brake calipers once according to the following procedure. 1) Loosen double nut (5), and loosen bolt (6) by approximately 5 turns. 2) Loosen lock nut (7), and loosen bolt (8) by approximately 3 turns. a Move lock nuts (5) and (7) to bracket (11) side. 11. Tighten adjustment bolt (9) until front and rear pads (1) touch disc (2).
GD535-5 (01)
30-85
Releasing parking brake manually
Releasing parking brake manually
30 Testing and adjusting
1
k If
a failure occurs in the hydraulic system, the wheel brake probably does not work normally. So, after releasing the parking brake manually, tow and move the machine at a low speed. k Park the machine on flat ground and confirm the safety of its surrounding area before starting manual releasing operations of the parking brake. When it is forced to release the parking brake on a slope, chock the tires positively. k Park the machine on flat ground, place the work equipment on the ground surely, set the gear shift lever to P (PARK) position, and then stop the engine. When the parking brake cannot be released due to a failure in its electrical or hydraulic system, refer to the procedure shown in this section so that you can release the brake manually and move the machine. Parking brake manual releasing procedure 1. Remove cover plug (2) from parking brake calipers (1).
4. Tow the machine at a low speed to a safe place. k After moving the machine, be sure to chock the tires. Restore the machine after finishing the work. 3 Lock nut (3): 102.8 to 128.2 Nm {10.5 to 13.1 kgm} 3 Cover plug (2): 59.0 to 73.5 Nm {6.0 to 7.5 kgm}
2. Loosen lock nut (3), and turn adjustment bolt (4) counterclockwise.
3. Check that there are clearances (c) and (d) between front and rear pads (5) and disc (6) . a For standard values, see the Standard value table, "Standard value table for machine".
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GD535-5 (01)
30 Testing and adjusting
Charging brake accumulator with gas
Charging brake accumulator with gas
1
3. Installing charging tool T 1) Remove plug (1) of the accumulator and remove the cap of valve (2).
a Tools for charging brake accumulator with gas Sym bol
Part No.
T
792-610-1702
Part name Charging tool
a When the gas in the brake accumulator is released or gas pressure drops, charge the accumulator with nitrogen gas according to the following procedure. 1. Releasing remaining pressure from brake circuit 1) Release the remaining pressure in the brake circuit. For details, see "Releasing remaining pressure from brake circuit". a This operation is not required when charging an independent accumulator with gas.
2) Screw in charging tool T into valve (2) of the accumulator. 3) Connect hose [3] to charging tool T and nitrogen gas cylinder (3).
2. Preparing charging tool T 1) Turn handle [1] counterclockwise until it stops. 2) Turn handle [2] counterclockwise until it stops. 3) Check that the connection parts of charging tool T are tightened completely.
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Charging brake accumulator with gas
30 Testing and adjusting
4. Charging with nitrogen gas 1) Slightly open the valve of the nitrogen gas cylinder to discharge nitrogen gas at extremely low pressure, and gas starts to come out of handle [2]. Turn handle [2] clockwise to stop discharge of the gas. a Operate the valve of the nitrogen gas cylinder gradually and slowly. a Discharge start pressure: Approximately 0.2 to 0.3 MPa {2 to 3 kg/cm2} 2) Turn handle [1] clockwise slowly so that it presses valve (2) of the accumulator. 3) Open the valve of the nitrogen gas cylinder gradually to charge the accumulator with nitrogen gas. a Close the valve of the nitrogen gas cylinder occasionally, and check the indicated value when the pointer of pressure gauge [4] of the charging tool is stabilized. 4) After charging the accumulator with nitrogen gas at the specified pressure, make sure to close the valve of the nitrogen gas cylinder. q Charge pressure: 3.4 ± 0.1 MPa {35 ±1 kg/cm2} (at 20 ± 5°C) q Charge amount: 3.75 l (for reference) a The relation between the charge pressure of nitrogen gas and gas temperature (≈ ambient temperature) is as follows. Px = 35 x (273 + t) / (273 + 20) (Px: Charge pressure [kg/cm2], t: Gas temperature [°C]) a If the accumulator is charged with nitrogen gas at a higher pressure, turn handle [2] counterclockwise gradually to release gas. 5) Turn handle [1] counterclockwise fully to close valve (2), and turn handle [2] counterclockwise to release the nitrogen gas in charging tool T. 5. Removing charging tool T 1) Remove charging tool T from the accumulator and nitrogen gas cylinder. 2) Apply water or soap water on valve (2) to check for gas leakage, and install the cap and cover (1) of valve (2). 6. Checking after gas charge q For approximately 1 week after gas charge, check if the charge pressure is maintained by using charging tool T. q After that, check the pressure once per month or once per 6 months depending on the operating conditions. q Charged gas decreases slightly and the pressure drops during a pressure check. Supply gas accordingly.
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GD535-5 (01)
30 Testing and adjusting
Testing work equipment oil pressure
Hydraulic system
1
Testing work equipment oil pressure
1
3. Install joint U3, and then install elbow U2.
a Tools for testing work equipment oil pressure Sym bol 1 U 2 3
Part No.
Part name
799-101-5002 Hydraulic tester 790-261-1205 Digital hydraulic tester 790-301-1530 Elbow 790-301-1271 Joint 07002-11023
O-ring
k Park
the machine on flat ground, place the work equipment on the ground surely, set the gear shift lever to P (PARK) position, and then stop the engine. k Chock the tires to prevent the machine from moving. a Perform the testing of the work equipment oil pressure under the following conditions. q Hydraulic oil temperature: 45 to 55°C
4. Install nipple [1] of hydraulic tester U1 and connect gauge [2] to it. a Use a 40-MPa {400-kg/cm2} gauge.
Testing 1. Remove cover (1) on the right side of the machine.
2. Remove work equipment pump pressure pickup plug (2).
5. Testing work equipment circuit relief pressure (cylinder) 1) Start the engine and operate the cylinder to measure to the stroke end. 2) While running the engine at high idle, relieve the cylinder and measure the oil pressure. a The pressure at the time when the main relief valve of the control valve is relieved is displayed. a For standard values, see the Standard value table, "Standard value table for machine". 6. Testing work equipment circuit relief pressure (motor) 1) Start the engine and make the blade dig into the ground without fail. 2) While running the engine at high idle, relieve the circle rotation motor and measure the oil pressure. a The pressure at the time when the main relief valve of the control valve is relieved is displayed.
GD535-5 (01)
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Testing work equipment oil pressure
30 Testing and adjusting
a For standard values, see the Standard value table, "Standard value table for machine". 7. Work after finishing the testing After finishing the test, remove the testing tools, and restore the machine.
30-90
GD535-5 (01)
30 Testing and adjusting
Testing lifter lock pin circuit pressure
Testing lifter lock pin circuit pressure
1
a Tools for testing lifter lock pin circuit pressure Sym bol
V
1 2
Part No.
Part name
799-101-5002 Hydraulic tester 790-261-1205 Digital hydraulic tester 799-401-3100 Adapter (size: 02)
k Park
the machine on flat ground, place the work equipment on the ground surely, set the gear shift lever to P (PARK) position, and then stop the engine. k Chock the tires to prevent the machine from moving. a Measure the lifter lock pin circuit oil pressure under the following condition. q Hydraulic oil temperature: 45 to 55°C 1. Release the remaining pressure in the brake circuit. For details, see "Releasing remaining pressure from brake circuit". k Do not perform measurement preparation without releasing the remaining pressure because the pressurized oil in the brake accumulator is acting on the lifter lock pin circuit even when the starting switch is turned to OFF position. 2. Remove hoses (1) and (2) from the lifter lock pin. a Measure the pressure in the head side and bottom side simultaneously because the lifter lock pin operates by the pressure difference between the head side and bottom side.
5. Start the engine, run it at high idle, and measure the oil pressure at the time that the lifter lock pin switch is operated.
a The lifter lock pin circuit pressure is normal if conditions shown in the following table are met. Lifter lock pin pilot lamp
Lifter lock pin circuit pressure
Pressure of both sides is equal to When lamp is the parking brake operating OFF pressure. (See Standard value table.) Bottom side: Pressure lower than the head side pressure When lamp is Head side: Almost equal to or ON lower than the parking brake operating pressure
3. Install adapter V2 and connect the disconnected hose again. 4. Install nipple [1] of hydraulic tester V1 and connect gauge [2] to it. a Use a 40-MPa {400-kg/cm2} gauge.
GD535-5 (01)
30-91
Testing lifter lock pin circuit pressure
30 Testing and adjusting
6. After finishing the test, remove the testing tools, and restore the machine.
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GD535-5 (01)
30 Testing and adjusting
Testing oil leakage of work equipment cylinder
Testing oil leakage of work equipment cylinder
1
a Tools for testing oil leakage of work equipment cylinder Sym bol W
Part No.
Part name
Commercially Measuring cylinder available
k Park
the machine on flat ground, place the work equipment on the ground surely, set the gear shift lever to P (PARK) position, and then stop the engine. k Chock the tires to prevent the machine from moving. a Perform testing of oil leakage of work equipment cylinder under the following conditions. q Hydraulic oil temperature: 45 to 55°C 1. Testing oil leakage of blade lift cylinder 1) Start the engine, and operate the right and left blade lift cylinder control levers to LOWER side to lower the blade horizontally to the ground. 2) Disconnect the connection of the tip of the rod and drawbar of the cylinder to check, and extend the cylinder to the stroke end. 3) Disconnect head side hose (1) of the cylinder to check and block the hose by using a plug k Be careful not to disconnect the hose on the cylinder bottom side. a Use the following parts to block the hose. 07376-70315 (Plug #03)
6) After finishing the adjustment, restore the machine. 2. Testing oil leakage of drawbar side shift cylinder 1) Start the engine, and operate the drawbar side shift control lever to the right shifting side to extend drawbar side shift cylinder (2) to the stroke end. 2) Disconnect hose (3) on the cylinder head side and block the hose by using a plug. k Be careful not to disconnect the hose on the cylinder bottom side. a Use the following parts to block the hose. 07376-70315 (Plug #03)
3) Start the engine, run it at high idle, and relieve the cylinder in Drawbar RIGHT shift operation. k Be careful not to operate the lever to "Drawbar LEFT shift" side. 4) Measure the amount of oil leakage by using measuring cylinder W for a minute after a lapse of 30 seconds from starting relief. 5) After finishing the adjustment, restore the machine.
4) Start the engine, run it at high idle, and relieve the cylinder in Blade LOWER operation. k Be careful not to operate the lever to "Blade RAISE" side. 5) Measure the amount of oil leakage by using measuring cylinder W for a minute after a lapse of 30 seconds from starting relief.
GD535-5 (01)
30-93
Testing oil leakage of work equipment cylinder
3. Testing oil leakage of blade side shift cylinder 1) Start the engine, and operate the blade side shift control lever to the left shifting side to extend blade side shift cylinder (4) to the stroke end. 2) Remove the cylinder cover (left), disconnect head side hose (5) from the cylinder and block the hose by using a plug. k Be careful not to disconnect the hose on the cylinder bottom side. a Use the following parts to block the hose. 07376-70315 (Plug #03)
3) Start the engine, run it at high idle, and relieve the cylinder in Blade LEFT shift operation. k Be careful not to operate the lever to "Blade RIGHT shift" side. 4) Measure the amount of oil leakage by using measuring cylinder W for a minute after a lapse of 30 seconds from starting relief. 5) After finishing the adjustment, restore the machine.
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30 Testing and adjusting
4. Testing oil leakage of power tilt cylinder [power tilt specification] 1) Start the engine, and operate the power tilt control lever to the large cutting angle side to extend power tilt cylinder (6) to the stroke end. 2) Disconnect head side hose (7) from the cylinder and block the hose by using a plug. k Be careful not to disconnect the hose on the cylinder bottom side. a Use the following parts to block the hose. 07376-70315 (Plug #03)
3) Start the engine, run it at high idle, and relieve the cylinder in Power tilt cutting angle LARGE operation. k Be careful not to operate the lever to "Power tilt cutting angle SMALL" side. 4) Measure the amount of oil leakage by using measuring cylinder W for a minute after a lapse of 30 seconds from starting relief. 5) After finishing the adjustment, restore the machine.
GD535-5 (01)
30 Testing and adjusting
Testing oil leakage of work equipment cylinder
5. Testing oil leakage of articulate cylinder 1) Start the engine, and operate the articulate control lever to extend articulate cylinder (8) to check to the stroke end. 2) Disconnect head side hose (9) of the cylinder to check and block the hose by using a plug k Be careful not to disconnect the hose on the cylinder bottom side. a Use the following parts to block the hose. 07376-70315 (Plug #03)
6. Testing oil leakage of leaning cylinder 1) Start the engine, and operate the leaning control lever to the right leaning side to extend leaning cylinder (10) to the stroke end. 2) Disconnect head side hose (11) from the cylinder and block the hose by using a plug. k Be careful not to disconnect the hose on the cylinder bottom side. a Use the following parts to block the hose. 07376-70315 (Plug #03)
3) Start the engine, run it at high idle, and relieve the cylinder in Cylinder EXTEND operation. k Be careful not to operate the lever to "Cylinder Retract" side. 4) Measure the amount of oil leakage by using measuring cylinder W for a minute after a lapse of 30 seconds from starting relief. 5) After finishing the adjustment, restore the machine.
3) Start the engine, run it at high idle, and relieve the cylinder in Cylinder EXTEND operation. k Be careful not to operate the lever to "Leaning LEFT" side. 4) Measure the amount of oil leakage by using measuring cylinder W for a minute after a lapse of 30 seconds from starting relief. 5) After finishing the adjustment, restore the machine.
GD535-5 (01)
30-95
Bleeding air from work equipment circuit
Bleeding air from work equipment circuit
30 Testing and adjusting
1
k Park
the machine on flat ground, place the work equipment on the ground surely, set the gear shift lever to P (PARK) position, and then stop the engine. k Chock the tires to prevent the machine from moving. Bleeding air from hydraulic cylinder a If the cylinder has been removed and installed or its cylinder piping has been disconnected and connected, bleed air according to the following procedure. a While bleeding air, make sure that the oil level in the hydraulic tank does not decrease below the specified level. 1. While running the engine at low idle, extend and retract the cylinder 4 to 5 times. k Stop the piston rod at approximately 50 mm before the stroke end to avoid relieving. 2. While running the engine at low idle, move the piston rod to the stroke end to relieve the cylinder.
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GD535-5 (01)
30 Testing and adjusting
Adjusting drawbar ball joint clearance
Work equipment Adjusting drawbar ball joint clearance
1
1
k Park
the machine on flat ground, place the work equipment on the ground surely, set the gear shift lever to P (PARK) position, and then stop the engine. k Chock the tires to prevent the machine from moving. a After replacing the parts related to drawbar ball joint, or if the drawbar does not move smoothly, adjust the drawbar ball joint clearance according to the following procedure. 1. Temporarily install ball joint (1) and holder (2) to frame (3) with nut (4) without inserting any shim. a Tighten 4 nuts (4) to the following torque. 3 Mounting nut: 58.8 to 73.6 Nm {6 to 7.5 kgm}
2. Measure clearance (a) of the nut (4) tightening part at 4 locations, and calculate the average value. 3. Select the number of shims to insert based on the average value of clearance (a). q Shim pack thickness (mm): Average value of clearance (a) + thickness of 2 shims q Available shims: 0.3 mm 4. Remove holder (2) and ball joint (1) from frame (3) once. 5. Fit selected shims and apply grease to ball joint (1) and holder (2), and install them to frame (3). 3 Mounting nut: 785 to 980 Nm {80 to 100 kgm} 6. Check that ball joint (1) can move smoothly. a No unusual noise due to backlash must be heard.
GD535-5 (01)
30-97
Testing and adjusting circle guide clearance
Testing and adjusting circle guide clearance
30 Testing and adjusting
1
k If q q
the following conditions occur after adjustment, replace the circle guide. When there is no longer clearance (R) between the circle and circle guide When the clearance between the tip of the gear teeth (or tooth bottom) of the circle gear and the tooth bottom (or tip of the gear teeth) of the pinion of the circle rotator is 0.
Testing 1. Measuring vertical clearance q With the blade suspended, measure clearance (P) between the upper surface of the circle and lower surface of the drawbar as shown in the figure. Standard clearance (P): 1.0 to 2.0 mm 2. Measuring longitudinal clearance q With the blade suspended and load is applied to the rear, measure clearances (QF) and (QR) between the circle and circle guide as shown in the figure. Standard clearance QF (front): 0 mm QR (rear): 1.5 mm Or, QF = QR = 1 mm
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GD535-5 (01)
30 Testing and adjusting
Testing and adjusting circle guide clearance
Adjusting 1. Adjusting vertical clearance 1) Raise the blade, remove bolts (1) and (5), remove circle guides (2) and (6), and then adjust the clearance by using shims. a Available shims: 1mm and 0.5 mm a Adjust the circle guide 1 place at a time. 2. Adjusting longitudinal clearance 1) Lower the blade to the ground lightly, loosen bolt (1) and lock nut (4), and loosen bolt (3) to open circle guides (2) so that QF = 0 holds. a Open right and left circle guides (2) evenly. 2) Adjust clearance (D) between the lower flange end surface of the circle drive and the sliding surface of the circle inner periphery. Standard clearance (D): 27.3 mm
3) With QF = 0 state, tighten lock nut (4), and tighten bolt (1). 3 Bolt (1): 455 to 565 Nm {46.5 to 58 kgm} 3. Adjusting lateral clearance 1) Loosen bolt (5) and lock nut (8), loosen bolt (7) to open circle guides (6) so that QR = 0 holds. a Open right and left circle guides (6) evenly. 2) With QR = 0 state, loosen bolt (7) by half turn, tighten lock nut (8), loosen circle guides (6) until it touches bolt (7), and tighten bolt (5). 3 Bolt (5): 455 to 565 Nm {46.5 to 58 kgm} 3) The standard clearance between the tip of the gear teeth of the circle gear and the tooth bottom of the pinion gear of the circle drive is 1.5 to 3.0 mm. 4) Check that the circle can rotate with the blade at 90 deg. high bank position to right or left.
GD535-5 (01)
30-99
Testing and adjusting slip clutch type circle drive
Testing and adjusting slip clutch type circle drive
30 Testing and adjusting
1
k Park
the machine on flat ground, place the work equipment on the ground surely, set the gear shift lever to P (PARK) position, and then stop the engine. k Chock the tires to prevent the machine from moving. Testing 1. Remove mounting bolts (1), and remove cover (2). 2. Check that the internal teeth of worm wheel (3) can be seen through the hole of part (P). a Check the slip state of the clutch based on the rotation of the worm wheel.
q q q
Make judgments depending on whether worm wheel (3) rotates. If worm wheel (3) rotates but the blade does not rotate, the clutch slips. If the worm wheel (3) does not rotate, the motor circuit is relieved and clutch does not slip.
Adjusting 1. When the clutch does not slip 1) Remove bolt (4) and holder (5), and add one 0.2-mm shim (6). 2) Tighten holder (5) and bolt (4). 3 Bolt (4): 98 to 123 Nm {10 to 12.5 kgm}
3. To prevent the circle from rotating, thrust the blade against the ground and raise the front wheels off ground or immobilize one end of the blade. q How to raise front wheels off ground 1] Lower the blade to the ground and extend blade lift cylinders until front wheels are raised off ground. 2] Apply the parking brake. 3) Check whether the clutch slips by following the testing procedure. 4) Repeat steps 1) to 3) until the clutch comes to slip so that the clutch is set to its slip limit. 5) If the clutch comes to slip, remove one 0.2-mm shim (6). a After the shim adjustment is complete, the clutch does not slip.
4. Run the engine at high idle, and operate the circle rotation control lever slowly to check whether the clutch slips.
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GD535-5 (01)
30 Testing and adjusting
2. When the clutch slips 1) Remove bolt (4) and holder (5), and remove one 0.2-mm shim (6). 2) Tighten holder (5) and bolt (4). 3 Bolt (4): 98 to 123 Nm {10 to 12.5 kgm}
3) Check whether the clutch slips by following the "testing" procedure. 4) Repeat steps 1) to 3) until the clutch comes not to slip so that the clutch is set to its slip limit. 5) With the clutch set at its slip limit, remove one 0.2-mm shim (6). a After the shim adjustment is complete, the clutch does not slip.
Testing and adjusting slip clutch type circle drive
Clutch running-in operation After replacing the clutch disc with a new one, perform clutch running-in operation according to the following procedure. a When installing the disc, apply GO80W90 oil to its both sides. 1) Set the clutch to its slip limit by following "adjusting" steps 1 and 2. 2) Add one 0.2-mm shim so that the clutch comes to slip. 3) Make the clutch slip for 3.5 to 4.0 seconds. q Engine speed: At High idle q The clutch rotates by 1 turn when it slips for 3.5 to 4.0 seconds. 4) Repeat step 3) for 20 to 25 times every 3 minutes. k If the temperature of the clutch housing exceeds 50 °C, stop the operation until it drops to the normal temperature. k If it stops slipping in the middle of the operation, add one 0.2-mm shim. 5) Wail until the temperature of the clutch drops to the normal temperature. 6) Set the clutch to its slip limit again (adjusting steps 1 and 2. 7) Remove one 0.2-mm shim to realize the shim pack thickness with which the clutch comes not to slip. a The running-in operation is complete.
q
3. Installing cover 1) Install cover (2) and tighten bolts (1). 3 Bolt (1): 59 to 74 Nm {6 to 7.5 kgm}
GD535-5 (01)
30-101
Procedure for testing diodes
30 Testing and adjusting
Electrical system
1
Procedure for testing diodes
1
a The direction of the continuity of a single diode is indicated on the surface of the diode as shown in the figure below.
How to test diodes by using analog multimeter 1. Selects the resistance range mode. 2. Apply the red (+) lead of the multimeter to the anode (P) side of the diode and apply the black (-) lead to the cathode (N) side and check the deflection of the pointer. 3. Apply the red (+) lead of the multimeter to the cathode (N) side of the diode and apply the black (-) lead to the anode (P) side and check the deflection of the pointer. 4. Evaluate the condition of the diode by the deflection of the pointer. Resulting deflection of pointer Step 2.
How to test diodes by using digital multimeter 1. Select the diode range mode to check the displayed values. a When an ordinary multimeter is used, the voltage of the internal battery is indicated. 2. Apply the red (+) lead of the multimeter to the anode (P) side of the diode and apply the black (-) lead to the cathode (N) side and check the indicated value. 3. Evaluate the condition of the diode by the indicated value. Indicated value does not change: No continuity (defective) Indicated value changes: Continuity (normal) (*) *: In the case of a silicon diode, a value in the range from 460 to 600 mV is indicated.
30-102
Quality judgment
Step 3.
Deflects
Does not deflect
Normal (Note that amplitude of deflection depends on multimeter type and selected measurement range.)
Deflects
Deflects
Defective (internal short circuit)
Does not deflect
Does not deflect
Defective (internal open circuit)
GD535-5 (01)
30 Testing and adjusting
Procedure for testing diodes
Setting and adjusting various equipment When having performed operations shown in the following table, such as replacement, disassembly and assembly, and retrofitting of equipment, be sure to implement needed setting and adjustment with the machine monitor. Contents of operation
Needed setting and adjusting items
Reference page
Setting of machine model selection
Default (Machine Model Select) (30-129 page)
Replacement of monitor controller
Setting of option selection
Default (Option Selection) (30-130 page)
Zero point adjustment of articulated angle indicator
Adjustment (Zero Point Adjustment For Art Angle) (30144 page)
Replacement or disassembly/assembly of transmission unit or transmission ECMV solenoid valve
Adjustment of transmission ECMV current
Adjustment (ECMV Automatic Compensation) (30-133 page)
Reset of transmission initial learning and implementation of learning
Adjustment (T/M Initial Learning) (30-136 page)
Setting of machine model selection
Default (Machine Model Select) (30-129 page)
Setting of option selection
Default (Option Selection) (30-130 page)
Adjustment of transmission ECMV current
Adjustment (ECMV Automatic Compensation) (30-133 page)
Replacement of transmission Reset of transmission initial learning controller and implementation of learning
Adjustment of inching pedal voltage
Adjustment (T/M Initial Learning) (30-136 page) Adjustment (Inching Pedal 0% Adjustment) (30-140 page) Adjustment (Inching Pedal 100% Adjustment) (30-141 page)
Retrofit and removal of optional equipment
Setting of option selection
Default (Option Selection) (30-130 page)
Replacement of articulate angle sensor
Zero point adjustment of articulated angle indicator
Adjustment (Zero Point Adjustment For Art Angle) (30144 page)
Replacement of inching pedal
Adjustment of inching pedal voltage
Adjustment (Inching Pedal 0% Adjustment) (30-140 page) Adjustment (Inching Pedal 100% Adjustment) (30-141 page)
When having received comments or requests that apply to the following from our customers, implement setting and adjustment shown below with the machine monitor. Comment or request
Testing/Adjusting item
Reference page
Hope to change the expressive unit of indicators
Setting of unit selection
Default (Unit Selection) (30-132 page)
Indicated travel speed is too fast or too slow.
Correction of tire size
Default (Option Selection) (30-130 page)
GD535-5 (01)
30-103
Special functions of machine monitor
Special functions of machine monitor
Machine monitor section (monitor panel section) (a): Multi-display At engine start, the battery voltage can drop rapidly depending on ambient temperature or battery condition. Under such conditions, the display screen of the machine monitor may turn off temporarily, but this is not a defect.
30-104
30 Testing and adjusting
1
Machine monitor section (switch section) F1: Function switch F1 F2: Function switch F2 F3: Function switch F3 F4: Function switch F4 F5: Function switch F5 F6: Function switch F6 F7: Function switch F7 F8: Function switch F8 The function assigned to each function switch is displayed by using a graphic symbol in a position within multi-display (a); over the function switch for F1 to F4 and on the left of function switch for F5 to F8. Function switches without graphic symbols do not work.
GD535-5 (01)
30 Testing and adjusting
Special functions of machine monitor
Operator mode and service mode of machine monitor The machine monitor has 2 functions of the operator mode and service mode and displays various information on multi-display (a). Some items are displayed automatically according to the internal setting of the machine monitor and the others are displayed according to the operation of the switches. q Operator mode The information items in this mode are displayed ordinarily. The operator can display and set them by operating the switches (display and setting of some items need specific operations of the switches). For the details, see the Operation and Maintenance Manual. Operator mode
q
Service mode The information items in this mode are not displayed ordinarily. Each technician can display them by operating specified switches. Use this mode for testing, adjusting, and troubleshooting. Service mode 01
Monitoring/defined (30-110 page)
02
Monitoring/Custom (30-113 page)
Display of KOMATSU logo Display of results of check before starting
03
Display of warning after check before starting
Abnormality Record (Mechanical System) (30-120 page) Abnormality Record (Electrical System) (30-121 page)
Display of maintenance due time over
04
Maintenance Time Reset (30-123 page)
Display of standard screen
05
Maintenance Record (30-124 page)
Display of end screen
06
Maintenance Mode Setting (30-125 page)
Operation to switch between clock display and service meter display
07
Phone Number Entry (30-128 page)
Check of maintenance information
Default (Machine Model Select) (30-129 page) 08
User mode setting and display (including KOMTRAX message to users) Display of ECO Guidance
Default (Unit Selection) (30-132 page) 09
Diagnostic Tests (Cylinder Cut-out) (30-132 page) Adjustment (ECMV Automatic Compensation) (30133 page)
Display of machine setting Display function of caution monitor
Adjustment (T/M Initial Learning) (30-136 page)
Display of action level and failure code
Adjustment (T/M Initial Learning Reset) (30-139 page)
Following functions require specific operations. Checking function of LCD display (30-106 page)
Default (Option Selection) (30-130 page)
10
Confirmation function of service meter and odometer (30106 page)
Adjustment (Inching Pedal 0% Adjustment) (30-140 page) Adjustment (Inching Pedal 100% Adjustment) (30141 page)
Function of usage limitation setting / changing password (30-106 page)
Adjustment (T/C Stall) (30-143 page) Adjustment (Zero Point Adjustment For Art Angle) (30-144 page) 11
No Injection (30-146 page) KOMTRAX Settings (Terminal Status) (30-147 page)
12
KOMTRAX Settings (GPS & Communication Status) (30-148 page) KOMTRAX Settings (Modem Status) (30-149 page)
13
GD535-5 (01)
Service Message (30-149 page)
30-105
Special functions of machine monitor
Operator mode This section describes only function items that require special operations in the operator mode. For detailed contents and operation procedures of each function and display, see "Structure and function" or "Operation and Maintenance Manual". Checking function of LCD display With the LCD displaying the standard screen, operate numeric input switches and function switches as described below to display the full-screen in white. Switch operation (press the switches in order while pressing F8): F8 + F6 q When finishing the switch operation, release your finger from F6 switch first. q If the LCD has any display error, the defective part alone is displayed in black. q One of the features of the liquid crystal unit is that there may be black spots (spots that do not light up) or white spots (spots that stay lit) on the screen. LCD with black spots and bright spots not more than 10 spots is not deemed to be a failed or defective display. q Press any function switch to return the screen display to the original one.
30 Testing and adjusting
Confirmation function of service meter and odometer To check the readings of the service meter and odometer with the starting switch set at OFF position, operate function switches as described below to display readings of the service meter and odometer. Switch operation (press the switches in order while pressing F2): F2 + F3
a Keep pressing the switches until the readings are displayed because the LCD has a little time lag of start-up. a If either of the switches is released, the machine monitor goes out. a For the machine monitor being used for a long term, blue bright spots may be seen on this screen display. But this phenomenon does not indicate any failure or defect. Function of usage limitation setting / changing password The machine monitor allows for setting a password as its usage limitation setting function. Once a password is set, the password entry screen appears when Maintenance Time Reset is tried. Set the usage limitation or change the password according to the following procedure. 1. With the standard screen being displayed, operate function switches as described below. Switch operation: While keep pressing F8, press F5 three times (simultaneously). a This switch operation cannot be accepted until 10 minutes or more has elapsed after the starting switch is turned to ON position.
30-106
GD535-5 (01)
30 Testing and adjusting
2. When "Usage Limitation Password" screen appears, operate function switches to input the current password. F1: Decreases number by 1. F2: Increases number by 1. F3: Returns the screen to standard screen. F4: Enters input password. F6: Moves input position to left. F7: Moves input position to right. F8: Clears all input numbers. a Default password: 000000 a When the input password is correct, the screen switches to the next one. a When the input password is incorrect, an indication that requires retyping appears. a The Usage limitation password differs from the Engine start Lock password.
Special functions of machine monitor
"Enable": Password input screen appears when implementing Option Setting or Maintenance Time Reset. F1: Moves selection downward. F2: Moves selection upward. F3: Cancels selection and returns screen to previous one. F4: Enters selection.
5. When "Usage Limitation Setting" screen appears, operate function switches to select "Change Password"". F1: Moves selection downward. F2: Moves selection upward. F3: Cancels selection and returns screen to previous one. F4: Enters selection. 3. When "Usage Limitation Setting" screen appears, operate function switches to select "Usage Limitation ON/OFF". F1: Moves selection downward. F2: Moves selection upward. F3: Cancels selection and returns screen to previous one. F4: Enters selection.
4. When "Usage Limitation ON/OFF" screen appears, operate function switches to select the desired setting. "Disable": Password input screen is not displayed.
GD535-5 (01)
6. When "New Password" screen for Usage Limitation appears, operate function switches to input and enter a new password. F1: Decreases number by 1. F2: Increases number by 1. F3: Returns screen to "Usage Limitation" menu screen. F4: Enters new password. F6: Moves input position to left. F7: Moves input position to right. F8: Clears all input numbers.
30-107
Special functions of machine monitor
30 Testing and adjusting
a Default password: 000000 a When the input password is correct, the screen switches to the next one. a When the input password is incorrect, an indication that requires retyping appears. a Set a new password of 4 to 6 digits (If it has only 3 or less digits or has 7 or more digits, it is not accepted). 7. When "New Password" screen for Usage Limitation appears, operate function switches to input and enter a new password. F1: Decreases number by 1. F2: Increases number by 1. F3: Returns screen to "Usage Limitation" menu screen. F4: Enters new password. F6: Moves input position to left. F7: Moves input position to right. F8: Clears all input numbers.
a If a password different from the first one is input, an indication that requires retyping appears. Change of password is complete if the standard screen appears after a screen to give notice of setting completion is displayed.
30-108
GD535-5 (01)
30 Testing and adjusting
Special functions of machine monitor
Service mode To change the operator mode to the service mode, perform the following operation. This operation is always required when you use the service mode. 1. With the standard screen being displayed, keep pressing function switch F8 and press F1, F2, and F3 in order. a The switch operation to use the service mode is accepted only while the standard screen is being displayed.
a A menu item with a code (2 digits) is displayed on the "Service Menu" screen. An item displayed on the right is a menu item of 1-rank lower layer. The following shows the items selectable from the "Service Menu" (including some items which need specific switch operations).
2. When "Service Menu" screen is displayed, the mode is switched to the service mode. On this screen, select a service menu item to use. F1: Moves selection downward. F2: Moves selection upward. F3: Returns screen to standard screen (operator mode). F4: Enters selection. F8: Moves screen to code entry screen.
a On the code entry screen, you can select a menu item directly by inputting the code with the function switches. F1: Decreases number by 1. F2: Increases number by 1. F3: Cancels selection and return screen to "Service Menu" screen. F4: Enters input code. F6: Moves input position to left. F7: Moves input position to right.
GD535-5 (01)
30-109
Special functions of machine monitor
Items selectable from service menu Service mode 01
Monitoring/defined (30-110 page)
02
Monitoring/Custom (30-113 page)
03
Abnormality Record (Mechanical System) (30-120 page) Abnormality Record (Electrical System) (30-121 page)
04
Maintenance Time Reset (30-123 page)
05
Maintenance Record (30-124 page)
06
Maintenance Mode Setting (30-125 page)
07
Phone Number Entry (30-128 page)
30 Testing and adjusting
Monitoring/defined The machine monitor can monitor the condition of the machine in real time by receiving signals from various switches, sensors, and actuators installed to various parts of the machine and the information from the controllers which is controlling switches, etc. In the Monitoring/defined, monitoring items that are more commonly used are selected in advance. 1. Select "Monitoring/defined" on "Service Menu" screen. a For the selection method, see relevant section in "Service mode".
Default (Machine Model Select) (30-129 page? 08
Default (Option Selection) (30-130 page) Default (Unit Selection) (30-132 page)
09
Diagnostic Tests (Cylinder Cut-out) (30-132 page) Adjustment (ECMV Automatic Compensation) (30133 page) Adjustment (T/M Initial Learning) (30-136 page) Adjustment (T/M Initial Learning Reset) (30-139 page)
10
Adjustment (Inching Pedal 0% Adjustment) (30-140 page) Adjustment (Inching Pedal 100% Adjustment) (30141 page) Adjustment (T/C Stall) (30-143 page) Adjustment (Zero Point Adjustment For Art Angle) (30-144 page)
11
No Injection (30-146 page)
2. When "Monitoring/defined" screen is displayed, you can check the items to be displayed in the screen by using function switches. F1: Switches gauge type to be displayed at bottom of screen (fuel level gauge, coolant temperature gauge, torque converter oil temperature gauge). F2: Switches setting between HOLD and HOLD CANCELED. (If HOLD is selected, a diagonal appears in HOLD box.) F3: Returns screen to "Service Menu" screen. F6: Moves screen to next page (screen). F7: Moves screen to previous page (screen).
KOMTRAX Settings (Terminal Status) (30-147 page) 12
KOMTRAX Settings (GPS & Communication Status) (30-148 page) KOMTRAX Settings (Modem Status) (30-149 page)
13
Service Message (30-149 page)
a For the items not displayed in "Monitoring/ defined", you can freely select and check them from "Monitoring/Custom" items.
30-110
GD535-5 (01)
30 Testing and adjusting
Special functions of machine monitor
Monitoring item list in Monitoring/defined Monitoring items in Monitoring/defined (01/10) Relating to machine basics (1) Unit SI
Non SI
Associated equipment
r/min
rpm
ENG
Coolant Temperature
°C
°F
ENG
03203
Battery Voltage
V
V
ENG
30100
T/C Oil Temperature
°C
°F
T/M
SI
Non SI
Associated equipment
°C
°F
T/M
SI
Non SI
Associated equipment
No.
ID
Item name
1
01002
Engine Speed
2
04107
3 4
Monitoring items in Monitoring/defined (02/10) Relating to machine basics (2) No.
ID
1
04401
Item name Hydraulic Oil Temperature
Unit
Monitoring items in Monitoring/defined (03/10) Relating to machine basics (3) Item name
Unit
No.
ID
1
01002
Engine Speed
r/min
rpm
ENG
2
36500
Boost Pressure
kPa
PSI
ENG
3
18500
Boost Temperature
°C
°F
ENG
SI
Non SI
Associated equipment
Monitoring items in Monitoring/defined (04/10) Relating to fuel injection Item name
Unit
No.
ID
1
01002
Engine Speed
r/min
rpm
ENG
2
36400
Common Rail Pressure
MPa
PSI
ENG
3
36200
Rail Pressure Command
MPa
PSI
ENG
SI
Non SI
Associated equipment
r/min
rpm
ENG
Monitoring items in Monitoring/defined (05/10) Relating to engine temperature Item name
Unit
No.
ID
1
01002
Engine Speed
2
04107
Coolant Temperature
°C
°F
ENG
3
18500
Boost Temperature
°C
°F
ENG
Monitoring items in Monitoring/defined (06/10) Relating to intake and exhaust pressure Unit SI
Non SI
Associated equipment
Engine Speed
r/min
rpm
ENG
37400
Ambient Pressure
kPa
PSI
ENG
36500
Boost Pressure
kPa
PSI
ENG
No.
ID
1
01002
2 3
GD535-5 (01)
Item name
30-111
Special functions of machine monitor
30 Testing and adjusting
Monitoring items in Monitoring/defined (07/10) Relating to transmission clutch (1) Unit SI
Non SI
Associated equipment
Fill Time (1st)
msec
msec
T/M
41803
Fill Time (2nd)
msec
msec
T/M
3
41804
Fill Time (3rd)
msec
msec
T/M
4
41805
Fill Time (4th)
msec
msec
T/M
No.
ID
1
41802
2
Item name
Monitoring items in Monitoring/defined (08/10) Relating to transmission clutch (2) Unit SI
Non SI
Associated equipment
Fill Time (Forward_L)
msec
msec
T/M
41808
Fill Time (Forward_H)
msec
msec
T/M
41806
Fill Time (Reverse)
msec
msec
T/M
No.
ID
1
41807
2 3
Item name
Monitoring items in Monitoring/defined (09/10) Relating to transmission clutch (3) Unit SI
Non SI
Associated equipment
ECMV Current (1st)
mA
mA
T/M
31603
ECMV Current (2nd)
mA
mA
T/M
3
31604
ECMV Current (3rd)
mA
mA
T/M
4
31605
ECMV Current (4th)
mA
mA
T/M
SI
Non SI
Associated equipment
No.
ID
1
31602
2
Item name
Monitoring items in Monitoring/defined (10/10) Relating to transmission clutch (4) ID
1
31607
ECMV Current (Forward_L)
mA
mA
T/M
2
31608
ECMV Current (Forward_H)
mA
mA
T/M
3
31606
ECMV Current (Reverse)
mA
mA
T/M
30-112
Item name
Unit
No.
GD535-5 (01)
30 Testing and adjusting
Monitoring/Custom The machine monitor can monitor the condition of the machine in real time by receiving signals from various switches, sensors, and actuators installed to various parts of the machine and the information from the controllers which is controlling switches, etc. With "Monitoring/Custom", monitoring items can be selected arbitrarily.
Special functions of machine monitor
q
q
1. Select "Monitoring/Custom" on "Service Menu" screen. a For the selection method, see relevant section in "Service mode".
q
q
2. When "monitoring item selection menu" screen is displayed, select items to monitor by using function switches. F1: Moves selection downward. F2: Moves selection upward. F3: Returns screen to "Service Menu" screen. F4: Enters selection. F6: Moves selection leftward F7: Moves selection rightward F8: Moves screen to "ID Input" screen.
q
To select monitoring items by using function switches, use F6 or F7 switch to select associated equipment first, use F1 or F2 switch to select monitoring items, and then use F4 switch to enter the selection. On the Monitoring/Custom screen, if you press F8 and input ID, you can select a monitoring item directly. F1: Decreases number by 1. F2: Increases number by 1. F3: Cancels input and return screen to " Monitoring/Custom" screen. F4: Enters input number. F6: Moves selection leftward F7: Moves selection rightward If the color of the selected box changes from yellow to red, the selection of the item of that box is entered. Up to 4 monitoring items can be selected at a time. The items, however, may not be set up to 4 items depending on the display formats of the selected items.
3. After selecting monitoring items, execute monitoring with a function switch. q To execute monitoring with a function switch, double click F4 or keep pressing it for approximately 2 seconds. q To execute monitoring by inputting ID, use function switches to input "99999" after the ID is entered, and then use F4 to enter the input to start monitoring. F1: Decreases number by 1. F2: Increases number by 1.
In the process of setting Monitoring/Custom, each time function switch F7 is pressed, the displayed name of equipment that is associated with the monitoring items changes in the order of "ENG" o "T/M" o "MON" o "ENG". (When function switch F6 is depressed, it changes in the reverse order.)
GD535-5 (01)
30-113
Special functions of machine monitor
F3: Cancels input and return screen to " Monitoring/Custom" screen. F4: Enters input number. F6: Moves selection leftward F7: Moves selection rightward q During selection of monitoring items, if the number of selected items reaches the limit number, the machine monitor automatically switches to monitoring execution state. a When monitoring only two items, for example, select respective items and enter them with F4. After the selection is complete, press F4 once again to switch the machine monitor to monitoring execution state.
30 Testing and adjusting
6. Selected monitoring items can be saved and cleared by using function switches. F6: Clears selected monitoring item. F7: Saves selected monitoring item. q When any saved item exists, if "Monitoring/ Custom" is selected on "Service Menu" screen, a confirmation screen with a message of "Display the memorized items?" is displayed. When F4 switch is pressed, the screen moves to "Monitoring" screen for the saved monitoring item.
4. After "Monitoring" screen is displayed, perform the necessary operation of the machine and check the monitoring information. a Monitoring information is indicated by value, ON/OFF, or special display. a The display unit can be set to "SI" or "Non SI" unit by using "Unit Selection" of "Default" menu.
q q
q
When an item is saved, it can be displayed as many times as required unless it is cleared. If another item is saved while having the previous item saved, the previously saved item is overwritten by the latest one. A saved item can be cleared by pressing F6 and F4 to enter the designation.
5. You can hold and release holding of the monitoring information by using the function switches. F1: Switches gauge type to be displayed at bottom of screen (fuel level gauge, coolant temperature gauge, torque converter oil temperature gauge). F2: Switches setting between HOLD and HOLD CANCELED. (If HOLD is selected, a diagonal appears in HOLD box.) F3: Returns screen to Monitoring/Custom screen. F7: Saves monitoring item currently displayed.
30-114
GD535-5 (01)
30 Testing and adjusting
Special functions of machine monitor
Monitoring item list Monitoring code
Monitoring item (Display on screen)
Unit SI
Non SI
Associated equipment
00201
Machine ID
-
-
ENG
20216
Engine Controller Software Version
-
-
ENG
20217
Engine Controller Data Version
-
-
ENG
18900
Engine Controller Internal Temperature
°C
°F
ENG
20400
Engine Controller S/N
-
-
ENG
01002
Engine Speed
r/min
rpm
ENG
36700
Engine Output Torque Ratio
%
%
ENG
31701
Throttle Position
%
%
ENG
03000
Throttle Position Sensor Voltage
V
V
ENG
17500
Engine Power Mode Selection
-
-
ENG
36400
Common Rail Pressure
MPa
PSI
ENG
36401
Common Rail Pressure Sensor Voltage
V
V
ENG
36200
Rail Pressure Command
MPa
PSI
ENG
04107
Coolant Temperature
°C
°F
ENG
04105
Coolant Temperature Sensor Voltage
V
V
ENG
37400
Ambient Pressure
kPa
PSI
ENG
37401
Ambient Pressure Sensor Voltage
V
V
ENG
36500
Boost Pressure
kPa
PSI
ENG
36501
Boost Pressure Sensor Voltage
V
V
ENG
03203
Battery Voltage
V
V
ENG
37300
Fuel Rate
ℓ/h
gal/sec
ENG
31706
Final Throttle Position
%
%
ENG
18500
Boost Temperature
°C
°F
ENG
18501
Boost Temperature Sensor Voltage
V
V
ENG
18300
Idle Validation SW1
-
-
ENG
18301
Idle Validation SW2
-
-
ENG
18600
Final Inject Fueling Command (in quantity)
mg/st
mg/st
ENG
18700
Engine Output Torque
Nm
lbft
ENG
18800
WIF Sensor State
-
-
ENG
08402
Droop SW selection
-
-
ENG
48900
Engine Operation Mode
-
-
ENG
41600
Engine Power Mode Selection
-
-
T/M
31200
T/M Input Shaft Speed
r/min
rpm
T/M
31300
T/M Intermediate Shaft Speed
r/min
rpm
T/M
31400
T/M output Shaft Speed
r/min
rpm
T/M
GD535-5 (01)
Remarks
Indicated in absolute figure (Including ambient pressure)
(*1)
30-115
Special functions of machine monitor
Monitoring code
Monitoring item (Display on screen)
30 Testing and adjusting
Unit SI
Non SI
Associated equipment
30100
T/C Oil Temperature
°C
°F
T/M
30101
T/C Oil Temperature Sensor Voltage
V
V
T/M
04401
Hydraulic Oil Temperature
°C
°F
T/M
04404
Hydraulic Oil Temperature Sensor Voltage
V
V
T/M
32500
T/M Oil Temperature
°C
°F
T/M
32501
T/M Oil Temperature Sensor Voltage
V
V
T/M
31909
Differential oil temperature
°C
°F
T/M
31910
Differential Oil Temperature Sensor Voltage
V
V
T/M
32601
Torque Converter Oil Pressure
MPa
PSI
T/M
32603
T/C Oil Pressure Sensor Voltage
V
V
T/M
04200
Fuel Level Sensor [V]
V
V
T/M
04201
Fuel Level Sensor [ohm]
Ω
Ω
T/M
43900
Articulate Sensor Voltage
V
V
T/M
44105
Inching Potentiometer Input Voltage
V
V
T/M
31602
ECMV Current (1st)
mA
mA
T/M
31603
ECMV Current (2nd)
mA
mA
T/M
31604
ECMV Current (3rd)
mA
mA
T/M
31605
ECMV Current (4th)
mA
mA
T/M
31606
ECMV Current (Reverse)
mA
mA
T/M
31607
ECMV Current (Forward_L)
mA
mA
T/M
31608
ECMV Current (Forward_H)
mA
mA
T/M
31609
ECMV Current (L/U)
mA
mA
T/M
38902
Clutch Trigger Compensation (1st)
-
-
T/M
38903
Clutch Trigger Compensation (2nd)
-
-
T/M
38904
Clutch Trigger Compensation (3rd)
-
-
T/M
38905
Clutch Trigger Compensation (4th)
-
-
T/M
38906
Clutch Trigger Compensation (Reverse)
-
-
T/M
38907
Clutch Trigger Compensation (Forward_L)
-
-
T/M
38908
Clutch Trigger Compensation (Forward_H)
-
-
T/M
38700
Gear shift mode state
-
-
T/M
44100
Inching Clutch Overload Times 1
-
-
T/M
44101
Inching Clutch Overload Times 2
-
-
T/M
44102
Inching Clutch Overload Times 3
-
-
T/M
41802
Fill Time (1st)
msec
msec
T/M
41803
Fill Time (2nd)
msec
msec
T/M
41804
Fill Time (3rd)
msec
msec
T/M
41805
Fill Time (4th)
msec
msec
T/M
41806
Fill Time (Reverse)
msec
msec
T/M
30-116
Remarks
GD535-5 (01)
30 Testing and adjusting
Monitoring code
Special functions of machine monitor
Monitoring item (Display on screen)
Unit SI
Non SI
Associated equipment
41807
Fill Time (Forward_L)
msec
msec
T/M
41808
Fill Time (Forward_H)
msec
msec
T/M
44201
Throttle Lower Limit Command
%
%
T/M
44200
Throttle Upper Limit Command
%
%
T/M
36000
Throttle Modification Value
%
%
T/M
03208
Controller Power Voltage (T/M)
V
V
T/M
03216
Solenoid Power Supply Voltage (T/M)
V
V
T/M
04307
Battery Charge Voltage (T/M)
V
V
T/M
Forward_L Clutch
ON/OFF
ON/OFF
T/M
94110
Trigger Initial Learning Flag 1
Forward_H Clutch
ON/OFF
ON/OFF
T/M
Reverse Clutch
ON/OFF
ON/OFF
T/M
1st Clutch
ON/OFF
ON/OFF
T/M
2nd Clutch
ON/OFF
ON/OFF
T/M
3rd Clutch
ON/OFF
ON/OFF
T/M
4th Clutch
ON/OFF
ON/OFF
T/M
Forward_L Clutch
ON/OFF
ON/OFF
T/M
Forward_H Clutch
ON/OFF
ON/OFF
T/M
Reverse Clutch
ON/OFF
ON/OFF
T/M
1st Clutch
ON/OFF
ON/OFF
T/M
2nd Clutch
ON/OFF
ON/OFF
T/M
3rd Clutch
ON/OFF
ON/OFF
T/M
4th Clutch
ON/OFF
ON/OFF
T/M
Shift Lever 1
ON/OFF
ON/OFF
T/M
Shift Lever 2
ON/OFF
ON/OFF
T/M
Shift Lever 3
ON/OFF
ON/OFF
T/M
Shift Lever 4
ON/OFF
ON/OFF
T/M
Shift Lever 5
ON/OFF
ON/OFF
T/M
Shift Lever 6
ON/OFF
ON/OFF
T/M
Shift Lever 7
ON/OFF
ON/OFF
T/M
Shift Lever 8
ON/OFF
ON/OFF
T/M
Shift Lever P
ON/OFF
ON/OFF
T/M
Shift Lever N
ON/OFF
ON/OFF
T/M
Shift Lever NP
ON/OFF
ON/OFF
T/M
Shift Lever F
ON/OFF
ON/OFF
T/M
Shift Lever R
ON/OFF
ON/OFF
T/M
Gear Shift Mode Switch
ON/OFF
ON/OFF
T/M
94120
02216
02217
02211
02212
02213
02214
GD535-5 (01)
Trigger Initial Learning Flag 2
Clutch Fill Switch Input 1
Clutch Fill Switch Input 2
T/M Con. Switch Input 1
T/M Con. Switch Input 2
T/M Con. Switch Input 3
T/M Con. Switch Input 4
Remarks
30-117
Special functions of machine monitor
Monitoring code
02215
02218
02231
03705
30 Testing and adjusting
T/M Con. Switch Input 5
T/M Con. Switch Input 6
T/M Con. Switch Input 7
T/M Con. Switch Output 1
Unit SI
Non SI
Associated equipment
RPMSet MODEAUTO
ON/OFF
ON/OFF
T/M
RPMSet MODEMANU
ON/OFF
ON/OFF
T/M
RPMSet ACCEL/ SET
ON/OFF
ON/OFF
T/M
RPMSet DECELL/ RESUM
ON/OFF
ON/OFF
T/M
Differential Switch
ON/OFF
ON/OFF
T/M
Engine Power Mode Selector Switch
ON/OFF
ON/OFF
T/M
Engine Starter
ON/OFF
ON/OFF
T/M
Stop Lamp Switch
ON/OFF
ON/OFF
T/M
Night Lighting SW
ON/OFF
ON/OFF
T/M
Front Brake Oil Press
ON/OFF
ON/OFF
T/M
Rear Brake Oil Press
ON/OFF
ON/OFF
T/M
Parking Brake Operating Relay
ON/OFF
ON/OFF
T/M
Differential Control Relay
ON/OFF
ON/OFF
T/M
Backup Lamp Relay
ON/OFF
ON/OFF
T/M
Engine Starter Relay
ON/OFF
ON/OFF
T/M
T/M Con. SelfHolding Relay
ON/OFF
ON/OFF
T/M
Monitoring item (Display on screen)
03706
T/M Con. Switch Output 2
20414
Assembly P/N (T/M Con.)
-
-
T/M
20413
Serial Number (T/M Con.)
-
-
T/M
20201
Software P/N (T/M Con.)
-
-
T/M
20223
Application Version (T/M Con.)
-
-
T/M
20224
Data Version (T/M Con.)
-
-
T/M
01001
Engine Speed (Tachometer)
r/min
rpm
MON
40000
Travel Speed (Speedometer)
km/h
MPH
MON
04202
Fuel Level Sensor [%]
%
%
MON
43910
Articulate Angle
deg.
deg.
MON
03220
Controller Power Voltage (MON)
V
V
MON
04306
Battery Charge Voltage (MON)
V
V
MON
F1
ON/OFF
ON/OFF
MON
F2
ON/OFF
ON/OFF
MON
F3
ON/OFF
ON/OFF
MON
F4
ON/OFF
ON/OFF
MON
04508
30-118
Monitor Input 1
Remarks
GD535-5 (01)
30 Testing and adjusting
Monitoring code
04509
Special functions of machine monitor
Monitor Input 2
Unit SI
Non SI
Associated equipment
F5
ON/OFF
ON/OFF
MON
F6
ON/OFF
ON/OFF
MON
F7
ON/OFF
ON/OFF
MON
F8
ON/OFF
ON/OFF
MON
Buzzer
ON/OFF
ON/OFF
MON
Personal Code Relay
ON/OFF
ON/OFF
MON
Monitoring item (Display on screen)
04700
Monitor Output
00205
Selected Machine (MON)
-
-
MON
20227
Assembly P/N (MON)
-
-
MON
20402
Serial No. (MON)
-
-
MON
20228
Software P/N (MON)
-
-
MON
20221
Application version (MON)
-
-
MON
20278
Data Version 1 (MON)
-
-
MON
20260
Assembly P/N (KOMTRAX)
-
-
MON
20418
Serial No. (KOMTRAX)
-
-
MON
20261
Software P/N (KOMTRAX)
-
-
MON
20273
Program Version (KOMTRAX)
-
-
MON
20262
Assembly P/N (ID Key Con.)
-
-
MON
20419
Serial No. (ID Key Con.)
-
-
MON
20263
Software P/N (ID Key Con.)
-
-
MON
Remarks
*1: "Fuel Rate" (code No. 37300) is theoretical fuel consumption. (It can slightly differ from actual fuel consumption rate because it is a theoretical value.) q Listing order in table Monitoring items are arranged in the order they are displayed on the monitoring item selection menu screen. q Unit The display unit can be set to either of "SI" or "Non SI" unit you prefer. (Switch the display unit to a desired one from "Unit Selection" of "Default" in the service menu.) "mg/st" of the display unit is an abbreviation for milligram/stroke. q Associated equipment ENG: The engine controller is responsible for collection of the monitoring information. T/M: The transmission controller is responsible for collection of the monitoring information. MON: The machine monitor is responsible for collection of the monitoring information.
GD535-5 (01)
30-119
Special functions of machine monitor
Abnormality Record (Mechanical System) The machine monitor records the past and currently occurring failures, classifying them into mechanical system abnormality and electrical system abnormality. Check the information of "Mechanical system abnormality record" according to the following procedure. For the failure code list, see "Failure code list" in Troubleshooting. 1. Select "Abnormality Record" on "Service Menu" screen. a For the selection method, see relevant section in "Service mode".
2. When "Abnormality Record" screen appears, operate function switches to select "Mechanical Systems". a For the selection method, see relevant section in "Service mode".
30 Testing and adjusting
F3: Returns screen to "Abnormality Record" screen.
a If no abnormality is recorded, the message "No Error" is displayed. a For the mechanical system abnormality record, up to 20 abnormalities in the record are displayed. a When the number of occurrences of an abnormality is 1 (first occurrence), the service meter reading at latest occurrence is the same as that at first occurrence. Since the value at the recovery is displayed as the service meter reading at latest occurrence, this may not apply. a If "E" is displayed on the left of a failure code, the abnormality is still occurring or correction of it is not confirmed. a For all of the failure codes that the machine monitor can record, see "Failure code list" in Troubleshooting. a If the number of characters to be displayed in the field for Detail of failure is large, the character string scrolls. a Abnormality record of the mechanical system cannot be deleted.
3. When the screen switches to "Mechanical Systems" screen, check the following information being displayed. a: Occurrence order of abnormalities from latest one/ Total number of records b: Failure code c: Detail of failure d: Number of occurrences (display range: 0 to 65535 times) e: Service meter reading at first occurrence f: Service meter reading at latest occurrence F1: Moves selection downward. F2: Moves selection upward.
30-120
GD535-5 (01)
30 Testing and adjusting
Abnormality Record (Electrical System) The machine monitor records the past and currently occurring failures classifying them into the mechanical system abnormality and electrical system abnormality. Check the information of "Electrical system abnormality record" according to the following procedure. For all of the failure codes that the machine monitor can record, see "Failure code list" in Troubleshooting. 1. Select "Abnormality Record" on "Service Menu" screen. a For the selection method, see relevant section in "Service mode".
2. When "Abnormality Record" screen appears, operate function switches to select "Electrical Systems". a For the selection method, see relevant section in "Service mode".
Special functions of machine monitor
F3: Returns screen to "Abnormality Record" screen.
a If no abnormality is recorded, the message "No Error" is displayed. a For the electrical system abnormality record, up to 20 abnormalities in the record are displayed. If the number of records reaches 21 or more, failure codes of later occurrences are displayed and those of older occurrences are cleared starting from the oldest one. a When the number of occurrences of an abnormality is 1 (first occurrence), the service meter reading at latest occurrence is the same as that at first occurrence. a If "E" is displayed on the left of a failure code, the abnormality is still occurring or correction of it is not confirmed. a For all of the failure codes that the machine monitor can record, see "Failure code list" in Troubleshooting. a If the number of characters to be displayed in the field for Detail of failure is large, the character string scrolls. 4. To clear the abnormality record information, perform following operations by using function switches with "Electrical Systems" screen being displayed. 1) Switch operation (while keep pressing F8): Press switches in the order of F1, F2, and F3.
3. When the screen switches to "Electrical Systems" screen, check the following information being displayed. a: Occurrence order of abnormalities from latest one/ Total number of records b: Failure code c: Detail of failure d: Number of occurrences (display range: 0 to 65535 times) e: Service meter reading at first occurrence f: Service meter reading at latest occurrence F1: Moves selection downward. F2: Moves selection upward.
GD535-5 (01)
30-121
Special functions of machine monitor
2) Check that the screen display is in the clear mode, use function switches to clear a piece of information individually or to clear all information collectively. a If "CLEAR" appears on the left of F8, the screen display comes to the clear mode. F1: Moves selection downward. F2: Moves selection upward. F3: Returns screen to "Abnormality Record" screen. F4: Executes deletion of selected abnormality records. F8: Executes deletion of all abnormality records.
30 Testing and adjusting
a Screen display when deletion of all abnormality records is tried
4) If the screen to notify the completion of deletion appears and then "Electrical Systems" screen (clear mode)"is displayed, deletion of selected abnormality record is complete. a Screen display when deletion of selected abnormality records is completed
a To clear a selected abnormality record, select the abnormality record with F1 or F2, and then press F4 to implement deletion of the abnormality record. a To clear all abnormality records together, press F8, and then all the records are cleared regardless of the selection. a If "E" is displayed on the left of a failure code, the clearing operation is accepted but the item is not cleared. 3) When "Electrical Sys. Error Reset" screen appears, operate function switches to execute deletion. F3: Returns screen to "Electrical Systems" screen (clear mode). F4: Executes deletion. a Screen display when deletion of selected abnormality records is tried
30-122
a Screen display when deletion of all abnormality records is completed
GD535-5 (01)
30 Testing and adjusting
Maintenance Time Reset The machine monitor allows reset of the maintenance remaining time of a maintenance item such as filter , oil, etc. when maintenance of them have been performed. 1. On "Service Menu" screen, select "Maintenance Time Reset". a For the selection method, see relevant section in "Service mode".
2. When "Maintenance Time Reset" screen is displayed, select items to reset by using function switches. a For the selection method, see relevant section in "Service mode".
Special functions of machine monitor
Items maintenance remaining time of which can be reset Code
Item
49
Air Cleaner Cleaning/Change
60
Coolant
41
Fuel Pre Filter
01
Engine Oil
02
Engine Oil Filter
13
T/M Oil Filter
03
Fuel Main Filter
12
T/M Oil
15
Axle Oil
04
Hydraulic Oil Filter
10
Hydraulic Oil
37
Circle Case Oil
36
Tandem Case Oil
3. When "Maintenance Time Reset" confirmation screen is displayed, execute the reset by using function switches. F3: Cancels reset and returns screen to "Maintenance Time Reset" screen. F4: Moves screen to "Maintenance Time Reset" reconfirmation screen.
4. When "Maintenance Time Reset" reconfirmation screen is displayed, execute the reset by using function switches. F3: Cancels reset and returns screen to "Maintenance Time Reset" screen. F4: Executes reset.
GD535-5 (01)
30-123
Special functions of machine monitor
30 Testing and adjusting
Maintenance Record The machine monitor records maintenance information of filters, oil, etc. The information can be displayed and checked according to the following procedure. When "Maintenance Time Reset" is executed in the operator mode or service mode after the maintenance of an item has been completed, the number of maintenance operations is recorded in this record. 1. On "Service Menu" screen, select "Maintenance Record". a For the selection method, see relevant section in "Service mode".
2. When "Maintenance Record" screen is displayed, select items to check by using function switches. F1: Moves selection downward. F2: Moves selection upward. F3: Returns screen to "Service Menu" screen. F8: Moves screen to code entry screen.
30-124
GD535-5 (01)
30 Testing and adjusting
Special functions of machine monitor
Selectable items in Maintenance Record Code
Item
49
Air Cleaner Cleaning/Change
60
Coolant
41
Fuel Pre Filter
01
Engine Oil
02
Engine Oil Filter
13
T/M Oil Filter
03
Fuel Main Filter
12
T/M Oil
15
Axle Oil
04
Hydraulic Oil Filter
10
Hydraulic Oil
37
Circle Case Oil
36
Tandem Case Oil
Items displayed on Maintenance Record screen a: Maintenance item b: Number of replacement times until now c: SMR (service meter reading) at previous replacement d: Current SMR (service meter reading)
GD535-5 (01)
Maintenance Mode Setting This menu item can specify whether to enable or disable the maintenance item function and set the replacement time of a maintenance item. q To enable or disable the maintenance item function q To change the set time of replacement interval for each maintenance item (by item) q To initialize replacement interval settings of all maintenance items 1. On "Service Menu" screen, select "Maintenance Mode Setting". a For the selection method, see relevant section in "Service mode".
2. When "Maintenance Mode Setting" screen is displayed, select items to select by using function switches. a For the selection method, see relevant section in "Service mode".
30-125
Special functions of machine monitor
Selectable items in Maintenance Mode Setting Code
Item
00
Maintenance Mode Change
49
Air Cleaner Cleaning/Change
60
Coolant
41
Fuel Pre Filter
01
Engine Oil
02
Engine Oil Filter
13
T/M Oil Filter
03
Fuel Main Filter
12
T/M Oil
15
Axle Oil
04
Hydraulic Oil Filter
10
Hydraulic Oil
37
Circle Case Oil
99
All Default Value
3. When selected "Maintenance Mode Change" screen is displayed, select "Maintenance Mode On/Off", select "On" or "Off", and enter the selection by using function switches. ON: Function of all maintenance items becomes effective in operator mode. OFF: Function of all maintenance items becomes ineffective in operator mode. F1: Moves selection downward. F2: Moves selection upward. F3: Cancels selection and returns screen to "Maintenance Mode Setting" screen. F4: Enters selection and Moves screen to "Maintenance Mode On/Off" screen. a Once this change of setting is entered, the setting overrides the ON/OFF setting of each item.
4. When "Maintenance Notice TimeSet"is selected and its screen is displayed, set the maintenance notice time by using the function switches.
30-126
30 Testing and adjusting
Default: Maintenance notice time set in machine monitor (unchangeable value recommended by the manufacturer) Set value: Maintenance interval that can be freely set. Maintenance reminder function works according to this set time in operator mode (the time increases or decreases in multiples of 10 hours). F1: Decreases set value. F2: Increases set value F3: Cancels set value and returns screen to "Maintenance Mode Change" screen. F4: Enters set value and returns screen to "Maintenance Mode Change" screen. F8: Cancels contents of setting not yet entered.
a When F4 is pressed to enter the set value, the screen returns to "Maintenance Mode Change" screen and the set value becomes effective. a If the set value of an item maintenance reminder function of which is set to "ON" is changed after 1 operating hour or more from the setup, the change is recognized as a reset of the remaining time. 5. When an individual maintenance item is selected and the screen for the individual maintenance item is displayed, select "OFF/ON Set". F1: Moves selection downward. F2: Moves selection upward. F3: Cancels selection and returns screen to "Maintenance Mode Setting" screen. F4: Enters selection and moves screen to "ON" or "OFF" screen for individual maintenance item F8: Moves screen to code entry screen.
GD535-5 (01)
30 Testing and adjusting
Special functions of machine monitor
F3: Cancels set value and returns screen to the screen for individual maintenance item. F4: Enters set value and returns screen to the screen for individual maintenance item. F8: Cancels contents of setting not yet entered.
a The screen display is an example of "Engine Oil replacement". a For the selection method, see "Operation method of service mode" in "Service mode". 6. When the screen for the individual maintenance item is displayed, select "ON" or "OFF" by using function switches. ON: Function of individual maintenance item becomes effective in operator mode. OFF: Function of individual maintenance item becomes ineffective in operator mode. F1: Moves selection downward. F2: Moves selection upward. F3: Cancels selection and returns screen to the screen for individual maintenance item. F4: Enters selection and returns screen to the screen for individual maintenance item.
7. When "Set"is selected and "Set" screen for the individual maintenance item is displayed, set the maintenance interval by using the function switches. Default: Maintenance notice time set in machine monitor (unchangeable value recommended by the manufacturer) Set value: Maintenance interval that can be freely set. Maintenance reminder function works according to this set time in operator mode (the time increases or decreases in multiples of 25 hours). F1: Decreases set value. F2: Increases set value
GD535-5 (01)
a When F4 is pressed to enter the set value, the screen returns to the screen for individual maintenance item and the set value becomes effective. a If the set value of an item maintenance reminder function of which is set to "ON" is changed after 1 operating hour or more from the setup, the change is recognized as a reset of the remaining time. 8. When "All Default Value" is selected and its screen is displayed, enter the setting by using function switches. If this menu item is executed, the set values of all the maintenance items are returned to their default values. F3: Returns screen to "Maintenance Mode Setting" screen. F4: Executes initialization. a After F4 is pressed, in a short time, the initialization completion screen is displayed. When "Maintenance Mode Setting" screen is displayed, initialization is complete.
30-127
Special functions of machine monitor
30 Testing and adjusting
Phone Number Entry The telephone number, which is displayed together with the "Error List" in the operator mode, can be input and changed according to the following procedure. To allow the telephone number to appear in the operator mode, it is required to input it by using this function in advance. 1. Select "Phone Number Entry" on service menu screen. a For the selection method, see relevant section in "Service mode".
2. When "Phone Number Entry" screen appears, register or correct the telephone number by using function switches. F1: Decreases number. F2: Increases number. F3: Returns screen to "Service Menu" screen. F4: Enters input. F6: Moves input position to left (except blank). F7: Moves input position to right (except blank). F8: Clears all input numerals. a The telephone number can be input with up to 14 digits flush on the left. Leave unused boxes blank. a If an input numeral is wrong, move the input position (orange background) to that digit and overwrite it with the correct numeral. a If F4 is pressed without inputting a digit, there is no information of a telephone number. Accordingly, no telephone number is displayed in the operator mode.
30-128
GD535-5 (01)
30 Testing and adjusting
Default (Machine Model Select) Default menu items are used to check or change various settings of the machine monitor and machine. "Machine Model Select" function to make controllers recognize the current machine model. 1. Select "Default" on the service menu screen. a For the selection method, see relevant section in "Service mode".
2. When "Default" screen appears, select "Machine Model Select". a For the selection method, see relevant section in "Service mode".
3. With "Machine Model Select" screen being displayed, operate function switches as described below. Switch operation (while keep pressing F8): Press switches in the order of F1, F2, and F3.
GD535-5 (01)
Special functions of machine monitor
4. Selection of machine model becomes possible. Select a machine model of the machine. F1: Moves selection downward. F2: Moves selection upward. F3: Cancels selection and returns screen to "Default" screen. F4: Enters selection.
a Selectable machine model displayed is only GD535. a When the selection of machine model is entered, respective settings become as follows. "Monitoring/Custom": Monitoring item being held is cleared. "Maintenance Mode Setting": Settings of "OFF/ ON" and "Maintenance Notice TimeSet" are returned to their default for the machine. "De faul t (O pt ion S ele cti on )" : S ett ing i s returned to default for the machine. "ECO Guidance": All fuel consumption data is cleared. a When the monitor controller is replaced with a new one that has recognized no machine model, if the service menu is opened for the first time, "Machine Model Select" screen shown below is displayed. Select the machine model first on the screen. (The screen display may be somewhat different from that when a machine model has already been selected.)
30-129
Special functions of machine monitor
5. When the screen requesting key-off operation is displayed, turn the starting switch to OFF position. 6. Turn the starting switch to ON position again.
30 Testing and adjusting
Default (Option Selection) Default menu items are used to check or change various settings of the machine monitor and machine. When all settings of "Option Selection" are reset after "Machine Model Select" in Default has been performed or when an optional equipment is retrofitted, "Option Selection" function in used to make the optional equipment enabled. 1. Select "Default" on "Service Menu" screen. a For the selection method, see relevant section in "Service mode".
Referring to the section in "Default (Option Selection)", perform "Default (Option Selection)".
2. When "Default" screen appears, select "Option Selection". a For the selection method, see relevant section in "Service mode".
3. When "Option Selection" screen appears, check whether optional equipment are installed or not to the machine, and select respective items. F1: Moves selection downward. F2: Moves selection upward. F3: Cancels selection and returns screen to "Default" screen. F4: Enters selection. F8: Moves screen to code entry screen. a When the current settings are acceptable, select either one of the items and press function switch F4 without changing the setting, and the settings apply to the machine.
30-130
GD535-5 (01)
30 Testing and adjusting
Special functions of machine monitor
5. Select "Tire Size Compensation" item to correct the set value. F1: Decreases set value by 1 %. F2: Increases set value by 1 %. F3: Cancels contents of setting not yet entered and returns screen to "Option Selection" screen. F4: Enters selection and returns screen to "Option Selection" screen.
4. When the setting screen of each item is displayed, select a setting by using function switches. F1: Moves selection downward. F2: Moves selection upward. F3: Cancels selection and returns screen to "Option Selection" screen. F4: Enters selection. 6. When settings of respective items are complete, press function switch F3 to return the screen from "Option Selection" screen to "Default" screen. a When you have never pressed function switch F4 (no change is made) for any item setting, even if you exit "Option Selection" screen and return to "Default" screen, this screen does not appear. 7. When the screen requesting key-off operation is displayed, turn the starting switch to OFF position. Items that can be set by using Option Selection function Item name
Default
Remarks
Differential Select "ADD" when the option NO ADD Control equipment is installed. Tire Type
Tire Size Compensation
GD535-5 (01)
13.00When 13.00-24-12PR tire is 24-12PR installed, select 13.00-24-12PR.
0%
If indicated travel speed is deemed to be different from actual speed, use this function to adjust it. (Each time the set value is increased by 1 %, indicated travel speed increases by 1 % relative to that at 0 %. See step 4.
Turning the starting switch to OFF position completes setting of "Option Selection".
30-131
Special functions of machine monitor
30 Testing and adjusting
Default (Unit Selection) Default menu items are used to check or change various settings of the machine monitor and machine. The Unit Selection function is used to select a display unit for the data to be displayed in the monitoring. 1. Select "Default" on "Service Menu" screen. a For the selection method, see relevant section in "Service mode".
Diagnostic Tests (Cylinder Cut-out) Use Diagnostic Tests menu items to check the machine monitor and machine or reset the settings. Cylinder cutout mode operation means to run the engine with one or more fuel injectors disabled electrically to reduce the number of effective cylinders. This operation is used to identify a cylinder that does not output power normally (combustion in it is abnormal). 2. When "Default" screen is displayed, select "Unit Selection" by using function switches. a For the selection method, see relevant section in "Service mode".
1. Select "Diagnostic Tests" on "Service Menu" screen. a For the selection method, see relevant section in "Service mode".
3. When "Unit Selection" screen is displayed, select the display unit to be set by using function switches. F1: Moves selection downward. F2: Moves selection upward. F3: Cancels selection and returns screen to "Default" screen. F4: Enters selection and returns the display to "Default" screen
2. When "Diagnostic Tests" screen is displayed, select "Cylinder Cut-out" by using function switches. a For the selection method, see relevant section in "Service mode".
30-132
GD535-5 (01)
30 Testing and adjusting
3. When "Cylinder Cut-out" screen is displayed, select a cylinder to be cut out by using the function switches. F2: Switches setting between HOLD and HOLD CANCELED. (If HOLD is selected, a diagonal appears in HOLD box.) F3: Returns screen to "Diagnostic Tests" screen. F4: Enters selection. F6: Moves selection leftward F7: Moves selection rightward
a This operation is allowed while the engine is running. a If background (a) of the selected cylinder number becomes white after you press F4, the cylinder is cut out. a If the machine monitor cuts out a cylinder but the engine controller cannot cut out that cylinder, the background (a) of the cylinder number becomes yellow. a One or more cylinders can be cut out. a The HOLD function is available for a cylinder, regardless of whether it is cut out or not. If a normally operating cylinder is cut out, the following phenomena occur. If the engine is running at near high idle, however, the engine speed may not lower for the reason of engine control. In this case, lower the engine speed with the accelerator pedal and judge by increase of the injection rate command. q Lowered engine speed q Increased Fuel Inject Command (quantity) 4. When changing a cylinder to be cut out or when cylinder cutout operation is finished, select a cutout cylinder to be reset with function switches. q The method to select a cutout cylinder to be reset is the same as that to select a cylinder to be cut out. q This operation is allowed while the engine is running. q When F4 is pressed, if background (a) of the selected cylinder number becomes gray, the cylinder is reset. q If the machine monitor reset a cutout cylinder but the engine controller cannot reset that cyl-
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q
inder, the background (a) of the cylinder number becomes red. The cylinder cut-out mode operation is not automatically reset even if the machine monitor returns to the operator mode. Accordingly, be sure to perform the reset operation after the cylinder cutout mode operation is finished.
Adjustment (ECMV Automatic Compensation) k Park the machine on flat ground, place the work equipment on the ground surely, set the gear shift lever to P (PARK) position, and then stop the engine. k Chock the tires to prevent the machine from moving. Use Adjustment menu items to check various settings or adjustment of the machine. Perform this Adjustment item under the following conditions. q Torque converter oil temperature: 70 to 90°C "ECMV Automatic Compensation" function is used to correct the variation in operational feeling among ECMVs due to the individual difference so that the variation is kept at a certain level through the transmission controller. 1. Start the engine. 2. Select "Adjustment" on "Service Menu" screen. a For the selection method, see relevant section in "Service mode".
3. When Adjustment screen is displayed, select "T/C Stall" by using function switches. a For the selection method, see relevant section in "Service mode".
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6. If "T/C Stall (01/02)" screen is displayed, confirmation of the change is requested. In this case, press F4 to enter the change. (a): Current setting (b): Revised setting When "F4" is pressed, "1" is displayed for (a) enabling the torque converter stall mode. The transmission mode is fixed to torque converter automatic mode (T/C AUTO) and the gear speed is fixed to N (neutral) or F8 gear. a If F3 is pressed and the screen is returned to "Adjustment" screen, the set mode is disabled. 4. When "T/C Stall (01/02)" screen is displayed, press function switches. a If "5" (Out of Condition) is displayed for (a), the gear shift lever is not set at P (PARK) position. Move the gear shift lever to P (PARK) position.
7. Display "T/C Stall (02/02)" screen. F6 and F7: Moves screen to "T/C Stall (02/02)" screen. 8. Depress the brake pedal with your left foot surely.
5. When the screen with "revised value input box" screen is displayed, input value 1 for the torque converter stall mode and enter it by using function switches. F1: Decreases number. F2: Increases number. F3: Cancels input. F4: Enters input. F6 and F7: Moves screen to "T/C Stall (02/02)" screen. 9. Move the gear shift lever to F8 position. 10. Depress the accelerator pedal gradually to stall the torque converter so that the torque converter oil temperature rises to 90°C. k Do not keep stalling torque converter for more than 20 seconds. Take care that torque converter oil temperature does not exceed 120°C. 11. When the torque converter oil temperature reaches 90°C, release your right foot from the accelerator pedal (low idle) immediately, and return the gear shift lever to P (PARK) position.
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k
Do not operate the gear shift lever with the accelerator pedal kept depressed. Doing so causes large gear shift shocks and shortens the service life of the machine as well.
Special functions of machine monitor
F2: Switches setting for monitoring value between HOLD and HOLD CANCELED. (If HOLD is selected, a diagonal appears in HOLD box.)
12. Run the engine at medium speeds and release your right foot from the accelerator pedal when the torque converter oil temperature lowers to 80°C. a Keep the gear shift lever set at P (PARK) position. 13. Repeat steps 8. to 12. 4 to 5 times to equalize the oil temperature of the torque converter and transmission. 14. Press F3 to return the screen to "Service Menu" screen and select "Adjustment" . a For the selection method, see relevant section in "Service mode".
15. When "Adjustment" screen is displayed, select "ECMV Automatic Compensation" by using function switches. a For the selection method, see relevant section in "Service mode".
When "ECMV Automatic Compensation" starts, the adjustment of each valve is conducted 4 times automatically and continuously. a During "ECMV Automatic Compensation", "- - -" is displayed for (c). a ECMV adjustment order and screen display (b) on the machine monitor are as follows.
16. When START is displayed for part (a), press F4 to start the adjustment. F3: Returns screen to "Adjustment" screen without starting adjustment. F4: Starts adjustment. F6 and F7: Moves screen to "ECMV Automatic Compensation (02/02)" screen.
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ECMV adjustment order and screen display on machine monitor Adjustment order
ECMV
Screen display (b) on machine monitor
1
FL
FL-1
FL-2
FL-3
FL-4
2
FH
FH-1
FH-2
FH-3
FH-4
3
R
R-1
R-2
R-3
R-4
4
1st
1-1
1-2
1-3
1-4
5
2nd
2-1
2-2
2-3
2-4
6
3rd
3-1
3-2
3-3
3-4
7
4th
4-1
4-2
4-3
4-4
1st time 2nd time 3rd time 4th time
17. For each adjustment work, whether it ends normally ("OK") or abnormally ("NG") is displayed. Take actions according to the displayed result. q Screen display at normal end When "4-4" (the last ECMV) and "0" (OK) is displayed for (b) and (c) respectively, all ECMVs are normal. q When "0": OK (normal end) is displayed: Adjustment work ends normally, so go to step 18. (b): ECMV for which adjustment ends normally (c): Adjustment result
q
Screen display at abnormal end When other than "0" (OK) is displayed for (c), the ECMV has an abnormality or the machine is NG (out of adjustment condition). Abnormal valve is displayed for (b). Conditions displayed for (c) and actions to take are as follows. q When "1: NG (Out Condition)" is displayed: Check the torque converter oil temperature and conditions at the adjustment again, and perform the adjustment work from step 1. q When "2:NG (No Fill Signal)" is displayed: Perform troubleshooting for failure codes
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q
[15S*MA] and [DXH*KA]. If the valve and conditions are determined to be normal, repeat the work from step 1. a The mark * denotes target clutch. When "3: NG (Over Compensation)" is displayed: Perform troubleshooting for failure code [15S*L1]. If the valve and conditions are determined to be normal, repeat the work from step 1. a The mark * denotes target clutch.
18. If the adjustment work ends normally, turn the starting switch to OFF position. a The adjusted value is saved in the transmission controller approximately 3 seconds after the starting switch is turned to OFF position. a After the adjustment, if it is needed to turn the starting switch to ON position promptly, wait 10 seconds or more after the starting switch is turned to OFF position by way of precaution, and then turn it to ON position, Adjustment (T/M Initial Learning) k Be sure to perform the learning work in a place where an ample traveling area is available while paying attention to safety in the surrounding area. Use Adjustment menu items to check various settings or adjustment of the machine. Perform this Adjustment item under the following conditions. q Torque converter oil temperature: 70 to 90°C q Power mode: P mode q Transmission mode: Manual mode (MANU) 1. Referring to "ECMV Automatic Compensation", correct the individual difference in operational feeling of each ECMV. 2. Hold the torque converter oil temperature within the range of temperature conditions. k If the adjustment is performed with the oil at a temperature out of the range of temperature conditions, a time lag or gear shift shock may occur.
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a For the method to increase the torque converter oil temperature, see "ECMV Automatic Compensation".
3. Initialize the initial learning data of the transmission. For details, see "Adjustment (T/M Initial Learning Reset)". 4. Set the transmission mode selector switch to the manual (MANU) mode.
5. Select P mode by using the power mode selector switch. When P mode is selected, the power mode symbol A shown below lights up on the machine monitor.
7. When "Adjustment" screen is displayed, select "T/ M Initial Learning" by using function switches. a For the selection method, see "Operation method of service mode" in "Service mode".
8. When "T/M Initial Learning (01/03)" screen is displayed, operate the accelerator pedal and gear shift lever according to the order shown in the following table. k Do not use the inching pedal to start and stop the machine or to make directional change in this adjustment. If the inching pedal is used, the "learning" of each clutch may not complete successfully. k Operating the gear shift lever causes the machine to move. Pay attention to safety in the surrounding area. F2: Switches setting for monitoring value between HOLD and HOLD CANCELED. (If HOLD is selected, a diagonal appears in HOLD box.) F3: Returns screen to "Adjustment" screen.
6. Select "Adjustment" on "Service Menu" screen. a For the selection method, see relevant section in "Service mode".
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Order
1
2
3
4
5
6
7
8
9
10
11
Directional lever
N
F1
F2
F3
F4
F3
F2
F1
N
R1
N
Accelerator pedal
Depress Depress Depress Depress to the to the to the to the Do not Do not Do not Do not Do not Do not Do not stroke stroke stroke stroke depress. depress. depress. depress. depress. depress. depress. end. end. end. end.
Holding time (at minimum)
5 10 3 3 40 3 3 3 10 3 3 seconds seconds seconds seconds seconds seconds seconds seconds seconds seconds seconds
9. After the machine stops, check the learning status of each clutch. q If "OFF" is displayed for any clutch, the learning has not been completed. In this case, do this adjustment item again starting from step 3. Initialization of the initial learning data of the transmission.
q
F7: Moves screen to "T/M Initial Learning (03/ 03)" screen.
When "ON" is displayed for all clutches and the learning has completed successfully, display "T/M Initial Learning (01/03)" screen and press F3 several times to return to the standard screen, and then turn the starting switch to OFF position. F3: Returns screen to "Adjustment" screen. F6: Moves screen to "T/M Initial Learning (02/ 03)" screen.
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Adjustment (T/M Initial Learning Reset) Use Adjustment menu items to check various settings or adjustment of the machine. This function is used to initialize the initial learning data of the transmission through the transmission controller. Perform this adjustment item if needed when executing the initial learning of the transmission. 1. Select "Adjustment" on "Service Menu" screen. a For the selection method, see relevant section in "Service mode".
4. When the screen appears, press F4 again to execute reset.
2. When "Adjustment" screen is displayed, select "T/ M Initial Learning Reset" by using function switches. a For the selection method, see relevant section in "Service mode".
3. When "T/M Initial Learning Reset" screen is displayed, check initialization status (a). q When "0: Learning Completed" is displayed, press F4 to go to step 4. q When "1: Learning Not Done Yet" is displayed, go to step 5.
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5. After the execution of reset, check that "1: Learning Not Done Yet" is displayed for initialization status (a), and then press F3.
This indicates that the initial learning data of the transmission has been initialized. Perform the adjustment item "T/M Initial Learning".
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Adjustment (Inching Pedal 0% Adjustment) Use Adjustment menu items to check various settings of the machine. This function is used to make the transmission controller recognize the neutral position of the inching pedal when it is not depressed. Be sure to perform this adjustment item after replacement of the transmission controller or removal and installation of the inching pedal. 1. Select "Adjustment" on "Service Menu" screen. a For the selection method, see relevant section in "Service mode".
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When "0" is displayed for (a) The machine monitor is waiting for execution of this adjustment. Proceed to the next step. q When "2" is displayed for (a) The output voltage of the inching pedal sensor is a value that indicates defective adjustment. Check the inching pedal for possible causes such as poor contact of the connector, defective installation of the inching pedal, etc. When "1" is displayed for (a), the transmission controller recognizes the neutral position of the inching pedal. q
2. When "Adjustment" screen is displayed, select "Inching Pedal 0% Adjustment" by using function switches. a For the selection method, see relevant section in "Service mode". 3. Check that the gear shift lever is set at P (PARK) position. a If the gear shift lever is set at a position other than P (PARK), this adjustment cannot be allowed. 5. Display "Inching Pedal 0% Adjustment (02/02)" screen and check the value of "Inching Pedal Sensor Volt". F6 and F7: Moves screen to "Inching Pedal 0% Adjustment (02/02)" screen. a Normal output voltage when the inching pedal is at its neutral position ranges as follows. q "Inching Pedal Sensor Volt": 1.26 to 1.56 V q F2: Switches setting for monitoring value between HOLD and HOLD CANCELED. (If HOLD is selected, a diagonal appears in HOLD box.) 4. When "Inching Pedal 0% Adjustment (01/02)" screen is displayed, enter the setting by using function switches. F3: Cancels execution of adjustment and returns screen to "Adjustment" screen. F4: Executes adjustment
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Adjustment (Inching Pedal 100% Adjustment) Use Adjustment menu items to check various settings of the machine. This function is used to make the transmission controller recognize the position of the inching pedal when it is depressed to its stroke end. Be sure to perform this adjustment item after replacement of the transmission controller or removal and installation of the inching pedal. 1. Select "Adjustment" on "Service Menu" screen. a For the selection method, see relevant section in "Service mode".
2. When "Adjustment" screen is displayed, select "Inching Pedal 100% Adjustment" by using function switches. a For the selection method, see relevant section in "Service mode". 3. Check that the gear shift lever is set at P (PARK) position. a If the gear shift lever is set at a position other than P (PARK), this adjustment cannot be allowed.
4. When "Inching Pedal 100% Adjustment (01/02)" screen is displayed, depress the inching pedal to its stroke end. q When "0" is displayed for (a) after the inching pedal is depressed The machine monitor is waiting for execution of this adjustment. Proceed to the next step.
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When "2" is displayed for (a) after the inching pedal is depressed The output voltage of the inching pedal sensor is a value that indicates defective adjustment. Check the inching pedal for possible causes such as poor contact of the connector, defective installation of the inching pedal, etc. a When "1" is displayed for (a), the transmission controller recognizes the stroke end position of the inching pedal.
q
5. Enter the setting by using function switches. F3: Cancels execution of adjustment and returns screen to "Adjustment" screen. F4: Executes adjustment F6 and F7: Moves screen to "Inching Pedal 100% Adjustment (02/02)" screen. 6. Display "Inching Pedal 100% Adjustment (02/02)" screen and check the value of "Inching Pedal Sensor Volt". a Normal output voltage when the inching pedal is depressed to its stroke end ranges as follows. q "Inching Pedal Sensor Volt": 3.41 to 3.71 V q F2: Switches setting for monitoring value between HOLD and HOLD CANCELED. (If HOLD is selected, a diagonal appears in HOLD box.)
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Adjustment (T/C Stall) Use Adjustment menu items to check various settings of the machine. This function is used to execute torque converter stall operation safely with the transmission mode and gear speed being fixed. Be sure to use this function when testing the machine under the torque converter stall condition. 1. Select "Adjustment" on "Service Menu" screen. a For the selection method, see relevant section in "Service mode".
2. When "Adjustment" screen is displayed, select "T/ C Stall" by using function switches. a For the selection method, see relevant section in "Service mode".
3. When "T/C Stall (01/02)" screen is displayed, press function switches. q When "0" is displayed for (a) The machine is currently in the normal working mode in which both the transmission mode and gear speed are not fixed. q When "1" is displayed for (a) The machine is currently set in the torque converter stall mode q When "5" is displayed for (a) Since the gear shift lever is not set at P (PARK) position, the machine is determined to be out of the fixing conditions. Move the gear shift lever to P (PARK) position.
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4. When the screen with "revised value input box" screen is displayed, input the number (0 or 1) for the desired mode and enter it by using function switches. q When "0: Normal" is selected: The machine is in the normal working mode in which both the transmission mode and gear speed are not fixed. Select this value to recover the normal working mode after the testing is finished. q When "1: T/C Stall" is selected: Select this value to test the machine in the torque converter stall mode. F1: Decreases number. F2: Increases number. F3: Cancels input. F4: Enters input. F6 and F7: Moves screen to "T/C Stall (02/02)" screen.
5. If "T/C Stall (01/02)" screen is displayed, confirmation of the change is requested. In this case, press F4 to enter the change. (a): Current setting (b): Revised setting
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Adjustment (Zero Point Adjustment For Art Angle) Use Adjustment menu items to check various settings of the machine. This function is used to make the transmission controller recognize the zero point of the articulate angle sensor. Be sure to perform this adjustment item after replacement of the transmission controller or removal and installation of the articulate angle sensor. 1. Set the machine in the straight travel posture, and insert the articulate lock pin in the locked position. 2. Check that installed length (a) of rod (2) that is installed to articulate angle sensor (1) is correct. a Installed length (a) of rod (2): 241 mm When the change is entered, a number (0 or 1) of selected mode is displayed for (a). a If F3 is pressed and the screen is returned to "Adjustment" screen, the set mode is disabled. a The gear speed during torque converter stall is determined depending on the gear shift lever position as shown in "List of gear shift lever position and gear speed".
3. Select "Adjustment" on "Service Menu" screen. a For the selection method, see relevant section in "Service mode".
List of gear shift lever position and gear speed Gear shift lever position
Gear speed
F8
F8
F1 to F7
N
N
N
R1 to R4
N
Since the machine is set in the selected mode, execute normal work or testing under the torque converter stall condition according to the set mode.
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4. When "Adjustment" screen is displayed, select "Zero Point Adjustment For Art Angle" by using function switches. a For the selection method, see relevant section in "Service mode".
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5. When "Zero Point Adjustment For Art Angle" screen is displayed, check output value (b) of the articulate angle sensor. (a): Current set value recognized by transmission controller (b) Output value of articulate angle sensor q When output value (b) of articulate angle sensor is within the setting range Proceed to the next step. q When output value (b) of articulate angle sensor is out of the setting range The zero point of the articulate angle sensor cannot be set. Check for possible causes such as poor contact of the connector, defective installation of the rod, etc.
a Setting range of articulate angle sensor: 2.1 to 2.6 V 6. Enter execution of the adjustment by using function switches. F3: Cancels execution of adjustment and returns screen to "Adjustment" screen. F4: Executes adjustment When the output value of the articulate angle sensor is displayed for (a), the transmission controller recognizes the zero point of the articulate angle sensor.
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No Injection If the engine is operated after long storage of the machine, it may be worn or damaged because of insufficient lubrication with oil. To prevent this, the machine has a function to crank the engine without injecting fuel to lubricate the engine before starting it. Set No Injection cranking while the engine is stopped. Even if the operator tries to perform No Injection cranking while the engine is running, the function is not enabled. This function can be selected even when the engine is running. However, if you execute No Injection cranking, a message "The engine is operating. Please turn the key off once." appears on the screen.
In the following cases, this function cannot be enabled even if the confirmation screen is displayed and No Injection cranking is activated. Turn the starting switch to OFF position once, and activate the function. q When communication between the machine monitor and engine controller is abnormal q When engine start operation is performed before the message "No Injection is possible" is displayed.
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2. When "No Injection" screen is displayed, the message to ask whether to execute No Injection cranking appears. Select the answer by using function switches. F3: Does not execute. (Returns screen to "Service Menu" screen.) F4: Executes.
3. When No Injection cranking (no fuel injection for all cylinders) is enabled, the message "No injection is possible. Please turn the key off after no injection ends." is displayed. Crank the engine by using the starting motor. k Do not crank the engine continuously for 20 seconds or longer in order to protect the starting motor. a While the screen is changing to the following screen, the screen of "Getting Ready" is displayed.
1. Select "No Injection" on the "Service Menu" screen. a For the selection method, see relevant section in "Service mode".
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KOMTRAX Settings (Terminal Status) KOMTRAX Settings screen allows check of setting status and operating condition of KOMTRAX. "KOMTRAX Settings (Terminal Status)" is used to check the setting condition of the KOMTRAX terminal. 1. Select "KOMTRAX Settings" on service menu screen. a For the selection method, see relevant section in "Service mode".
4. After the cranking is over, turn the starting switch to OFF position. You cannot switch the screen described above to another screen.
2. When "KOMTRAX Settings" screen is displayed, select "Terminal Status" by using function switches. a For the selection method, see relevant section in "Service mode".
3. Following information is displayed on "Terminal Status" screen. Terminal Type: Type of KOMTRAX communication modem KOMTRAX Communication: State of the implementation of KOMTRAX Communication opening GMT Time: Greenwich mean time (9 hours before Japan time) F3: Returns screen to "KOMTRAX Settings" screen.
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KOMTRAX Settings (GPS & Communication Status) KOMTRAX Settings screen allows check of setting status and operating condition of KOMTRAX. "GPS & Communication Status" is used to check the positioning and communication conditions of the KOMTRAX terminal. 1. Select "KOMTRAX Settings" on service menu screen. a For the selection method, see relevant section in "Service mode".
2. When "KOMTRAX Settings" screen is displayed, select "GPS & Communication Status" by using function switches. a For the selection method, see relevant section in "Service mode".
3. Following information is displayed on "GPS & Communication Status" screen. Positioning: Positioning condition of GPS Communication: Communication environment and connection status of communication modem No. of message(s) not yet sent: No. of mail messages that are stored in the machine monitor and have not yet been sent. F1: Moves screen to next page. F2: Moves screen to previous page. F3: Returns screen to "KOMTRAX Settings" screen.
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KOMTRAX Settings (Modem Status) KOMTRAX Settings screen allows check of setting status and operating condition of KOMTRAX. "Modem Status" is used to check the phone number and IMSI of KOMTRAX communication modem. 1. Select "KOMTRAX Settings" on service menu screen. a For the selection method, see relevant section in "Service mode".
2. When "KOMTRAX Settings" screen is displayed, select "Modem Status" by using function switches. a For the selection method, see relevant section in "Service mode".
Special functions of machine monitor
Service Message This function allows check of messages only for technicians from KOMTRAX base station (dealer, etc.). 1. Select "Service Message" on "Service Menu" screen. a For the selection method, see relevant section in "Service mode".
2. Display messages. q Displaying messages (read only) If there is a message, the contents are displayed. If there is no message, "No message." is displayed. F1: Moves screen to next page (displays if message extends over 2 or more pages). F2: Moves screen to previous page (displays if message extends over 2 or more pages). F3: Returns screen to "Service Menu" screen.
3. The phone number and IMSI are displayed F3: Returns screen to "KOMTRAX Settings" screen.
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a The messages differ from those sent in the operator mode for operators. a Since the messages are only for technicians, even if a message is received, no message symbol is displayed unlike in the case of the operator mode. q Displaying messages (with reply function) When the guidance icon is displayed for F4, pressing F4 displays the message reply screen.
1) When the message reply screen is displayed, input a numeral and enter it by using function switches. A message "Proceed?" will be displayed. F1: Decreases input value by 1. F2: Increases input value by 1. F3: Cancels input and return screen to "Service Menu" screen. F4: Enters input value.
2) When message "Proceed?" is displayed, if a numeral is input and entered, the information is returned to the KOMTRAX base station. F3: Cancels sending and returns screen to "Message Reply" screen. F4: Enters sending. a The messages differ from those sent in the operator mode for operators. a Since the messages are only for technicians, even if a message is received, no message symbol is displayed unlike in the case of the operator mode.
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Handling high-voltage circuit of engine controller
Handling high-voltage circuit of engine controller
1
1. Be sure to turn the starting switch to OFF position and disconnect the battery ground wire before disconnecting or connecting the connectors between the engine controller and engine. 2. When you perform troubleshooting, do not start the engine while a T-adapter is inserted into or connected to the connector between the engine controller and engine. a You may turn the starting switch to OFF or ON position but must not turn it to START position.
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KOMTRAX terminal start-up procedure
KOMTRAX terminal start-up procedure
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1
To use KOMTRAX , observe the following procedures. 1. KOMTRAX-Keyperson performs "Machine Registration" by using KOMTRAX client PC. 2. Perform "Machine side inspection for KOMTRAX Communication opening". q For operating procedures, see "Global KOMTRAX Web Reference Manual (For Key Person)". q Operating the KOMTRAX client PC requires the KOMTRAX operation administrator authority at each distributor. Therefore you must consult the KOMTRAX-Keyperson before using it. When KOMTRAX terminal is replaced. O bser ve the fol lowing pr oced ure when using KOMTRAX after replacement of KOMTRAX terminal. 1. Our technician provides a new terminal, and records the part number and serial number. 2. Our technician replaces the terminal with a new one and performs "Machine side inspection for KOMTRAX Communication opening". Our technician reports completion of the work and information on the new terminal to KOMTRAX-Keyperson. 3. KOMTRAX-Keyperson performs "Terminal Replacement" process by using KOMTRAX client PC. 4. KOMTRAX-Keyperson fills in required items on "Terminal Replacement Sheet", and sends it by email to KOMTRAX support center via KOMTRAX administrator in the subsidiary. q For operating procedures, see "Global KOMTRAX Web Reference Manual (For Key Person)". q Operating the KOMTRAX client PC requires the KOMTRAX operation administrator authority at each distributor. Therefore you must consult the KOMTRAX-Keyperson before using it. Machine side inspection for KOMTRAX Communication opening q When operation of the KOMTRAX terminal is started or the KOMTRAX terminal is replaced, inspection for KOMTRAX Communication opening must be done to check that the terminal can perform normal communication. q Implementation of the inspection for KOMTRAX Communication opening allows KOMTRAX to start communication. q To perform GPS and data communication check at the inspection for KOMTRAX communication opening, the machine should be desirably placed outside under an open sky where radio waves are not blocked. The KOMTRAX Communication opening may not be completed when the machine is placed indoors where radio waves from the satellite are blocked.
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1. Checking whether machine is subjected to inspection for KOMTRAX Communication opening Check whether implementation of inspection for KOMTRAX Communication opening is needed for the machine as follows. 1) On the "Service Menu" screen, select "KOMTRAX Settings" by using switches at the switch panel section. a For the selection method, see relevant section in "Service mode".
2) When "KOMTRAX Settings" screen is displayed, select "Terminal Status" by using function switches. a For the selection method, see relevant section in "Service mode".
3) When "Terminal Status" screen is displayed, check the status of KOMTRAX Communication. If "Not updated" is displayed for "KOMTRAX Communication", perform step 2. If "Already Open." is displayed, inspection for KOMTRAX Communication opening is not needed.
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2. Implementation of inspection for KOMTRAX Communication opening Implement KOMTRAX Communication opening according to the following procedure. 1) Select "KOMTRAX Settings" on "Service Menu" screen. a For the selection method, see relevant section in "Service mode".
2) When "KOMTRAX Settings" screen is displayed, select "GPS & Communication Status." a For the selection method, see relevant section in "Service mode".
KOMTRAX terminal start-up procedure
4) When the message "Are you sure you want to open?" is displayed, use function switches to implement the opening. F3: Returns screen to "GPS & Communication Status" screen. F4: Implements inspection for KOMTRAX Communication opening.
5) Implementation status of the inspection for KOMTRAX Communication opening is displayed. Check that "OK" is displayed for all items. "Modem": "OK" appears when it is determined to be within communication range. GPS: "OK" appears when it acquires GPS data. "Transmission": "OK" appears when it transmits data correctly. "Inspection Status": "OK" appears when "OK" is displayed for all of "Modem". "GPS", and "Transmission". q It takes 90 seconds to 15 minutes to approve all items.
3) When "GPS & Communication Status" screen is displayed, press function switches in the order of F1, F2, and F3 while keep pressing F8.
GD535-5 (01)
30-153
KOMTRAX terminal start-up procedure
30 Testing and adjusting
6) When all items are "OK", "KOMTRAX Communication Opened." screen is automatically displayed. Press the function switch. If "GPS & Communication Status" screen appears, the machine side inspection for KOMTRAX Communication opening is completed. In other cases than the above, perform step 3.
q
q
Moving to other screens, turning the starting switch to OFF position, or starting the engine during waiting time for "OK" being displayed for all items does not matter. If there is nothing abnormal, the inspection for KOMTRAX Communication opening finishes automatically. Select screens in the order of "Service Menu","KOMTRAX Settings", and "Terminal Status", and check that "Already Open." is indicated for the item "KOMTRAX Communication" on"Terminal Status" screen. The opening may not be completed when the machine is placed indoors where radio waves from the satellite are blocked.
3. Troubleshooting when inspection for KOMTRAX Communication opening resulted in abnormal end q If any of sub steps 1) to 5) in step 2. cannot be performed normally, perform the steps again from step 2.-1). q If step 2.-6) cannot be completed normally, possible causes are as follows.
Troubleshooting when inspection for KOMTRAX Communication opening resulted in abnormal end Symptom
Cause
Remedy
Something on the cab prevents monitoring of GPS Remove the obstacle on the cab. satellite.
"OK" is not displayed for GPS. GPS antenna cable is not connected to the machine monitor or loosely connected.
Mobile phone is out of communication range. "OK" is not displayed for Modem.
Check the connection and connect it surely if it is loose. Use a mobile phone in hand to check whether the machine is within communication range. If the machine is outside communication range, move it to a region within communication range to implement the inspection.
Communication antenna cable is not connected to Check the connection and connect it surely if it is KOMTRAX terminal or loosely connected. loose. KOMTRAX terminal is not connected to the wiring harness on machine side or loosely connected.
Check the connection and connect it surely if it is loose.
4. After the troubleshooting, perform the steps again from step 2.-1).
30-154
GD535-5 (01)
30 Testing and adjusting
KOMTRAX terminal start-up procedure
If the problem cannot be solved, contact the local support center.
GD535-5 (01)
30-155
Preparatory work for troubleshooting of electrical system failure
Preparatory work for troubleshooting of electrical system failure
1
30 Testing and adjusting
2. Engine controller a The engine controller is installed to the engine on the right side of the machine. 1) Open R.H. side cover (4).
a When performing troubleshooting of electric circuits of machine monitor, engine controller, and transmission controller, expose the applicable connector part according to the following procedure. 1. Machine monitor 1) Remove mounting bolts (1) and (2), and pull out machine monitor (3) toward the operator's seat.
2) Connect or insert T-adapters for troubleshooting to connectors ECM and EC2 of engine controller (5). a Since connectors ECM and EC2 are secured with screws, loosen the screws before disconnecting them. a When returning the connectors to the original state, tighten the screws to the specified torque to fix them.
2) Insert or connect T-adapters for troubleshooting into or to FP1 connector of the machine monitor.
30-156
3
Screw: 2.55 to 3.1 Nm {0.26 to 0.32 kgm}
GD535-5 (01)
30 Testing and adjusting
Preparatory work for troubleshooting of electrical system failure
3. Transmission controller a The transmission controller is installed in the rear section of operator's compartment (6).
1) Insert or connect T-adapters for troubleshooting into or to connectors TM39, TM40, and TM41 of transmission controller (7). a Since the connectors are secured with screws, loosen the screws before disconnecting them. a When returning the connectors to the original state, tighten the screws to the specified torque to fix them. 3 Screw: 2.82 Nm {0.288 kgm}
GD535-5 (01)
30-157
Pm Clinic
30 Testing and adjusting
Pm Clinic Pm Clinic
30-158
1
1
GD535-5 (01)
30 Testing and adjusting
Pm Clinic
Pm Clinic measurement location (1/3)
Reference item (page) for measurement procedure *1 Engine speed: Testing engine speed (30-16 page) *2 Blowby pressure: Testing blowby pressure (30-29 page) *3 Engine oil pressure: Testing engine oil pressure (30-30 page) *4 Boost pressure: Testing boost pressure (30-18 page) *5 Exhaust gas temperature: Testing exhaust gas temperature (30-20 page)
GD535-5 (01)
30-159
Pm Clinic
30 Testing and adjusting
Pm Clinic measurement location (2/3)
Reference item (page) for measurement procedure *6 Power train oil pressure: Testing power train oil pressure (30-48 page)
30-160
GD535-5 (01)
30 Testing and adjusting
Pm Clinic
Pm Clinic measurement location (3/3)
Reference item (page) for measurement procedure *7 Steering oil pressure: Testing and adjusting steering oil pressure (30-74 page) *8 Brake oil pressure: Testing and adjusting brake oil pressure (30-78 page) *9 Work equipment oil pressure: Testing work equipment oil pressure (30-89 page)
GD535-5 (01)
30-161
Pm Clinic
30 Testing and adjusting
Pm Clinic check sheet (1/3) Machine serial number
GD535-5 #
Engine serial No.
SAA6D107E - 1 #
Service meter reading
Inspector
Hours check
Work instruction
Date of inspection Year
Month
Day
h
Condition q q q
Engine speed q
q
Blowby pressure
q q
Engine
q q
Engine oil pressure
q
q
Boost pressure
q q q q
Exhaust gas temperature (turbocharger inlet temperature)
q q q q q q
Coolant temperature: 80 to 90°C Hydraulic oil temperature: 45 to 55°C Torque converter oil temperature: 60 to 80°C Select torque converter stall mode (when testing engine speed at torque converter stall).
Unit
Low idle E mode High idle P mode
Repair limit Standard value
750 to 850
750 to 850
Meas uring Result
1825 to 1925 1825 to 1925 rpm
Torque converter stall
Coolant temperature: 60 to 100°C Hydraulic oil temperature: 45 to 55°C Torque converter oil temperature: 60 to 80°C At rated horsepower
Standard value for new machine
Good
Item
No good
a Check after starting the engine. Keep torque converter oil temperature at 90°C or below during torque converter stall.
kPa {mmH2O}
2100 to 2200 2100 to 2200
1790 ± 1990
1790 ± 1990
Max. 1.17 {Max. 120}
Max. 1.96 {Max. 200}
Min. 0.29 {Min. 3.0}
Min. 0.25 {Min. 2.5}
Min. 0.10 {Min. 1.0}
Min. 0.07 {Min. 0.7}
Coolant temperature: 60 to 100°C High idle Engine Oil (*1) EO10W30-LA EO15W40-LA Low idle EOS5W30-LA EOS5W40-LA
MPa {kg/ cm2}
Coolant temperature: 60 to 100°C Hydraulic oil temperature: 45 to 55°C Torque converter oil temperature: 60 to 80°C At rated horsepower At aftercooler outlet
kPa {mmHg}
Min. 127 {Min. 950}
Min. 100 {Min. 750}
Coolant temperature: 60 to 100°C Hydraulic oil temperature: 45 to 55°C Torque converter oil temperature: 60 to 80°C Whole speed range Ambient temperature: 20°C At turbocharger inlet
°C
Max. 650
Max. 700
*1: KES diesel engine oil
30-162
GD535-5 (01)
Unit
q
q
Torque converter inlet pressure
Power train oil pressure
Torque converter outlet pressure
q
q
Torque converter lockup clutch pressure
FL
q
Transmission control valve set pressure
q q
Item
Brake accumulator charge pressure
q
q
Wheel brake operating pressure
q q q
Wheel brake braking distance
GD535-5 (01)
Torque converter oil temperature: 60 to 80°C Transmission oil temperature: 60 to 80°C Rated speed (2,000 rpm)
q q
Hydraulic oil temperature: 45 to 55°C With engine running at High idle
Max. 0.9 {Max. 9.2}
Max. 0.9 {Max. 9.2}
0.48 to 0.68 {4.9 to 6.9}
0.48 to 0.68 {4.9 to 6.9}
1.56 to 1.96 1.56 to 1.96 {16.0 to 20.0} {16.0 to 20.0} MPa {kg/cm2}
1.96 to 2.45 1.96 to 2.45 {20.0 to 25.0} {20.0 to 25.0} 1.96 to 2.45 1.96 to 2.45 {20.0 to 25.0} {20.0 to 25.0}
R
1.96 to 2.45 1.96 to 2.45 {20.0 to 25.0} {20.0 to 25.0}
1st
1.96 to 2.45 1.96 to 2.45 {20.0 to 25.0} {20.0 to 25.0}
2nd
1.96 to 2.45 1.96 to 2.45 {20.0 to 25.0} {20.0 to 25.0}
3rd
1.96 to 2.45 1.96 to 2.45 {20.0 to 25.0} {20.0 to 25.0}
4th
1.96 to 2.45 1.96 to 2.45 {20.0 to 25.0} {20.0 to 25.0}
Unit
MPa {kg/cm2}
Hydraulic oil temperature: 45 to 55°C With engine stopped (after charging accumulator) When brake pedal is depressed Hydraulic oil temperature: 45 to 55°C With engine running at High idle Braking distance when traveling at 35 km/h
Standard value for new machine
Repair limit Standard value
Test results
8.86 to 9.36 8.56 to 9.36 {90.4 to 95.5} {87.3 to 95.5}
Cut-in pressure Cut-out pressure
Test results
2.53 to 2.93 2.53 to 2.93 {25.9 to 29.9} {25.9 to 29.9}
FH
Condition
q
Brake
Torque converter oil Rated temperature: speed 60 to 80°C (2,000 rpm) Transmission oil temRated perature: 60 to 80°C With engine running at speed Low idle, or at rated (2,000 rpm) speed (2,000 rpm) Rated While running wheels speed idle off ground with gear shift lever at P or (2,000 rpm) each gear Rated speed (2,000 rpm)
Repair limit Standard value
2.35 to 2.75 2.35 to 2.75 {24.0 to 28.0} {24.0 to 28.0}
Low idle Main relief pressure of power train
Standard value for new machine
Good
Condition
No good
Item
Good
Pm Clinic
No good
30 Testing and adjusting
13.3 to 13.8 {135.7 to 140.8}
13.3 to 13.8 {135.7 to 140.8}
4.0 to 4.8 4.0 to 4.8 {40.9 to 49.1} {40.9 to 49.1}
m
Max. 15.8
Max. 15.8
30-163
Pm Clinic
30 Testing and adjusting
q q q q
Work equipment oil pressure
Item
Surface temperature of hydraulic tank
Work equipment oil pressure
30-164
Hydraulic oil temperature: 45 to 55°C With engine at high idle With steering cylinder in relief condition With engine at low idle Front wheels raised off the ground
Condition
Repair limit Standard value
mm
0 to 25
0 to 25
Unit
Standard value for new machine
Repair limit Standard value
°C
-
-
With engine stopped
q
Hydraulic oil temperature: 45 to 55°C 19.1 to 19.6 18.6 to 19.6 With engine at high idle MPa Work equipment circuit relief pressure: {kg/cm2} {195 to 200} {190 to 200} with leaning cylinder in relief condition
q
Test results
16.6 to 18.2 16.6 to 18.2 MPa {kg/cm2} {169 to 190} {169 to 190}
q
q
Test results
No good
Play of steering wheel
q
Unit
No good
Steering pressure
Condition
Good
Steering
Item
Standard value for new machine
Good
Pm Clinic check sheet (2/3)
GD535-5 (01)
Blade lift speed
Blade side shift speed
Drawbar side shift speed
q q
Work equipment speed
q
Blade rotation speed
q q q
Power tilt speed
q q q
Articulate speed
q
Hydraulic oil temperature: 45 to 55°C With engine at high idle Blade lift: Move cylinder between stroke ends and operate both cylinders independently. Drawbar side shift: Move cylinder between stroke ends. Blade side shift: Move cylinder between stroke ends. Blade rotation: Move blade between rotation start and 90 deg. rotation positions. Power tilt: Move cylinder between stroke ends. Articulate: Move cylinder between stroke ends. Leaning: Move cylinder between stroke ends. Scarifier lift: Move cylinder between stroke ends.
Leaning speed
Scarifier lift speed
Unit
Repair limit Test Standard results value
RAISE
1.7 to 2.3
Max. 4.0
LOWER
2.6 to 3.4
Max. 5.0
Left shifting
6.9 to 9.5
Max. 10.0
Right shifting
4.5 to 6.1
Max. 7.0
Left shifting
1.9 to 2.7
Max. 4.0
Right shifting
2.8 to 3.8
Max. 5.0
Left rotation
6.8 to 9.4
Max. 10.0
Right rotation
6.8 to 9.4
Max. 10.0
1.7 to 2.3
Max. 3.0
In small cutting angle direction
1.4 to 2.0
Max. 3.0
Left turn
3.6 to 4.8
Max. 6.0
Right turn
3.5 to 4.9
Max. 6.0
Leaning to left
0.6 to 0.8
Max. 2.0
Leaning to right
0.9 to 1.1
Max. 2.0
RAISE
0.8 to 1.2
Max. 2.0
LOWER
1.1 to 1.7
Max. 3.0
Unit
Standard value for new machine
Repair limit
mm/10 min.
Max. 20
Max. 35
In large cutting angle direction
Sec.
No good
Condition
No good
Item
Standard value for new machine
Good
Pm Clinic
Good
30 Testing and adjusting
a Set the blade in the specified posture and stop the engine.
Hydraulic drift
Item
Natural drift of blade (while raising machine off ground)
GD535-5 (01)
Condition
q q q
With engine stopped With cylinder at LOWER stroke end Measure retraction amount of cylinder.
Test results
30-165
Pm Clinic
30 Testing and adjusting
With engine stopped
-
Condition
Unit
Standard value for new machine
Repair limit
Test results
No good
Item
q
Unit
Good
Visual check of final drive drain plug
Condition
Good
Final drive
Item
No good
Pm Clinic check sheet (3/3) a Replace the plug with a spare plug.
Metal powder should not be noticeable.
Standard value for new machine
Repair limit
Test results
Front wheel, left Front wheel, right
Tire
Rear wheel, left front Tire inflation pressure
Rear wheel, left rear Rear wheel, right front
13.00 - 24 - 12PR: kPa {kg/ 240 to 280 {2.4 to 2.8} cm2} 14.00 - 24 - 12PR: 240 to 280 {2.4 to 2.8}
Rear wheel, right rear
Note: Write down the phenomena and information which draws your attention during today's checkup.
30-166
GD535-5 (01)
40 Troubleshooting
GD535-5 (03)
40-1
Contents
40 Troubleshooting
Contents
1
Acronyms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Information related to troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Points to remember when troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - How to proceed in troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Checks before troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Inspection procedure before troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Troubleshooting procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code list - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Symptoms and troubleshooting numbers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Information described in troubleshooting table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Diagnosis of open harness in pressure sensor system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Connector list and layout - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Connector pin layout - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - T-box and T-adapter list - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Locations of fuses - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Troubleshooting by failure code (display of code) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [1500L0] Double Engagement of T/M Clutches - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [15G0MW] Failure of R-Clutch System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [15H0MW] Failure of Clutch System (FH) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [15J0MW] Failure of Clutch System (FL)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [15K0MW] Failure of Clutch System (1st) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [15L0MW] Failure of Clutch System (2nd) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [15M0MW] Failure of Clutch System (3rd)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [15N0MW] Failure of Clutch System (4th) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [15SBL1] Release Trouble of ECMV (R) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [15SBMA] Malfunction of ECMV (R) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [15SCL1] Release Trouble of ECMV (FH) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [15SCMA] Malfunction of ECMV (FH) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [15SDL1] Release Trouble of ECMV (FL) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [15SDMA] Malfunction of ECMV (FL) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [15SEL1] Release Trouble of ECMV (1st) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [15SEMA] Malfunction of ECMV (1st) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [15SFL1] Release Trouble of ECMV (2nd) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [15SFMA] Malfunction of ECMV (2nd) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [15SGL1] Release Trouble of ECMV (3rd) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [15SGMA] Malfunction of ECMV (3rd) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [15SHL1] Release Trouble of ECMV (4th)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [15SHMA] Malfunction of ECMV (4th)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [15SJMA] Malfunction of ECMV (L/U) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [15U0NT] Overload of Inching Clutch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [989L00] Engine Controller Lock Caution 1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [989M00] Engine Controller Lock Caution 2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [989N00] Engine Controller Lock Caution 3- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [AB00KE] Charge Voltage Low - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [AB00KY] Hot Short of Alternator R Terminal- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [B@BAZG] Derating in speed due to engine oil pressure drop - - - - - - - - - - - - - - - - - - - Failure code [B@BCNS] Engine Overheat - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [B@CENS] T/C Oil Temp. Overheat - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [B@CKNS] DIFF Oil Temp. Overheat - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [B@HANS] HYD Oil Temp. Overheat - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA111] Engine NE, controller internal error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-2
40-8 40-13 40-13 40-14 40-15 40-17 40-32 40-34 40-42 40-45 40-47 40-49 40-67 40-103 40-108 40-111 40-111 40-112 40-113 40-114 40-115 40-116 40-117 40-118 40-119 40-121 40-123 40-125 40-127 40-129 40-131 40-133 40-135 40-137 40-139 40-141 40-143 40-145 40-147 40-148 40-149 40-151 40-153 40-154 40-155 40-156 40-157 40-158 40-159 40-160 40-161 40-163 40-165
GD535-5 (03)
40 Troubleshooting
Failure code [CA115] Engine NE, Bkup speed sensor error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA122] Charge pressure sensor high error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA123] Charge pressure sensor low error- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA131] Throttle sensor high error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA132] Throttle sensor low error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA144] Coolant sensor high error- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA145] Coolant sensor low error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA153] Charge temperature sensor high error- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA154] Charge temperature sensor low error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA155] Speed derating error by high charge temperature- - - - - - - - - - - - - - - - - - - - - - Failure code [CA187] Sensor power supply 2 low error- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA221] Atmospheric pressure sensor high error - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA222] Atmospheric pressure sensor low error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA227] Sensor power supply 2 high error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA234] Engine overspeed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA238] Ne speed sensor power supply error- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA271] IMV short-circuit error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA272] IMV open circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA322] Injector #1 (L/B #1) open/short - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA323] Injector #5 (L/B #5) open/short - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA324] Injector #3 (L/B #3) open/short - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA325] Injector #6 (L/B #6) open/short - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA331] Injector #2 (L/B #2) open/short - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA332] Injector #4 (L/B #4) open/short - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA342] Data compatibility error in engine controller - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA351] Injector drive circuit error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA352] Sensor power supply 1 low error- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA386] Sensor power supply 1 high error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA428] Water-in-fuel sensor high error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA429] Water-in-fuel sensor low error- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA431] Idle validation switch error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA432] Idle validation action error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA435] Engine oil pressure switch error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA441] Power supply voltage low error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA442] Power supply voltage high error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA449] Common rail pressure high error 2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA451] Common rail pressure sensor high error - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA452] Common rail pressure sensor low error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA488] Torque derating error by high charge temperature - - - - - - - - - - - - - - - - - - - - - Failure code [CA553] Common rail pressure high error 1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA559] Supply pump pressure low error 1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA689] Engine Ne speed sensor error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA731] Engine Bkup speed sensor phase error- - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA757] All continuous data lost error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA778] Engine Bkup speed sensor error- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA1633] KOMNET (CAN communication) error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA2185] Throttle sensor power supply high error- - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA2186] Throttle sensor power supply low error - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA2249] Supply pump pressure low error 2- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA2311] Abnormality in IMV (IMA) solenoid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA2555] Intake heater relay open circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA2556] Intake heater relay short circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [D160KA] Disconnection of Backup Light Relay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [D160KB] Ground Fault of Backup Light Relay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
GD535-5 (03)
Contents
40-166 40-167 40-169 40-171 40-173 40-176 40-178 40-180 40-182 40-184 40-185 40-187 40-189 40-191 40-192 40-193 40-194 40-196 40-198 40-200 40-202 40-204 40-206 40-208 40-210 40-211 40-212 40-214 40-215 40-217 40-219 40-222 40-225 40-226 40-228 40-229 40-230 40-232 40-234 40-235 40-236 40-238 40-240 40-242 40-243 40-247 40-250 40-252 40-254 40-255 40-256 40-258 40-260 40-262
40-3
Contents
40 Troubleshooting
Failure code [D160KY] Hot Short of Back Lamp Relay Output - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [D19JKZ] Personal Code Relay Abnormality - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [D19KKZ] Failure of Diff Control Relay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [D1EHKA] Disconnection of Engine Start Relay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [D1EHKB] Ground Fault of Engine Start Relay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [D1EHKY] Hot Short of Engine Start Relay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [D1FBKB] Ground Fault of Sol. Self-Holding Relay - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [D8AQKR] CAN2 Discon (KOMTRAX) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DAF0MB] Monitor ROM Abnormality - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DAF0MC] Monitor Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DAF3KK] Controller Power Source Low (MON) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DAQ0KK] Controller Power Source Low (T/M) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DAQ0MC] T/M Con Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DAQ1KA] Disconnection of Key SW ACC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DAQ2KK] Solenoid Power Source Low (T/M) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DAQQKR] CAN2 Discon (Transmission Con) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DAQRMA] Inconsistency of Option Selection (T/M)- - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DB2QKR] CAN2 Discon (Engine Con) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DD1PKB] Abnormality of RPM Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DD1QKB] Abnormality of RPM Set Mode Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DDB6L4] Parking brake signal error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DDTHKA] Disconnection of Fill Switch (FH) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DDTJKA] Disconnection of Fill Switch (FL)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DDTKKA] Disconnection of Fill Switch (1st) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DDTLKA] Disconnection of Fill Switch (2nd) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DDTMKA] Disconnection of Fill Switch (3rd)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DDTNKA] Disconnection of Fill Switch (R) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DDTPKA] Disconnection of Fill Switch (4th) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DF10KA] Disconnection of Shift Lever Input - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DF10L4] Gear Speed/Travel Direction Signal Error - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DGF1KX] Out of Range of T/M Oil Temp. Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DGH2KB] Ground Fault of Hydraulic Oil Temp. S - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DGT1KX] Out of Range of T/C Oil Temp. Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DGT7KB] Ground Fault of Diff Oil Temp. S.(C) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DHT5L6] Failure of T/C Oil Press Sensor- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DJF1KA] Disconnection of Fuel Level Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DK70KX] Out of Range of Inching Potentio. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DKD0KX] Out of Range of Articulated Angle Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DLF1LC] Failure of T/M Input Speed Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DLF2KA] Disconnection of T/M Inter. Speed Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DLF2LC] Failure of T/M Intermediate Speed Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DLM3KA] Rad Fan Spd Sen Opn/Shrt Cir - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DLM3LC] Rad Fan Spd Sen Sig Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DLM3MB] Rad Fan Spd Sen Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DLT3KA] Disconnection of T/M output Speed Sensor - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DW4BKA] Disconnection of Parking Brake Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DW4BKB] Ground Fault of Parking Brake Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DW4BKY] Hot Short of Parking Brake Solenoid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-4
40-264 40-266 40-268 40-270 40-271 40-272 40-273 40-275 40-276 40-278 40-279 40-280 40-281 40-283 40-285 40-286 40-287 40-289 40-291 40-292 40-293 40-294 40-298 40-300 40-302 40-304 40-305 40-306 40-307 40-308 40-309 40-310 40-311 40-315 40-318 40-320 40-322 40-324 40-325 40-327 40-329 40-331 40-333 40-335 40-337 40-339 40-341 40-343 40-345 40-346 40-347 40-349 40-351 40-353
GD535-5 (03)
40 Troubleshooting
Contents
Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup)- - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DXH2KA] Disconnection of ECMV Solenoid (High) - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DXH2KB] Ground Fault of ECMV Solenoid (High) - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DXH2KY] Hot Short of ECMV Solenoid (High) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DXH3KA] Disconnection of ECMV Solenoid (Low) - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DXH3KB] Ground Fault of ECMV Solenoid (Low)- - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DXH3KY] Hot Short of ECMV Solenoid (Low) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st)- - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd) - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse) - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse) - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th) - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th) - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Troubleshooting of electrical system (E-mode) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-1 Engine does not start (Starting motor does not rotate). - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-2 Manual preheating system does not work - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-3 When starting switch is turned ON, machine monitor displays nothing. - - - - - - - - - - - - - - - - - - - E-4 LCD panel backlight of machine monitor fails (goes out or flickers). - - - - - - - - - - - - - - - - - - - - - - E-5 LCD display failure of machine monitor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-6 The switch of machine monitor switch panel does not work. - - - - - - - - - - - - - - - - - - - - - - - - - - - E-7 Two-switch operation of switch panel on machine monitor does not function. - - - - - - - - - - - - - - - E-8 Machine monitor buzzer does not sound. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-9 Some gauges or caution lamps of machine monitor do not work normally. - - - - - - - - - - - - - - - - - E-10 Speedometer or engine speed display is abnormal. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-11 Engine coolant temperature is displayed abnormally. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-12 Articulated meter display is abnormal.- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-13 Torque converter oil temperature is displayed abnormally. - - - - - - - - - - - - - - - - - - - - - - - - - - - E-14 Fuel gauge is displayed abnormally. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-15 Centralized warning lamps do not light or do not go out. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-16 Alarm buzzer does not sound or does not stop sounding. - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-17 Transmission mode cannot be switched. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-18 Engine mode cannot be switched. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-19 Differential gear lock function does not operate or is not canceled (for differential gear lock model). - - E-20 Cannot be locked or canceled by the lifter lock pin. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-21 Horn does not sound or does not stop sounding. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-22 Backup alarm does not sound or does not stop sounding.- - - - - - - - - - - - - - - - - - - - - - - - - - - - E-23 Headlamps, clearance lamps, and tail lamps do not light up or go out. - - - - - - - - - - - - - - - - - - - E-24 Working lamps do not light up or go out. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-25 Turn indicator light or emergency flashing light does not flash. - - - - - - - - - - - - - - - - - - - - - - - - E-26 Stop lamp does not light up or does not go out. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-27 Backup lamp does not light up or does not go out - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-28 All wipers do not operate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-29 Front wiper does not operate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-355 40-357 40-358 40-360 40-362 40-364 40-366 40-368 40-370 40-372 40-374 40-376 40-378 40-380 40-382 40-384 40-386 40-388 40-390 40-392 40-394 40-396 40-398 40-400 40-402 40-402 40-406 40-412 40-415 40-416 40-417 40-418 40-419 40-420 40-421 40-422 40-424 40-426 40-428 40-430 40-431 40-433 40-435 40-437 40-439 40-441 40-443 40-446 40-454 40-459 40-468 40-470 40-472 40-474
GD535-5 (03)
40-5
Contents
40 Troubleshooting
E-30 Rear wiper does not operate- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-478 E-31 Left and right door wiper does not operate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-481 E-32 Left door wiper does not operate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-484 E-33 Right door wiper does not operate- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-486 E-34 Front or door washer does not operate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-488 E-35 Rear washer does not operate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-490 E-36 KOMTRAX system does not operate normally. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-492 Troubleshooting of hydraulic and mechanical system (H-mode) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-494 How to use troubleshooting table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-494 H-1 Engine speed drops significantly or engine stalls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-500 H-2 Machine does not move off. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-501 H-3 Gear speed does not shift. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-502 H-4 Travel speed or power is low. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-503 H-5 Torque converter lockup does not operate or is not canceled. - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-506 H-6 Machine starts or gear speed shifts with long time lag. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-507 H-7 Torque converter oil temperature is high. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-510 H-8 Differential gear lock function does not operate or is not canceled.- - - - - - - - - - - - - - - - - - - - - - - - 40-513 H-9 Steering speed or power is insufficient. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-514 H-10 Steering wheel does not move - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-515 H-11 Wheel brakes do not work or are weak - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-516 H-12 Wheel brakes are not released or drag - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-517 H-13 Parking brake does not work or it is weak - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-518 H-14 Parking brake (including emergency release system) is not released or drags - - - - - - - - - - - - - - 40-519 H-15 All work equipment operates slowly or lacks power- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-520 H-16 Work equipment does not operate. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-521 H-17 Unusual noise is heard from around hydraulic pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-522 H-18 Blade lift speed or power is low. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-523 H-19 Hydraulic drift of lifted blade is large. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-524 H-20 Drawbar side shift speed or power is low - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-525 H-21 Blade side shift speed or power is low. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-526 H-22 Power tilt speed or power is low. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-527 H-23 Articulate speed or power is low. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-528 H-24 Leaning speed or power is insufficient. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-529 H-25 Hydraulic drift (tilting) of leaning is large. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-530 H-26 Blade does not rotate. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-531 H-27 Lifter lock pin is not locked or is not canceled. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-532 Troubleshooting of engine (S-mode) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-533 How to read matrix - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-533 S-1 Engine startability is poor.- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-536 S-2 Engine does not start. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-537 S-3 Engine does not pick-up smoothly. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-540 S-4 Engine stops during operation. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-541 S-5 Engine runs rough or is unstable. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-542 S-6 Engine lacks power.- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-543 S-7 Exhaust smoke is black (Incomplete combustion) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-544 S-8 Large oil consumption (or blue exhaust gas) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-545 S-9 Oil becomes contaminated early. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-546 S-10 Fuel consumption is excessive.- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-547 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) - - - - - - - - - - - - - - - - - - - - - - 40-548 S-12 Oil pressure drops. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-549 S-13 Oil amount increases (due to water or fuel mixing). - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-550 S-14 Coolant temperature rises too high (overheating).- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-551 S-15 Unusual noise is heard. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-552 S-16 Vibration is excessive. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-553
40-6
GD535-5 (03)
40 Troubleshooting
GD535-5 (03)
Contents
40-7
Acronyms
40 Troubleshooting
Acronyms q q q q
1
The abbreviations of unknown parts, equipment and functions have been extracted from the Shop Manual, and their official names and details are defined in this Acronyms. Abbreviations that are commonly used in society might not be described. Special and rarely used abbreviations are described in the supplementary explanation in the text. The acronyms consist of two parts: the list of abbreviations that are used in the text, and the list of abbreviations that are used in circuit diagrams.
Abbreviations that are used in the text Abbreviations
Official name
Application (Applicable models (*1) and equipment) Traveling, brake
ABS
Antilock Brake System
AISS
Automatic Idling Setting Engine System
AJSS
Advanced Joystick Steering System
ARAC
Automatic Retarder Accelerator Control
(HD series, HM series)
Steering (WA series) Traveling, brake (HD series, HM series) Traveling, brake
ARSC
Automatic Retarder Speed Control
ASR
Automatic Spin Regulator
ATT
Attachment
BCV
Brake Cooling oil control Valve
CAN
(HD series, HM series) Traveling, brake (HD series, HM series) Work equipment
Explanation With this function, when the tires skid (wheels stop rotating), the brakes are released, and when the wheels start to rotate, the brakes are applied again. This function automatically sets the idle speed. A lever is used to perform the steering operations instead of a steering wheel. Moreover, it shifts gear and changes direction (FORWARD or REVERSE). When the accelerator pedal is released while the machine is traveling downhill, this function automatically applies the retarder with a constant braking force. When the accelerator pedal is released while the machine is traveling downhill, this function automatically applies the retarder to ensure that the machine speed does not accelerate above the speed set by the operator. When the tires spin on soft ground surfaces, this function automatically uses the optimum braking force to drive both wheels. The function or parts which are attached to the standard model and used
(HD series)
When the retarder is not being used, this valve bypasses part of the brake cooling oil to reduce the load on the hydraulic pump.
Controller Area Network
Communication, electronic control
One of communication standards that is used in the network on the machine
CDR
Crankcase Depression Regulator
Engine
A regulator valve which is installed to KCCV ventilator. It is written as CDR valve and it is not used independently.
CLSS
Closed-center Load Sensing System
Hydraulic system
This system can simultaneously actuate multiple actuators regardless of the load (provides better combined operation than OLSS).
Engine
Engine controller electronically controls supply pump, common rail, and injector. This function maintains optimum fuel injection amount and fuel injection timing.
Electronic control
Electronic control device that receives signals from each sensor of the machine and that specifies the optimum operation to the actuators. (Same as ECU)
40-8
CRI
Common Rail Injection
ECM
Electronic Control Module
Brake
1
GD535-5 (03)
40 Troubleshooting
Abbreviations
Acronyms
Official name
ECMV
Electronic Control Modulation Valve
ECSS
Electronically Controlled Suspension System
Application (Applicable models (*1) and equipment) Transmission (D series, HD series, WA series and others) Traveling (WA series)
Explanation Proportional solenoid valve that reduces the connection shock by gradually increasing the hydraulic pressure to engage the clutch. This system ensures smooth high-speed travel by absorbing vibration of machine during travel with hydraulic spring effect of accumulator.
ECU
Electronic Control Unit
Electronic control
Electronic control device that receives signals from each sensor of the machine and that specifies the optimum operation to the actuators. (Same as ECM)
EGR
Exhaust Gas Recirculation
Engine
This function recirculates part of exhaust gas to the combustion chamber in order to reduce combustion temperature and control the emission of NOx.
Equipment Management Monitoring System
Machine monitor
This system allows data (filter, oil replacement interval, malfunctions on machine, failure code, and failure history) from each sensor on the machine to be checked on the monitor.
EPC
Electromagnetic Proportional Control
Hydraulic system
Electromagnetic proportional control This mechanism allows actuators to be operated in proportion to the current supplied.
FOPS
Falling Object Protective Structure
Operator's cab, canopy
F-N-R
Forward-NeutralReverse
Operation
Forward-Neutral-Reverse
Communication
GPS
Global Positioning System
Global positioning system The satellite positioning system to determine the current position on the earth
GNSS
Global Navigation Satellite System
EMMS
This structure protects the operator's head from falling objects. (Falling Object Protective Structure) This performance is standardized as ISO 3449.
(KOMTRAX, KOMTRAX Plus) Communication (KOMTRAX, KOMTRAX Plus) Steering
Global navigation satellite system A general term for positioning system using satellites such as GPS, GALILEO, etc. This function uses a combination of hydraulic motor and bevel shaft to control difference in travel speed of right and left tracks. Accordingly machine can turn without using steering clutch.
HSS
Hydrostatic Steering System
HST
Hydro Static Transmission
ICT
Information and Communication Technology
Communication, electronic control
A general term for the engineering and its socially applied technology of information processing and communication.
IMA
Inlet Metering Actuator
Engine
Valve that adjusts fuel intake amount at inlet port of pump in order to control fuel discharged volume of supply pump. (Same as IMV)
IMU
Inertial Measurement Unit
Engine
This is a device to detect the angle (or angular velocity) and acceleration of the 3 axes that control motions.
IMV
Inlet Metering Valve
Engine
Valve adjusting fuel intake amount at inlet port of pump in order to control fuel discharged volume of supply pump. (Same as IMA)
GD535-5 (03)
(D series) Transmission (D series, WA series)
This function uses a combination of hydraulic pump and hydraulic motor to shift the speed range steplessly without using gears.
40-9
Acronyms
Abbreviations
40 Troubleshooting
Official name
Application (Applicable models (*1) and equipment)
KCCV
KOMATSU Closed Crankcase Ventilation
Engine
KCSF
KOMATSU Catalyzed Soot Filter
Engine
KDOC
KOMATSU Diesel Oxidation Catalyst
Engine
KDPF
KOMATSU Diesel Particulate Filter
Explanation The mechanism for oil separation from gas in order to re-burn the blow-by gas and for oil return to the intake system. It is mainly composed of filters. The filter to capture the soot from exhaust gas. It is built in the KDPF. The catalyst for exhaust gas purification.
Engine
It may be built in the KDPF or combined with the muffler. This component is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it. It is used instead of the conventional muffler.
Traveling, brake
This function recovers the drive force of the wheels by braking automatically with the optimum force and at the same time activates the inter-axle differential lock when the wheels idle while the machine travels on the soft ground road.
KOMATSU Traction Control System
(HM series)
LCD
Liquid Crystal Display
Machine monitor
The liquid crystal display panel. Image display device such as a monitor which assembles in the liquid crystal element.
LED
Light Emitting Diode
Electronic components
Light emitting diode It refers to semiconductor element that emits light when the voltage is applied in forward direction.
LIN
Local Interconnect Network
Communication, electronic control
One of communication standards that is used in the network on the machine
LS
Load Sensing
Hydraulic system
Function that detects differential pressure of pump and controls discharged volume corresponding to load.
KTCS
Low Voltage Differential Communication, electronic Signaling control
One of communication standards that is used in the network on the machine
MAF
Mass Air Flow
Engine
The intake airflow rate of the engine. It is not used alone, but used in combination with sensors. The intake airflow sensor may be called the MAF sensor.
MMS
Multimedia Messaging Service
Communication
The service to allow transmission and reception of short messages such as characters, voice and images between mobile phones.
Normally Closed
Electric system, hydraulic system
The characteristics of an electric or hydraulic circuit that is normally closed when the system is not operating, and that is normally opened when the system is operating.
Normally Open
Electric system, hydraulic system
The characteristics of an electric or hydraulic circuit that is normally opened when the system is not operating, and that is normally closed when the system is operating.
Open-center Load Sensing System
Hydraulic system
The hydraulic system that can simultaneously operate multiple actuators regardless of the load.
Pressure Compensation
Hydraulic system
The function to compensate for the hydraulic pressure.
LVDS
NC
NO
OLSS PC
40-10
GD535-5 (03)
40 Troubleshooting
Abbreviations
Acronyms
Official name
Application (Applicable models (*1) and equipment)
Explanation
Steering Palm Command Control System (D series)
The function to make the controller analyze the lever, pedal, and dial data instantaneously, and to allow the electronic control of engine, transmission and others appropriately.
PCV
Pre-stroke Control Valve
Engine
This valve is installed at inlet port of pump and it adjusts fuel intake amount in order to control fuel discharged volume of supply pump.
PPC
Proportional Pressure Control
Hydraulic system
Used for controlling proportional pressure. This system moves actuators in proportion to the hydraulic pressure.
PPM
Piston Pump and Motor
PTO
Power Take Off
Power transmission
Power take-off mechanism
PTP
Power Tilt and power Pitch dozer
Work equipment (D series)
This function performs hydraulic control of the tilt and pitch of the bulldozer blade.
Operator's cab, canopy
The structure to protect the operator (fastened with seat belt) if the machine falls. (Roll-over protective structure for operator)
PCCS
ROPS
Roll-Over Protective Structure
Hydraulic system (D series, PC series, others)
Piston hydraulic pump and motor.
This performance is standardized as ISO 3471.
Selective Catalytic Reduction
Urea SCR system
The exhaust gas purification device, that uses urea water and converts the nitrogen oxides (NOx) into harmless nitrogen and water (by reduction reaction). It may be called part of the exhaust gas purifying catalyst or the related device name.
Le Systeme International d’ Unites
Unit
Abbreviated for the "International System of Units". It is the universal unit system and "A single unit for a single quantity" is the basic principle applied.
SOL
Solenoid
Electrical system
It refers to an actuator consisting of a solenoid and an iron core that is moved by the magnetic force when the solenoid is energized.
TWV
2-Way Valve
Hydraulic system
Solenoid valve that switches over direction of flow.
VGT
Variable Geometry Turbocharger
Engine
Turbocharger having the variable geometry of exhaust passage
SCR
SI
*1: Applicable model codes D: Bulldozer HD: Dump truck HM: Articulated dump truck PC: Hydraulic excavator WA: Wheel loader
GD535-5 (03)
40-11
Acronyms
40 Troubleshooting
Abbreviations used in circuit diagrams Abbreviations Air Conditioner
A/D
Analogue-to-Digital
A/M
Air Mix damper
ACC
Accessory
ADD
Additional
AUX
Auxiliary
BR
Battery Relay
CW
Clockwise
CCW
Counter Clockwise
ECU
Electronic Control Unit
ECM
Electronic Control Module
ENG
Engine External Ground
F.G.
Frame Ground
GND
Ground
IMA
Inlet Metering Actuator
NC
No Connection
S/T STRG
Steering
SIG
Signal
SOL
Solenoid
STD
Standard
OPT OP PRESS SPEC SW TEMP
40-12
Official name
A/C
EXGND
1
Option Pressure Specification Switch Temperature
T/C
Torque Converter
T/M
Transmission
GD535-5 (03)
40 Troubleshooting
Points to remember when troubleshooting
Information related to troubleshooting
1
Points to remember when troubleshooting
1
k Stop
the machine on a level place and make sure than the lock pin, chocks, parking brake, etc. are applied normally. k When performing the operation with 2 or more service technicians, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. k If you remove the radiator cap when the engine is still hot, the hot water gushes out and you will burn. Remove the cap only when engine is cool. k Be extremely careful not to touch any hot parts or to get caught in any rotating parts. k When disconnecting wiring, always disconnect the cable from the negative (-) terminal of the battery first. k When removing the plug or cap from a location which is under pressure of oil, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. Troubleshooting denotes to locate the primary cause, repair the failure without delay and prevent its recurrence. Despite the importance of understanding the structure and operation of the target system in troubleshooting, you should be aware how interviewing with the operator concerned can facilitate in roughly identifying the cause of the given undesirable symptom. 1. When performing troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately after any failure occurs, q parts that have no connection with the failure or other unnecessary parts are disassembled. q It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when performing troubleshooting, it is necessary to perform thorough prior investigation and to perform troubleshooting corresponding to the fixed procedure. 2. Points to ask the user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Is there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been performed before the failure? When were these repairs performed? 6) Has the same kind of failure occurred before?
4. Checking failure Check the extent of the failure yourself, and judge whether it is a real failure or a problem of the method of operation, etc. a When operating the machine to reenact the failure symptoms, do not perform any investigation or measurement that may make the problem worse. 5. Troubleshooting Use the results of the investigation and inspection in Items 2 to 4 to narrow down the probable causes of the failure, then use the troubleshooting flow chart (matrix) to locate the failure exactly. a The basic procedure for troubleshooting is as follows. 1] Start from the simple points. 2] Start from the most likely points. 3] Investigate other related parts or information. 6. Fundamental measures for determining failure cause Even if the failure is repaired in hand, if the root cause of the failure is not repaired, the same failure will occur again. To that end, you must locate and eliminate the primary cause behind the given failure.
3. Checks before troubleshooting 1) Is there abnormal symptoms in the machine? 2) Check the work inspection points. 3) Check the other inspection points. 4) Check other maintenance matters which can be checked externally and are considered to be necessary.
GD535-5 (03)
40-13
How to proceed in troubleshooting
How to proceed in troubleshooting
40-14
40 Troubleshooting
1
GD535-5 (03)
40 Troubleshooting
Checks before troubleshooting
Checks before troubleshooting
b. Hydraulic and mechanical equipment
a. Engine, lubricating oil, and coolant
No.
Item
1
Criteria
Remedy
1
Check for unusual noise and smell
-
Repair
2
Check of engine for dirt
-
Remove
3
Check of engine for water leakage
-
Repair
4
Check of engine for oil leakage
-
Repair
5
Check of fuel line for leakage
-
Repair
6
Check of radiator for clogging
-
Remove
7
Check of fuel level and type
-
Refilling with fuel
8
Check of foreign material in fuel
-
Clean and drain
9
Check of fuel prefilter
-
Replace
10
Check of fuel filter
-
Replace
11
Check of engine oil level (in oil pan) and type
Between H and L
Refilling with oil
12
Check of coolant level (in sub tank)
Between H and L
Refilling with coolant
13
Check of air cleaner for clogging
Machine monitor does not indicate clogging.
Clean or replace
1
Check for unusual noise and smell
-
Repair
2
Check for oil leakage
-
Repair
3
Check of hydraulic oil
Between H and L
Refilling with oil
4
Check of hydraulic oil strainer
-
Clean and drain
5
Check of hydraulic oil filter
-
Replace
6
Check of transmission case oil level
Between H and L
Refilling with oil
7
Check of power train pump strainer
-
Clean and drain
8
Replacement of transmission oil filter
-
Replace
9
Check of final drive case oil level
Between H and L
Refilling with oil
10
Bleeding air
-
Air bleeding
GD535-5 (03)
40-15
Checks before troubleshooting
e. Interior
d. Exterior
c. Electrical equipment
No.
40-16
40 Troubleshooting
Item
Criteria
Remedy
1
Check of battery terminal for looseness and corrosion
-
Retighten or replace
2
Check of alternator terminal for looseness and corrosion
-
Retighten or replace
3
Check of starting motor terminal for looseness and corrosion
-
Retighten or replace
4
Check of battery voltage (with engine stopped)
20 to 30 V
Charge or replace
5
Check of battery electrolyte level
Between H and L
Add or replace
6
Check of wiring harness for discoloration, burnt areas and cover peeling
-
Repair or replace
7
Check for coming off of wiring harness clamp and sagging of wiring harness
-
Repair
8
Check of grounding
-
Repair
9
Check for loose connector and damaged lock
-
Repair or replace
10
Check of connector pin for corrosion, bends and deformation
-
Repair or replace
11
Check of connector for water and foreign material
-
Dry, clean or replace
12
Check of wiring harness for open or short circuit
-
Repair or replace
13
Check of fuse for blowout and corrosion
-
Replace
14
Slow-blow fuse
-
Replace
15
Check of alternator voltage (when engine speed is medium or higher)
27.5 to 29.5 V after few minutes operation
Replace
16
Check of battery relay operation sound (when starting switch is turned to ON or OFF position)
-
Replace
17
Check and clean rear-view camera
-
Clean or repair
1
Check of tires
-
Repair
2
Check of handrails and steps
-
Repair
3
Check of mirrors
-
Clean or repair
1
Check of gauges and monitors
-
Clean or replace
2
Check of seat belt
-
Repair
GD535-5 (03)
40 Troubleshooting
Inspection procedure before troubleshooting
Inspection procedure before troubleshooting
1
Walk-around check Before starting the engine, look around and under the machine to check for any loose nuts or bolts, leakages of oil, fuel, or coolant, and check the condition of the work equipment and hydraulic system. Check the connectors for looseness, wiring harnesses for play, and accumulation of dust in places that reach high temperatures. k
Any accumulation of flammable materials, or leakage of fuel or oil, around the battery, engine itself, muffler, turbocharger, or other high temperature engine parts can cause the machine to catch fire. Check them carefully, and repair them if abnormal.
a1. and b1. Check for unusual sound and smell Check for unusual sound or smell. If the machine is operated with the unusual sound or smell, the underlying cause may damage the machine, so stop the operation immediately once you recognize it. a2. Check around engine and dirt removal Check if there is any accumulated dirt around the engine, and combustibles (dead leaves, twigs, etc.) on engine itself, turbocharger, or the other surroundings of engine parts that reach high temperature. If any, remove them. a3. Check for water leakage around engine a4. Check for oil leakage around engine Check for oil leakage from engine and coolant leakage from cooling system. If any abnormality is found, repair it. a5. Check for leakage from fuel line Check for fuel leakage, check hoses and pipes for damage. If any abnormality is found, repair it. a6. Check for radiator and dirt removal Check if there is any accumulated dirt and any combustibles (dead leaves, twigs, etc.) around the radiator. If any, remove them. For removal of dirt from the radiator, see the Operation and Maintenance Manual, "Cleaning and testing of radiator fins, oil cooler fins, aftercooler fins, and air conditioner condenser fins (machine with the air conditioner)". b2. Check of work equipment, cylinders, linkage and hoses for breakage, wear and clearance Check the work equipment, cylinders, linkage, and hoses for breakage, wear, and clearance. If any abnormality is found, repair it. b3. Check of hydraulic equipment, hydraulic tank, hoses, and joints for oil leakage Check for oil leaks. If any abnormality is found, repair it.
GD535-5 (03)
c1. Check around batteries and dirt removal Check for any accumulated dirt and combustibles (dead leaves, twigs, etc.) around the batteries. If any, remove them. d1. Check of tires for abnormality, wear, and loose bolts If any abnormality is found, repair it. d2. Check of handrails and steps for abnormality and looseness of bolts If any abnormality is found, repair it and tighten any loose bolts. d3. Check and clean rearview mirrors (if equipped) Check rearview mirror for abnormality. If any, repair it. Clean the mirror surface and adjust the mirror angle so that the rear of the machine can be seen from the operator's seat. e1. Check of gauges and monitors for abnormality Check gauges and monitors in the operator's cab for abnormality. If any abnormality is found, replace it with a new one. Clean up the surfaces. e2. Check of seat belt and mounting hardware Check the hook, the lock, and hook mounting part for damage. If any abnormality is found, replace it with a new one.
Testing according to testing procedure a. Engine, lubricating oil, and coolant a7. Check of fuel level and type k Fuel is highly flammable and dangerous. Never bring open flames near fuel. k When adding fuel, never spill it or let it overflow. k Wipe off any spilled fuel. If fuel spills over soil or sand, remove all the fuel and soil or sand together.
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Inspection procedure before troubleshooting
40 Troubleshooting
1. Turn the starting switch to ON position, and check the fuel level with fuel level gauge (G) on the monitor panel. After checking, turn the switch back to OFF position.
2. If fuel level is low, open fuel filler cap (F) of fuel tank, and add fuel through filler port to the level enough for checking. q If breather hole (1) in the oil filler cap is clogged, the pressure in the tank decreases and fuel may not be supplied. To prevent this, clean the breather hole.
a9. Check of fuel prefilter (water separator) k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Accordingly, wait until all parts have cooled down before starting the work. k High pressure is generated inside the engine fuel piping system when the engine is running. Stop the engine and wait at least 30 seconds until the inner pressure is released and then replace the filter. k Never bring open flames near fuel. a A special filter with high-efficiency filtering properties is adopted for Komatsu genuine fuel prefilter cartridges. Be sure to use Komatsu genuine parts when replacing.
a The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genuine fuel filter cartridge is used, foreign material may enter, and it may cause problems in the injection system. Do no use substitute parts. a During testing or maintenance of the fuel system, take extreme care not to allow any foreign material to enter the fuel system. If any dust or other material sticks to any part, wash the part thoroughly with clean fuel. q Prepare an oil reserver. q Prepare a filter wrench.
a8. Check of foreign material in fuel Open drain valve (1) under the fuel tank, and drain the water mixed in the fuel and sediments.
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GD535-5 (03)
40 Troubleshooting
1. Open the engine side cover on the left side of the machine. 2. Disconnect connector (1), and remove clamp (2). a Cover the terminals of disconnected connector with a plastic bag and tapes so that the terminals are not contaminated. 3. Place an oil reservoir under filter cartridge (3).
4. Disconnect hose (6) from drain plug (5). 5. Turn filter cartridge (3) counterclockwise by using the filter wrench, and remove it. 6. The water separator is mounted at the bottom of the cartridge you have just removed. Rotate cup (4) of the water separator counterclockwise and remove it. If it is damaged, replace it with a new one. 7. Install currently removed cup (4) to the bottom of the new fuel prefilter cartridge. At this time, be sure to replace the O-ring with a new one. 3 Tightening torque of cup (4): 10 Nm {1.0 kgm} a When replacing seal ring, apply clean oil on its surface. 8. Check that drain plug (5) on the bottom of fuel prefilter cap (4) is tightened securely. 3 Tightening torque: 0.2 to 0.45 Nm {0.02 to 0.046 kgm} 9. Clean the filter holder.
Inspection procedure before troubleshooting
12. Remove filter cartridge cap (A), and install it to the filter holder. 13. When installing the cartridge, tighten it until the packing surface contacts the sealing surface of the filter holder, then tighten it 3/4 of a turn. a If the filter cartridge is overly tightened, the packing will be damaged and this leads to leakage of fuel. If the filter cartridge is too loose, fuel will also leak from the packing. Therefore, be sure to observe the fastening angle. 14. Connect all connector (1), clamp (2) and hose (6) that you have disconnected before.
15. Then, proceed to Step "a10. Check of fuel filter". a10. Check of fuel filter k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Accordingly, wait until all parts have cooled down before starting the work. k High pressure is generated inside the engine fuel piping system when the engine is running. Stop the engine and wait at least 30 seconds until the inner pressure is released and then replace the filter. k Never bring open flames near fuel. a A special filter with high-efficiency filtering properties is adopted for Komatsu genuine fuel filter cartridges. Be sure to use Komatsu genuine parts when replacing.
a The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genuine fuel filter cartridge is used, foreign material may enter, and it may cause problems in the injection system. Do no use substitute parts. 10. Fill the filter cartridge with clean fuel, using 8 small holes (B) of the new filter cartridge. 11. Thinly coat the packing surface of filter cartridge with clean oil.
GD535-5 (03)
a During testing or maintenance of the fuel system, take extreme care not to allow any foreign material to enter the fuel system. If any dust or other material sticks to any part, wash the part thoroughly with clean fuel.
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Inspection procedure before troubleshooting
q q
1. 2. 3. 4.
Prepare an oil reserver. Prepare a filter wrench. Open the engine right side cover. Place an oil pan under the filter cartridge. Turn filter cartridge (1) counterclockwise by using the filter wrench, and remove it. Clean the filter holder.
40 Troubleshooting
3. Remove dipstick (G) and wipe off oil on it with a cloth. 4. Insert dipstick (G) fully and pull it out.
5. If the oil level is between H mark and L mark on dipstick (G), it is appropriate. If the oil level is below L mark, add oil through oil filler port (F). 5. Thinly coat the packing surface of filter cartridge with oil. 6. Remove filter cartridge cap (A), and install it to the filter holder. 7. When installing the cartridge, tighten it until the packing surface contacts the sealing surface of the filter holder, then tighten it 3/4 of a turn. a If the filter cartridge is overly tightened, the packing will be damaged and this leads to leakage of fuel. If the filter cartridge is too loose, fuel will also leak from the packing. Therefore, be sure to observe the fastening angle.
a11. Check of engine oil level (in oil pan) and type k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Accordingly, wait until all parts have cooled down before starting the work. a When checking the oil level after the engine has been operated, wait at least 15 minutes after stopping the engine. a If the machine is at an angle, make it level before checking. 1. Stop the engine. 2. Open the engine right side cover.
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6. When the oil is above FULL level, 1) Place oil reservoir (P) under drain plug (P) at the right rear position. 2) Drain oil by opening drain plug (P). 3) Tighten drain plug (P). 3 Drain plug tightening torque: 118 to 162 Nm {12 to 16.5 kgm}
7. If the oil is at the correct level, tighten the oil filler cap securely and close the engine hood.
GD535-5 (03)
40 Troubleshooting
a12. Check of coolant level (in reservoir tank) k There is no need to open the radiator cap at the usual checks. When checking the coolant level, check it in reservoir tank when the engine is cooled down. k Immediately after the engine is stopped, the coolant is still very hot and the pressure is accumulated in the radiator. If the cap is removed under these conditions, you may be scalded. If you need to remove the radiator cap, wait until the temperature drops before you do. Then turn the cap slowly to release the pressure and remove it with care. 1. Check that coolant level is between FULL and LOW marks of reservoir tank (1). If the coolant is insufficient, remove the cap and add the Super Coolant (AF-NAC) between FULL and LOW marks. 2. After refilling with coolant, tighten the cap securely. 3. If the reservoir tank is empty, coolant may be leaking. If any abnormality is found after the check, repair it immediately. If normal, remove bolts (2), and remove cover (3). Remove the cap, add Super Coolant (AF-NAC) (contained in the radiator) through coolant filler port (4), and add it to the reservoir tank.
Inspection procedure before troubleshooting
a13. Check of air cleaner for clogging k When using compressed air for cleaning, put on personal protective items such as protective eyeglasses, gloves, dust mask, etc. to protect yourself from dirt that will fly out. k When removing the outer element from the air cleaner body, do not forcibly pull it out, otherwise it can be dangerous. Be careful not to fall from a high location on unsafe scaffolding as a reaction when pulling out the outer element. k If performing testing, cleaning, or maintenance while the engine running, dust may enter into the engine and engine may be damaged. Stop the engine before performing the works. Testing 1. Open the engine right side cover. 2. If yellow indicator panel (2), mounted in the transparent part of dust indicator (1), has reached red line (3), clean the air cleaner element.
GD535-5 (03)
40-21
Inspection procedure before troubleshooting
40 Troubleshooting
a If the element is cleaned frequently before the yellow indicator panel of dust indicator (1) reaches the red line, the air cleaner will not deliver the optimum performance, and the cleaning effect will decrease. Cleaning or replacement of outer element a Do not leave the air cleaner element in the the direct sunlight before and after cleaning of the element. a When the outer element is cleaned 6 times or used for 1 year, replace it. When replacing it, replace the inner element at the same time. a Even when the number of cleanings of the outer element is less than 6 times, the inner and outer elements must be replaced if the yellow indicator panel of the dust indicator reaches the center of the scale (5 kPa). 1. Open the engine right side cover, remove clips (4), and remove dust cup (5).
3. Blow dry compressed air (Max. 0.20 MPa {2 kg/ cm2}) from the inside of the element along the pleats. Then blow it from outside along the pleats, and finally blow it from the inside again. 4. After clearing the element, throw light on its inside by using a light bulb to check it. If it has a small hole or thin part, replace it. a Do not tap or hit the element against any other object when cleaning it. a Do not use the element if its folds or gasket or seal is damaged. a Install the element by pushing it straight. Do not force to mount it, or clips and air cleaner body may be damaged. a Do not start the engine when the inner element is removed. If so, the engine may be damaged.
2. Remove outer element (6), and clean both the inside of air cleaner body and dust cup (5). a Never remove inner element (7). If it is removed, dirt will enter and can lead to engine trouble. a Do not remove evacuator valve (8) when cleaning the dust cup.
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GD535-5 (03)
40 Troubleshooting
Inspection procedure before troubleshooting
b. Hydraulic and mechanical equipment
5. Set the cleaned outer element, install dust cup (5), and secure it using clips (4). k After you have replaced the inner or outer element, be sure to replace O-ring (9) with a new one. 6. Press the button of dust indicator (1) to return the yellow indicator panel to its original position. 7. Close the engine right side cover.
b3. Check of hydraulic oil level k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Accordingly, wait until all parts have cooled down before starting the work. k When removing the oil filler cap, the oil may spurt out. Turn it slowly to release the internal pressure, then remove it. 1. When you check the hydraulic oil, place the machine as follows: q Return the leaning of front tires to the upright position to allow straight driving. q Straighten the front frame and rear frame (zero articulation angle), and mount the articulation lock pins. q Return the blade side shift control lever to its center position, tilt the blade in a right angle to the chassis, and lightly ground the blade. q If the machine has the blade accumulator, turn the blade accumulator switch ON in order to drain oil from the accumulator, and lift the blade to the highest position. Then, turn the accumulator switch OFF, and ground the blade. 2. Start the engine, and run it at low idle state. 3. Check the oil level using sight gauge (G). It is normal if the oil is at sight gauge (G) level. a Be careful not to add oil any higher than sight gauge (G) level since it can damage the hydraulic circuit or allow the spurting of oil. a If oil level is excessively high, stop the engine and wait for the oil temperature to cool down. Then, drain excessive oil from the drain plug.
4. If the oil is below the sight gauge (G) level, refill with oil through oil filler port (F). 5. If the oil is above sight gauge (G), drain the excessive oil from the drain plug and check the oil level again. 6. If the oil is at the correct level, tighten oil filler cap (F) securely.
GD535-5 (03)
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Inspection procedure before troubleshooting
b4. Check of hydraulic oil strainer k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Accordingly, wait until all parts have cooled down before starting the work. k When you remove the oil filler cap, oil may spurt out. Be careful to rotate it slowly, and release inner pressure gradually. 1. Slowly open oil filler cap (F), and release the air completely from the hydraulic tank.
40 Troubleshooting
8. Insert strainer (5) in projected portion (6) of the tank to install. 9. Install the bolts (1) while pressing down spring (3) with the projection at the bottom of cover (2).
10. Tighten drain plug (P).
2. Stop the engine, and return the oil from accumulator to the tank by pressing the brake pedal approximately 20 times. If the machine has the blade accumulator, turn the blade accumulator switch ON, stop the engine, and release the pressure by operating the blade lift lever. 3. Place an oil reservoir under drain plug (P). 4. Remove drain valve (P) with care not to get splashed with drained oil, and drain oil. a Loosen drain plug (P) carefully so that the oil does not spurt out.
b.5 Check of hydraulic oil filter k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Accordingly, wait until all parts have cooled down before starting the work. k When you remove the oil filler (F) cap, oil may spurt out. Be careful to rotate it slowly, and release inner pressure gradually. 1. Remove bolts (1), and remove cover (2).
2. Remove the element, clean the removed parts and inside of filter case, and install a new element. 3. Install cover (2) and tighten bolts (1). 5. When drained, remove 6 clamping bolts (1), and remove cover (2). a When removing bolts (1), keep pressing down cover (2) since it may jump out by spring (3) action. 6. Pull out the top of rod (4) upward, and remove spring (3) and strainer (5). 7. Remove any dirt stuck to strainer (5), then wash it in flushing oil. If strainer (5) is damaged, replace it with a new one.
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GD535-5 (03)
40 Troubleshooting
Inspection procedure before troubleshooting
b6. Check of transmission case oil level k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Accordingly, wait until all parts have cooled down before starting the work. k Before this check, shift the gear shift lever to the "P" (Parking) position so that the machine does not move. Also, make sure that each lever is at neutral position. q You cannot measure the exact oil level until 12 hours elapses after the engine is stopped because the oil remains in various parts. 1. Stop the engine. 2. Remove the cap of oil filler port (F). 3. Remove dipstick (G), clean it with a cloth, fully insert the dipstick and remove it. 4. The oil level should be between the H and L marks on dipstick (G). q If the oil level is below L mark, add oil through oil filler port (F).
5. If the oil is above H mark, remove drain plug (1), and loosen drain plug (2) slowly. Then, drain the excessive oil, and check the oil level again.
6. If the oil level is correct, insert dipstick (G) fully into the dipstick pipe, and close the cap of oil filler port. q Dipstick (G) has some marks. "A" shows the oil level when engine is stopped (ENG STOP), and "B" shows oil level when engine idles (ENG IDLING) on either side of dipstick. Use "A" shows the oil level when engine is stopped (ENG STOP).
GD535-5 (03)
b7. Transmission 1. Place an oil reservoir under the transmission case. 2. Remove drain plug (1). q Loosen drain plug (2) carefully so that the oil does not spurt out. 3. When drained, tighten drain plug (2) and install drain plug (1). 3 Drain plug (1): 59 to 78.5 Nm {6 to 8 kgm} 3 Drain plug (2): 49 to 78.5 Nm {5 to 8 kgm} 3 Drain plug (3): 9.8 to 12.7 Nm {1.0 to 1.3 kgm} 4. Remove drain plug (3) to drain the hydraulic oil. 5. Remove bolts (4), remove cover (5), and remove and clean oil strainer (7).
6. Remove any dirt stuck to strainer (7), then wash with clean light oil or flushing oil. If the strainer is damaged, replace it with a new one. 7. After cleaning, install oil strainer (7), and install new O-ring (6) on the cover. Install cover (5), and tighten bolts (4).
40-25
Inspection procedure before troubleshooting
8. Add specified amount of oil through oil filler port (F). 9. After refilling it with oil, confirm that oil is refilled to the specified level according to "Check of oil level of transmission case".
b8. Replacement of transmission oil filter and cartridge k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Accordingly, wait until all parts have cooled down before starting the work. q Prepare a filter wrench. 1. Place an oil reservoir under the filter cartridge. 2. Turn filter cartridge (1) counterclockwise and remove it by using the filter wrench. 3. Clean the filter holder, coat the seal surface of the new filter cartridge with clean engine oil, and install it. 3 Tightening torque: 54 to 64 Nm {5 to 6 kgm}
40-26
40 Troubleshooting
b9. Check of final drive case oil level k Since the oil may spurt out due to internal pressure, rotate the plug gradually from its side to release the internal pressure and then remove it carefully. 1. Stop the engine, and leave it more than 5 minutes to cool it down. 2. Remove the oil filler cap, pull out oil level gauge (G), and clean it with a cloth. Fully insert the dipstick and remove it. 3. The oil level should be between the H and L marks on dipstick (G). q If the oil level is below L mark, add oil through oil filler port (F).
4. If the oil is above H mark, drain the excessive oil from drain plug (P) and check the oil level again. 5. If the oil level is correct, insert dipstick (G) fully into the dipstick pipe, and close the cap of oil filler port.
GD535-5 (03)
40 Troubleshooting
Inspection procedure before troubleshooting
b10. Air bleeding q For the bleeding air from the fuel system, see Testing and adjusting, "Bleeding air from fuel circuit". q For air bleeding from the hydraulic system, see Testing and adjusting, "Bleeding air from work equipment circuit". c. Electrical equipment c1. Check of battery terminal for looseness and corrosion The battery is mounted at the left rear side of operator's cab. Check the terminals of battery (1) for looseness and corrosion.
c2. Check of alternator terminal for looseness and corrosion Open the engine hood, and check cables at terminals B and R of alternator for open circuit, looseness and corrosion.
c3. Check of starting motor terminal for looseness and corrosion Open the engine hood, and check cables at terminals B and C of starting motor for open circuit, looseness and corrosion.
GD535-5 (03)
c4. Check of battery voltage (with engine stopped) Check the battery voltage by using the battery tester while the engine is stopped. c5. Check of battery electrolyte level Check before operating the machine. k Do not use the battery if the battery electrolyte level is below LOWER LEVEL line. If it is used under that condition, its inside deteriorates, its service life is shortened, and it may lead to an explosion. k Since the battery produces combustible gas that can explode, do not bring any open flame near it. k Battery electrolyte is dangerous. Take care that it does not come in contact with your eyes or skin. If it does, wash it away with water and contact your doctor. a Do not add the battery fluid above the UPPER LEVEL line. If the electrolyte level is too high, it may leak and cause damage to the paint surface or corrode other parts. a To avoid freezing, add purified water (such as a commercial battery fluid) before starting work the next day. q When checking the electrolyte level through the side face of the battery 1. Wipe and clean the battery surface, especially around the battery level lines with a wet cloth, and check to see that the battery fluid is between the UPPER LEVEL (U.L.) and LOWER LEVEL (L.L.) lines. a Do not clean the battery with a dry cloth since static electricity may cause an explosion.
40-27
Inspection procedure before troubleshooting
2. If the electrolyte level is below the center between the UPPER LEVEL (U.L.) and LOWER LEVEL (L.L.) lines, remove cap (2) and add purified water (example: commercially available battery fluid) to the UPPER LEVEL (U.L.) line immediately. 3. After adding the purified water, tighten cap (1) securely.
a If the fluid exceeds the UPPER LEVEL, remove the fluid using a dropping pipette or others until the fluid drops to the UPPER LEVEL. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water. q When electrolyte level cannot be checked through the side face of the battery 1. Remove cap (1) on the top of battery. (described previously) 2. Check the fluid level by watching fluid opening (2). If the fluid level is below sleeve (3), always add the purified water (such as a commercial battery fluid) until it reaches the bottom of sleeve (the UPPER LEVEL). q (A) Correct level: Since the electrolyte level reaches to the sleeve bottom, the shape of the electrode plates will appear distorted due to the surface tension. q (B) Low: Electrolyte level does not reach the bottom of sleeve, so pole plates appear straight and not bent. 3. After adding fluid, tighten cap (1).
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40 Troubleshooting
a If the fluid exceeds the UPPER LEVEL, remove the fluid using a dropping pipette or others until the fluid drops to the UPPER LEVEL. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water. c6. Check of wiring harness for discoloration, burn and cover peeling q Check the wiring harness and cables for discoloration and burn. a If discolored or burnt, the circuit may be shorted or grounded. q Check the wiring harnesses and cables for damage and peeling of the covers. q If any abnormality is found, repair or replace the wiring harness or cables. c7. Check for coming off of wiring harness clamp and sagging of wiring harness q Check wiring harness for sagging and looseness due to coming off of harness clamp a In particular, carefully check around the hot and movable parts. q If removed from the clamp, secure it with the clamp.
c8. Check of grounding Check the connection of each ground terminal. q Check the mounting bolts and nuts for looseness. q Check ground terminal (1) and the contact surface of machine body for rusting and adhering of insulation materials including foreign material. This figure gives an example of battery grounding. q For each grounding position, see the "Connector list and layout".
GD535-5 (03)
40 Troubleshooting
c9. Check for loose connector and damaged lock q Check the connection of male and female connectors by pulling them by hand. q If the connection is loose, secure it.
Inspection procedure before troubleshooting
c10. Check connector pins for corrosion, bending and deformation. q Disconnect the connectors, and check their pins for corrosion, bending, sinking than other pins, and extension of female pins. q If pins are defective, repair or replace them. a If the pins are not shiny, apply contact restorer to them and connect and disconnect the connectors several times to shine them. (If the pins do not become shiny, connect and disconnect the connector 10 times.) c11. Check of connector for water and foreign material insertion q Disconnect connectors, and check them for entering of water or foreign material inside the connector.
Check the connectors for unlocking, and check the lock and connector housing for cracking. 1. Remove cover (1).
q
2. Check lock screws (L) of the transmission controller for looseness. a Use a hexagonal wrench with 4 mm width across flats.
GD535-5 (03)
a If there is entering of water or foreign material inside connector, the seals may be damaged. Check the seals for damage. a If the seal is defective, repair or replace it. a Dry the inside of the connector with a dryer.
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Inspection procedure before troubleshooting
q
40 Troubleshooting
3) Face the connector (at the plug side) straight to receptacle (since the seal is protruding), and slightly insert the connector. During this time, take care not to peel the seal. 4) Tighten the hexagonal bolt (at the center of connector) for 2 or 3 turns. 5) Fully insert the connector at the plug side, and adjust the connector at the plug side so that clearance between the engaged receptacle and the connector at plug side is even in all directions. 6) Tighten the lock bolt with the specified torque. 3 Hexagonal bolts: 2.8 ± 0.3 Nm {0.28 ± 0.03 kgm} a If tightening it too strong, the lock bolt may break. So be careful.
Wipe and remove any foreign material inside connector with a cloth or others, and blow the air to clean the connector.
Cautions 1. Unplugging connector R1 Slowly pull out the connector, and check it for damage or peeling of seal. Also check the adhesion of foreign materials. a If the seal is damaged, replace it.
c12. Check of wiring harness for open or short circuit q Check the connection (crimped part) between connector pins and wiring harness. q If the line is open as shown in (A), repair or replace the wiring harness or cables.
q
2. Plugging connector R1 1) Check to see that seal is attached to the plug correctly. 2) Make sure that key engages with the groove of receptacle (in normal direction).
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Visually check wiring harnesses for peeling of harness covers and the pins for contact with adjacent pins due to defective crimping.
GD535-5 (03)
40 Troubleshooting
Inspection procedure before troubleshooting
c13. Check of fuse for blow and corrosion a Make sure to turn off the power supply (starting switch is OFF) before replacing the fuse. q The fuse holder is located at the rear left of operator's seat. q If a fuse is corroded and coated with white powder, or there is any play between the fuse and fuse holder, replace the fuse. q Replace each fuse with the one of the same capacity.
c14. Slow-blow fuse If an overcurrent flows, the electric circuit is cut off by the slow-blow fuse, and electrical equipment and wirings are protected from damage. q When you turn the starting switch to ON position but the power is not supplied, the slow-blow fuse may be blown. Check the fuse and replace it if necessary. q
c15. Check of alternator voltage (when engine speed is medium or higher) 1. Open the engine hood. 2. Apply the positive (+) probe of multimeter to terminal (B) of alternator, and apply the negative () probe to the chassis ground. 3. Start the engine, warm it up, and measure the voltage while running the engine at a medium or a higher speed. q If the voltage is abnormal, repair or replace the alternator.
(1)60A: Slow-blow fuse for secondary power supply (2)30A: Slow-blow fuse for continuous power supply (3)120A: Slow-blow fuse for heater relay (intake air heater) (4)120A: Slow-blow fuse for alternator c16. Check of battery relay operation sound 1. Open the battery cover. 2. Turn the starting switch to the ON and OFF positions, and check whether the battery relay operation sound is heard or not. q If the operation sound is not heard, check the related circuits, by referring to the description of troubleshooting for E-1 described in the Emode troubleshooting. q If the relating circuit is normal, replace the battery relay.
GD535-5 (03)
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Troubleshooting procedure
40 Troubleshooting
Troubleshooting procedure Classification of troubleshooting Mode Code display
Content
3) Press the [F4] function key to enter, and go to the "Abnormality Record" screen.
Troubleshooting by failure code
E-mode
Troubleshooting of electrical system
H-mode
Troubleshooting of hydraulic and mechanical systems
S-mode
Troubleshooting of engine
1. Check to see that both an action level and failure code are displayed on the machine monitor. a If multiple failure codes are displayed simultaneously, all the codes are displayed repeatedly in order. Note down all the codes. If action level and failure code are displayed on the standard screen of the machine monitor, perform the troubleshooting for the corresponding "Display of code" corresponding to the displayed failure code. 2. Check a mechanical system failure code and an electrical system failure code with the abnormality record function of the machine monitor. 1) Hold down the [F8] function key on the standard screen, and press the [F1], [F2] and [F3] keys sequentially.
2) On the Service Menu screen, press the [F1] function key twice and select "03 Abnormality Record".
40-32
1
4) Press the [F4] function key to enter, and go to the "Mechanical System Abnormality Record" screen. 5) Press the [F1] function key, check if the next failure code is displayed, and note down all of the failure codes. a A failure code of the mechanical system cannot be deleted. 6) Press the [F3] function key to return to the "Abnormality Diagnosis Record" screen.
7) On the Service Menu screen, press the [F1] function key twice and select "03 Abnormality Record".
GD535-5 (03)
40 Troubleshooting
8) Press the [F4] function key to enter, and go to the "Abnormality Record" screen.
9) Press the [F4] function key to enter, and go to the "Electrical Systems Abnormality Record" screen. 10)Press the [F1] function key, check if the next failure code is displayed, and note down all of the failure codes.
a Character "E" on the left of a failure code indicates that the failure code is "active" (the failure remains or restoration to normal has not been checked). If "E" is not displayed, the failure code is "inactive" and the code is cleared in the subsequent clearing step. Be sure to record this failure code on a paper. q If the failure code is found in the Abnormality Record: Perform troubleshooting for the displayed "Failure code". a If an electrical system failure code is displayed, delete all the codes once and reproduce them, and then see if the failure is still detected. a A failure code of the mechanical system cannot be deleted. q If the failure code is not found in the Abnormality Record q A failure that the machine cannot find out by itself may have occurred in the electrical system or hydraulic and mechanical system.
GD535-5 (03)
Troubleshooting procedure
In this case, check a symptom which is assumed to be a cause of failure again and select the same phenomenon from the table of "Symptom and troubleshooting numbers", and then perform troubleshooting corresponding to that phenomenon in the "E mode", "H mode" or "S mode". 3. After repairing, clear all the failure codes from the Electrical System Abnormality Record. 1) Hold down the [F8] function key, and press the [F1], [F2] and [F3] keys sequentially to enter the "Clear mode". 2) Press the [F8] function key. 3) Press the [F4] function key to clear all failure codes. 4) Press the [F3] function key to return to the "Electrical System Abnormality Record" screen. See if any failure code is still displayed and note down the displayed ones. 5) Press the [F3] function key to return to the "Abnormality Record" screen. 6) Note down information of all columns. a Similar to the Electrical System Failure Record, character "E" on the left of a failure code indicates that the failure code is "active" (the failure remains or restoration to normal has not been checked). 7) Press the [F8] function key to clear all failure codes. Check if the failure is still displayed or not, and write it down. 8) Press the [F3] function key to return to the "Abnormality Record" screen. q
40-33
Failure code list
40 Troubleshooting
Failure code list Failure code
1
Applicable equipment
Action level
History category
Failure code [1500L0] Double Engagement of T/M Clutches
TM
L04
Mechanical system
15G0MW
Failure code [15G0MW] Failure of Clutch System (R)
TM
L03
Electrical system
15H0MW
Failure code [15H0MW] Failure of Clutch System (FH)
TM
L03
Electrical system
15J0MW
Failure code [15J0MW] Failure of Clutch System (FL)
TM
L03
Electrical system
15K0MW
Failure code [15K0MW] Failure of Clutch System (1st)
TM
L03
Electrical system
15L0MW
Failure code [15L0MW] Failure of Clutch System (2nd)
TM
L03
Electrical system
15M0MW
Failure code [15M0MW] Failure of Clutch System (3rd)
TM
L03
Electrical system
15N0MW
Failure code [15N0MW] Failure of Clutch System (4th)
TM
L03
Electrical system
15SBL1
Failure code [15SBL1] Release Trouble of ECMV (R)
TM
L01
Electrical system
15SBMA
Failure code [15SBMA] Malfunction of ECMV (R)
TM
L03
Electrical system
15SCL1
Failure code [15SCL1] Release Trouble of ECMV (FH)
TM
L01
Electrical system
15SCMA
Failure code [15SCMA] Malfunction of ECMV (FH)
TM
L03
Electrical system
15SDL1
Failure code [15SDL1] Release Trouble of ECMV (FL)
TM
L01
Electrical system
15SDMA
Failure code [15SDMA] Malfunction of ECMV (FL)
TM
L03
Electrical system
15SEL1
Failure code [15SEL1] Release Trouble of ECMV (1st)
TM
L01
Electrical system
15SEMA
Failure code [15SEMA] Malfunction of ECMV (1st)
TM
L03
Electrical system
15SFL1
Failure code [15SFL1] Release Trouble of ECMV (2nd)
TM
L01
Electrical system
15SFMA
Failure code [15SFMA] Malfunction of ECMV (2nd)
TM
L03
Electrical system
15SGL1
Failure code [15SGL1] Release Trouble of ECMV (3rd)
TM
L01
Electrical system
15SGMA
Failure code [15SGMA] Malfunction of ECMV (3rd)
TM
L03
Electrical system
15SHL1
Failure code [15SHL1] Release Trouble of ECMV (4th)
TM
L01
Electrical system
15SHMA
Failure code [15SHMA] Malfunction of ECMV (4th)
TM
L03
Electrical system
15SJMA
Failure code [15SJMA] Malfunction of ECMV (L/U)
TM
L03
Electrical system
1500L0
40-34
Failure (displayed on screen)
GD535-5 (03)
40 Troubleshooting
Failure code
Failure code list
Failure (displayed on screen)
Applicable equipment
Action level
History category
TM
L02
Mechanical system
15U0NT
Failure code [15U0NT] Overload of Inching Clutch
2G42ZG
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front)
MON
L03
Mechanical system
2G43ZG
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear)
MON
L03
Mechanical system
989L00
Failure code [989L00] Engine Controller Lock Caution1
MON
-
Electrical system
989M00
Failure code [989M00] Engine Controller Lock Caution2
MON
-
Electrical system
989N00
Failure code [989N00] Engine Controller Lock Caution3
MON
-
Electrical system
AB00KE
Failure code [AB00KE] Charge Voltage Low
MON
L03
Electrical system
AB00KY
Failure code [AB00KY] Hot Short of Alternator R TerminalTerminal
TM
L03
Electrical system
B@BAZG
Failure code [B@BAZG] Derating in speed due to engine oil pressure drop
ENG
L03
Electrical system
B@BCNS
Failure code [B@BCNS] Engine Overheat
ENG
L02
Mechanical system
B@CENS
Failure code [B@CENS] T/C Oil Temp. Overheat
MON
L02
Mechanical system
B@CKNS
Failure code [B@CKNS] DIFF Oil Temp. Overheat
MON
L02
Mechanical system
B@HANS
Failure code [B@HANS] HYD Oil Temp. Overheat
MON
L02
Mechanical system
CA111
Failure code [CA111] Engine controller internal error
ENG
L03
Electrical system
CA115
Failure code [CA115] Engine Ne, Bkup speed sensor error
ENG
L03
Electrical system
CA122
Failure code [CA122] Charge pressure sensor high error
ENG
L03
Electrical system
CA123
Failure code [CA123] Charge pressure sensor low error
ENG
L03
Electrical system
CA131
Failure code [CA131] Throttle sensor high error
ENG
L03
Electrical system
CA132
Failure code [CA132] Throttle sensor low error
ENG
L03
Electrical system
CA144
Failure code [CA144] Coolant sensor high error
ENG
L01
Electrical system
CA145
Failure code [CA145] Coolant sensor low error
ENG
L01
Electrical system
CA153
Failure code [CA153] Charge temperature sensor high error
ENG
L01
Electrical system
CA154
Failure code [CA154] Charge temperature sensor low error
ENG
L01
Electrical system
GD535-5 (03)
40-35
Failure code list
Failure code
40 Troubleshooting
Failure (displayed on screen)
Applicable equipment
Action level
History category
CA155
Failure code [CA155] Speed derating error by high charge temperature
ENG
L03
Electrical system
CA187
Failure code [CA187] Sensor power supply 2 low error
ENG
L03
Electrical system
CA221
Failure code [CA221] Atmospheric pressure sensor high error
ENG
L01
Electrical system
CA222
Failure code [CA222] Atmospheric pressure sensor low error
ENG
L01
Electrical system
CA227
Failure code [CA227] Sensor power supply 2 high error
ENG
L03
Electrical system
CA234
Failure code [CA234] Engine overspeed
ENG
L02
Mechanical system
CA238
Failure code [CA238] Ne speed sensor power supply error
ENG
L03
Electrical system
CA271
Failure code [CA271] IMV/IMA: Short circuit
ENG
L03
Electrical system
CA272
Failure code [CA272] IMV/IMA open circuit
ENG
L03
Electrical system
CA322
Failure code [CA322] Injector #1 (L#1) open/short
ENG
L03
Electrical system
CA323
Failure code [CA323] Injector #5 (L#5) open/short
ENG
L03
Electrical system
CA324
Failure code [CA324] Injector #3 (L#3) open/short
ENG
L03
Electrical system
CA325
Failure code [CA325] Injector #6 (L#6) open/short
ENG
L03
Electrical system
CA331
Failure code [CA331] Injector #2 (L#2) open/short
ENG
L03
Electrical system
CA332
Failure code [CA332] Injector #4 (L#4) open/short
ENG
L03
Electrical system
CA342
Failure code [CA342] Data compatibility error in engine controller
ENG
L03
Electrical system
CA351
Failure code [CA351] Injector drive circuit error
ENG
L03
Electrical system
CA352
Failure code [CA352] Sensor power supply 1 low error
ENG
L03
Electrical system
CA386
Failure code [CA386] Sensor power supply 1 high error
ENG
L03
Electrical system
CA428
Failure code [CA428] Water-in-fuel sensor high error
ENG
L01
Electrical system
CA429
Failure code [CA429] Water-in-fuel sensor low error
ENG
L01
Electrical system
CA431
Failure code [CA431] Idle validation switch error
ENG
L01
Electrical system
CA432
Failure code [CA432] Idle validation action error
ENG
L03
Electrical system
40-36
GD535-5 (03)
40 Troubleshooting
Failure code
Failure code list
Failure (displayed on screen)
Applicable equipment
Action level
History category
CA435
Failure code [CA435] Engine oil pressure switch error
ENG
L01
Electrical system
CA441
Failure code [CA441] Power supply voltage low error
ENG
L03
Electrical system
CA442
Failure code [CA442] Power supply voltage high error
ENG
L03
Electrical system
CA449
Failure code [CA449] Common rail pressure high error 2
ENG
L03
Electrical system
CA451
Failure code [CA451] Common rail pressure sensor high error
ENG
L03
Electrical system
CA452
Failure code [CA452] Common rail pressure sensor low error
ENG
L03
Electrical system
CA488
Failure code [CA488] Torque derating error by high charge temperature
ENG
L03
Electrical system
CA553
Failure code [CA553] Common rail pressure high error 1
ENG
L03
Electrical system
CA559
Failure code [CA559] Supply pump pressure low error 1
ENG
L03
Electrical system
CA689
Failure code [CA689] Engine Ne speed sensor error
ENG
L03
Electrical system
CA731
Failure code [CA731] Engine Bkup speed sensor phase error
ENG
L03
Electrical system
CA757
Failure code [CA757] All continuous data lost error
ENG
L03
Electrical system
CA778
Failure code [CA778] Engine Bkup speed sensor error
ENG
L03
Electrical system
CA1633
Failure code [CA1633] KOMNET (CAN communication) error
ENG
L03
Electrical system
CA2185
Failure code [CA2185] Throttle sensor power supply high error
ENG
L03
Electrical system
CA2186
Failure code [CA2186] Throttle sensor power supply low error
ENG
L03
Electrical system
CA2249
Failure code [CA2249] Supply pump pressure low error 2
ENG
L03
Electrical system
CA2311
Failure code [CA2311] Abnormality in IMV (IMA) solenoid
ENG
L03
Electrical system
CA2555
Failure code [CA2555] Intake heater relay open circuit
ENG
L01
Electrical system
CA2556
Failure code [CA2556] Intake heater relay short circuit
ENG
L01
Electrical system
D160KA
Failure code [D160KA] Disconnection of Backup Light Relay
TM
L01
Electrical system
D160KB
Failure code [D160KB] Ground Fault of Backup Light Relay
TM
L01
Electrical system
D160KY
Failure code [D160KY] Hot Short of Backup Lamp Relay Output
TM
L01
Electrical system
GD535-5 (03)
40-37
Failure code list
Failure code
40 Troubleshooting
Failure (displayed on screen)
Applicable equipment
Action level
History category
MON
L03
Electrical system
D19JKZ
Failure code [D19JKZ] Personal Code Relay Abnormality
D19KKZ
Failure code [D19KKZ] Failure of Diff Control Relay
TM
L01
Electrical system
D1EHKA
Failure code [D1EHKA] Disconnection of Engine Start Relay
TM
L03
Electrical system
D1EHKB
Failure code [D1EHKB] Ground Fault of Engine Start Relay
TM
L03
Electrical system
D1EHKY
Failure code [D1EHKY] Hot Short of Engine Start Relay
TM
L03
Electrical system
D1FBKB
Failure code [D1FBKB] Ground Fault of Sol. Self-Holding Relay
TM
L03
Electrical system
D8AQK4
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2
MON
L03
Electrical system
D8AQKR
Failure code [D8AQKR] CAN2 Discon (KOMTRAX)
MON
-
Electrical system
DAF0KT
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON)
MON
L03
Electrical system
DAF0MB
Failure code [DAF0MB] Monitor ROM Abnormality
MON
-
Electrical system
DAF0MC
Failure code [DAF0MC] Monitor Error
MON
-
Electrical system
DAF3KK
Failure code [DAF3KK] Controller Power Source Low (MON)
MON
-
Electrical system
DAQ0KK
Failure code [DAQ0KK] Controller Power Source Low (T/M)
TM
L03
Electrical system
DAQ0KT
Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M)
TM
L01
Electrical system
DAQ0MC
Failure code [DAQ0MC] T/M Con Error
TM
-
Electrical system
DAQ1KA
Failure code [DAQ1KA] Disconnection of Key SW ACC
TM
L03
Electrical system
DAQ2KK
Failure code [DAQ2KK] Solenoid Power Source Low (T/M)
TM
L03
Electrical system
DAQ9KQ
Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M)
TM
L03
Electrical system
DAQQKR
Failure code [DAQQKR] CAN2 Discon (Transmission Con)
MON
L03
Electrical system
DAQRMA
Failure code [DAQRMA] Inconsistency of Option Selection (T/M)
TM
L03
Electrical system
DB2QKR
Failure code [DB2QKR] CAN2 Discon (Engine Con)
MON
L03
Electrical system
DD1PKB
Failure code [DD1PKB] Abnormality of RPM Switch
TM
L03
Electrical system
DD1QKB
Failure code [DD1QKB] Abnormality of RPM Set Mode Switch
TM
L03
Electrical system
40-38
GD535-5 (03)
40 Troubleshooting
Failure code
Failure code list
Failure (displayed on screen)
Applicable equipment
Action level
History category
DDB6L4
Failure code [DDB6L4] Parking brake signal error
TM
L03
Electrical system
DDTHKA
Failure code [DDTHKA] Disconnection of Fill Switch (FH)
TM
L01
Electrical system
DDTJKA
Failure code [DDTJKA] Disconnection of Fill Switch (FL)
TM
L01
Electrical system
DDTKKA
Failure code [DDTKKA] Disconnection of Fill Switch (1st)
TM
L01
Electrical system
DDTLKA
Failure code [DDTLKA] Disconnection of Fill Switch (2nd)
TM
L01
Electrical system
DDTMKA
Failure code [DDTMKA] Disconnection of Fill Switch (3rd)
TM
L01
Electrical system
DDTNKA
Failure code [DDTNKA] Disconnection of Fill Switch (R)
TM
L01
Electrical system
DDTPKA
Failure code [DDTPKA] Disconnection of Fill Switch (4th)
TM
L01
Electrical system
DF10KA
Failure code [DF10KA] Disconnection of Shift Lever Input
TM
L03
Electrical system
DF10L4
Failure code [DF10L4] Gear speed/travel direction signal error
TM
L03
Electrical system
DGF1KX
Failure code [DGF1KX] Out of Range of T/M Oil Temp. Sensor
TM
L03
Electrical system
DGH2KB
Failure code [DGH2KB] Ground Fault of Hydraulic Oil Temp. S
TM
L01
Electrical system
DGT1KX
Failure code [DGT1KX] Out of Range of T/C Oil Temp. Sensor
TM
L01
Electrical system
DGT7KB
Failure code [DGT7KB] Ground Fault of Diff Oil Temp. S.(C)
TM
L01
Electrical system
DHT5KX
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor
TM
L01
Electrical system
DHT5L6
Failure code [DHT5L6] Failure of T/C Oil Press Sensor
TM
L01
Electrical system
DJF1KA
Failure code [DJF1KA] Disconnection of Fuel Level Sensor
MON
L01
Electrical system
DK70KX
Failure code [DK70KX] Out of Range of Inching Potentio.
TM
L03
Electrical system
DKD0KX
Failure code [DKD0KX] Out of Range of Articulate Angle Sensor
TM
L01
Electrical system
DLF1KA
Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor
TM
L03
Electrical system
DLF1LC
Failure code [DLF1LC] Failure of T/M Input Speed Sensor
TM
L03
Electrical system
DLF2KA
Failure code [DLF2KA] Disconnection of T/M Inter. Speed Sensor
TM
L03
Electrical system
DLF2LC
Failure code [DLF2LC] Failure of T/M Intermediate Speed Sensor
TM
L03
Electrical system
GD535-5 (03)
40-39
Failure code list
Failure code
40 Troubleshooting
Failure (displayed on screen)
Applicable equipment
Action level
History category
DLM3KA
Failure code [DLM3KA] Rad Fan Spd Sen Opn/Shrt Cir
TM
L01
Electrical system
DLM3LC
Failure code [DLM3LC] Rad Fan Spd Sen Sig Error
TM
L03
Electrical system
DLM3MB
Failure code [DLM3MB] Rad Fan Spd Sen Error
TM
L01
Electrical system
DLT3KA
Failure code [DLT3KA] Disconnection of T/M output Speed Sensor
TM
L03
Electrical system
DW4BKA
Failure code [DW4BKA] Disconnection of Parking Brake Valve
TM
L03
Electrical system
DW4BKB
Failure code [DW4BKB] Ground Fault of Parking Brake Valve
TM
L03
Electrical system
DW4BKY
Failure code [DW4BKY] Hot Short of Parking Brake Solenoid
TM
L03
Electrical system
DXH1KA
Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup)
TM
L03
Electrical system
DXH1KB
Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup)
TM
L03
Electrical system
DXH1KY
Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup)
TM
L03
Electrical system
DXH2KA
Failure code [DXH2KA] Disconnection of ECMV Solenoid (High)
TM
L03
Electrical system
DXH2KB
Failure code [DXH2KB] Ground Fault of ECMV Solenoid (High)
TM
L03
Electrical system
DXH2KY
Failure code [DXH2KY] Hot Short of ECMV Solenoid (High)
TM
L03
Electrical system
DXH3KA
Failure code [DXH3KA] Disconnection of ECMV Solenoid (Low)
TM
L03
Electrical system
DXH3KB
Failure code [DXH3KB] Ground Fault of ECMV Solenoid (Low)
TM
L03
Electrical system
DXH3KY
Failure code [DXH3KY] Hot Short of ECMV Solenoid (Low)
TM
L03
Electrical system
DXH4KA
Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st)
TM
L03
Electrical system
DXH4KB
Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st)
TM
L03
Electrical system
DXH4KY
Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st)
TM
L03
Electrical system
DXH5KA
Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd)
TM
L03
Electrical system
DXH5KB
Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd)
TM
L03
Electrical system
DXH5KY
Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd)
TM
L03
Electrical system
DXH6KA
Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd)
TM
L03
Electrical system
40-40
GD535-5 (03)
40 Troubleshooting
Failure code
Failure code list
Failure (displayed on screen)
Applicable equipment
Action level
History category
DXH6KB
Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd)
TM
L03
Electrical system
DXH6KY
Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd)
TM
L03
Electrical system
DXH7KA
Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse)
TM
L03
Electrical system
DXH7KB
Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse)
TM
L03
Electrical system
DXH7KY
Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse)
TM
L03
Electrical system
DXHHKA
Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th)
TM
L03
Electrical system
DXHHKB
Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th)
TM
L03
Electrical system
DXHHKY
Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th)
TM
L03
Electrical system
a This table lists failure codes in alphabetical order. a Applicable equipment is the controller or machine monitor which checks the system. MON: Machine monitor ENG: Engine controller TM: Transmission controller a The failure codes that do not have numbers in Action Level columns are not displayed on the standard screen even when a failure related to them occurs. They are simply recorded in the abnormality record (electrical system or mechanical system) of the service menu. a History category means the classification of either electrical system or mechanical system which is used for storage in the Failure History of the service menu.
GD535-5 (03)
40-41
Symptoms and troubleshooting numbers
40 Troubleshooting
Symptoms and troubleshooting numbers No.
Symptom of failure
1
Troubleshooting Index
Described page
Action code and failure code 1
The action code and failure code are displayed on the machine monitor.
2
The abnormality record is checked and the failure code is displayed in the Mechanical System Abnormality Record.
3
The abnormality record is checked and the failure code is displayed in the Electrical System Abnormality Record.
No.
Symptom of failure
Perform troubleshooting for failure code
Troubleshooting Index
Described page
S-1
40-536
E-1, S-2
40-402, 40-537
S-3
40-540
S-4, H-1
40-541, 40-500
Symptom related to engine 4
Engine startability is poor.
5
Engine does not start.
6
Engine does not pick-up smoothly.
7
Engine stops during operation.
8
Engine runs rough or is unstable.
S-5
40-542
9
Engine lacks power.
S-6
40-543
10
Exhaust smoke is black (Incomplete combustion)
S-7
40-544
11
Large oil consumption (or blue exhaust gas)
S-8
40-545
12
Oil becomes contaminated early.
S-9
40-546
13
Fuel consumption is excessive.
S-10
40-547
14
Oil is in coolant (or coolant spurts back or coolant level goes down).
S-11
40-548
15
Oil pressure drops.
S-12
40-549
16
Oil amount increases (due to water or fuel insertion).
S-13
40-550
17
Coolant temperature rises too high (overheating).
S-14
40-551
18
Unusual noise is heard.
S-15
40-552
19
Vibration is excessive
S-16
40-553
20
Preheating system does not work.
E-2
40-406
Symptom related to power train 21
Machine does not move off.
H-2
40-501
22
Gear speed does not shift.
H-3
40-502
23
Travel speed or power is low.
H-4
40-503
24
Torque converter lockup does not operate or is not canceled.
H-5
40-506
25
Machine starts or gear speed shifts with long time lag.
H-6
40-507
26
Torque converter oil temperature is high.
H-7
40-510
27
Differential gear lock function does not operate or is not canceled.
H-8, E-19
40-513, 40-437
H-9
40-514
Symptoms related to steering 28
40-42
Steering speed or power is insufficient.
GD535-5 (03)
40 Troubleshooting
No. 29
Symptoms and troubleshooting numbers
Symptom of failure Steering wheel does not move.
Troubleshooting Index
Described page
H-10
40-515
Symptoms related to brake 30
Wheel brakes do not work or are weak.
H-11
40-516
31
Wheel brakes are not released or drag.
H-12
40-517
32
Parking brake does not work or its performance is low.
H-13
40-518
33
Parking brake (including emergency release system) is not released or drags.
H-14
40-519
Symptoms related to work equipment 34
All work equipment operates slowly or lacks power.
H-15
40-520
35
All work equipment do not operate.
H-16
40-521
36
Unusual noise is heard from around hydraulic pump.
H-17
40-522
37
Blade lift speed or power is low.
H-18
40-523
38
Hydraulic drift of lifted blade is large.
H-19
40-524
39
Drawbar side shift speed or power is low.
H-20
40-525
40
Blade cross slide speed or power is low.
H-21
40-526
41
Power tilt speed or power is low.
H-22
40-527
42
Articulate speed or power is low.
H-23
40-528
43
Leaning speed or power is insufficient.
H-24
40-529
44
Hydraulic drift (tilting) of leaning is large.
H-25
40-530
45
Blade does not rotate.
H-26
40-531
46
Lifter lock pin is not locked or is not canceled.
H-27, E-16
40-532, 40-431
Symptom related to machine monitor 47
When starting switch is turned to ON position, machine monitor displays nothing.
E-3
40-412
48
The LCD panel backlight of machine monitor fails (goes out or flickers).
E-4
40-415
49
LCD display failure of machine monitor
E-5
40-416
50
The switch of machine monitor switch panel does not work.
E-6
40-417
51
2 switches operation of switch panel on machine monitor does not function
E-7
40-418
52
The machine monitor buzzer does not sound.
E-8
40-419
53
Some gauge or caution lamps of machine monitor do not work normally.
E-9
40-420
54
Speedometer or engine speed display is abnormal.
E-10
40-421
55
Engine coolant temperature is displayed abnormally.
E-11
40-422
56
Articulated meter display is abnormal.
E-12
40-424
57
Torque converter oil temperature is displayed abnormally.
E-13
40-426
58
Fuel gauge is displayed abnormally.
E-14
40-428
59
Centralized warning lamps do not light up or go out.
E-15
40-430
60
Alarm buzzer does not sound or does not stop sounding.
E-16
40-431
GD535-5 (03)
40-43
Symptoms and troubleshooting numbers
No.
40 Troubleshooting
Troubleshooting
Symptom of failure
Index
Described page
See section 80, "Explanation of procedure for testing and troubleshooting of air conditioner".
80-24
Others
61
Air conditioner does not work normally. (Including failure codes for air conditioner)
62
Transmission mode cannot be switched.
E-17
40-433
63
Engine mode cannot be switched.
E-18
40-435
64
Differential gear lock function does not operate or is not canceled (for differential gear lock model).
E-19
40-437
65
Cannot be locked or canceled by the lifter lock pin.
E-20
40-439
66
Horn does not sound or does not stop sounding.
E-21
40-441
67
Backup alarm does not sound or does not stop sounding
E-22
40-443
68
Headlamps, clearance lamps, and tail lamps do not light up or go out.
E-23
40-446
69
Working lamps do not light up or go out.
E-24
40-454
70
Turn indicator light or emergency flashing light does not flash.
E-25
40-459
71
Stop lamp does not light up or does not go out
E-26
40-468
72
Backup lamp does not light up or does not go out
E-27
40-470
73
All wipers do not operate
E-28
40-472
74
Front wiper does not operate
E-29
40-474
75
Rear wiper does not operate
E-30
40-478
76
Left and right door wiper does not operate
E-31
40-481
77
Left door wiper does not operate
E-32
40-484
78
Right door wiper does not operate
E-33
40-486
79
Front or door washer does not operate
E-34
40-488
80
Rear washer does not operate
E-35
40-490
81
KOMTRAX system does not operate normally.
E-36
40-492
40-44
GD535-5 (03)
40 Troubleshooting
Information described in troubleshooting table
Information described in troubleshooting table
1
(Rev. 2010/02) a The following information is summarized in the troubleshooting table. Before performing troubleshooting, understand that information fully. Action code
Failure code
Display on machine monitor
Display on machine monitor
Detail of failure
Failure
Failure name displayed on Abnormality Record screen of the machine monitor
Description of the failure detected by the machine monitor or controller
Response by the machine An action that is performed to protect the system and devices when a failure is detected by the machine monitor or monitor or controller controller Problem on machine
A problem that appears as a failure on the machine as a result of an action (shown above) that is performed by the machine monitor or controller.
Related information
Information on occurred failure or troubleshooting
No.
Cause
Procedure, measuring location, criteria, and remarks
Procedure q Measurement location q
1
Defective ---
a "Between A and B" denotes measuring values such as voltage and resistance between A and B.
Criteria to judge probable causes (during normal) Remarks for determination of probable cause Open or short circuit in q Perform troubleshooting procedures in following order. wiring harness q If the check result does not meet the criteria, the probable cause described on the left column is the actual cause of the failure. q If the check result meet the criteria and there is no specific instruction, proceed to the next Open circuit in wiring step (cause). harness q If a defect is found and repaired, check that the defect has been corrected. (Wire breakage or
defective contact of q Open circuit connector) Connection of connector is defective or wiring harness is broken. q Ground fault Ground fault in wiring A wiring harness not to be connected to the ground (earth) circuit comes into contact with harness the ground (earth) circuit or chassis accidentally. (Contact with ground q Hot short circuit circuit) A wiring harness not to be connected to the power (24 V) circuit comes into contact with the power (24 V) circuit accidentally. q Short circuit Hot short circuit An independent wire in the harness abnormally comes into contact with another wire. (Contact with ground (Defective insulation in connector or others) circuit)
(1) Connector number indication method and handling of T-adapter For troubleshooting, insert or connect T-adapters as follows unless otherwise specified. q q
2
3
4
5
6
Short circuit in wiring harness
q
q
7
Defective controller
(2) Pin number description sequence and tester lead handling For troubleshooting, connect the positive (+) and negative (-) leads as shown below unless otherwise specified. q q
GD535-5 (03)
When "Male" or "Female" is not indicated with a connector number, disconnect the connector, and insert T-adapter between the male and female connectors. When "Male" or "Female" is indicated with a connector number, disconnect the connector, and connect T-adapter to the indicated side of connector.
Connect the positive (+) lead to pin or wiring harness indicated first. Connect the negative (-) lead to a pin or wiring harness indicated second.
40-45
Information described in troubleshooting table
40 Troubleshooting
Related circuit diagram
This is the excerpted circuit diagram related to troubleshooting q The circuit diagram contains the connector No., pin No., and connector color related to the failure. q The circuit diagram contains the destination or source of the branch line in a wiring harness. q Arrow (io): Approximate installation portion on the machine. q NO: Normally Open q NC: Normally Closed
40-46
GD535-5 (03)
40 Troubleshooting
Diagnosis of open harness in pressure sensor system
Diagnosis of open harness in pressure sensor system
1
The pressure sensor consists of not only resistors but electronic devices such as amps. As their characteristics and polarity may vary, they must be measured carefully. Applicable failure codes q CA123: Charge air pressure sensor low error q CA451: Common rail pressure sensor high error Procedure 1. Measure the resistance of pressure sensor alone, and write it down. 1) Unplug connector (1) of the pressure sensor, and plug the connector into socket (2) at sensor side. 2) Measure resistance R1 and R2 between each pin. q If you touch the multimeter probes in reverse polarity, the measurement value may change. Apply probes in the correct polarity in Steps 1 and 2, and measure the resistance. q If the measured value is infinite, reverse the polarity and use the value that you can measure. q As the measured value may vary, measure the resistance several times. This may be caused by electrical charge in the sensor. Measure the resistance several times in a similar way to Steps 1 and 2. In Step 3, consider this variation and check the wiring harness for an open.
2. Connect the engine controller harness to the pressure sensor, measure the resistance of pressure sensor, and write it down. 1) As the 5 V power of the pressure sensor is also supplied to other sensors, unplug the other sensor connectors. (*) 2) Keeping the pressure sensor you wish to measure connected, unplug connector (3) from the engine controller, and connect T-adapter (4) to the wiring harness. 3) Connect T-box (5) to T-adapter (4), and measure resistance R1' and R2' between each pin. 3. Determining of disconnection If there is an apparent difference between resistance R1 and R2 measured in Step 1 and resistance R1' and R2' measured in Step 2, you may ascertain that "the wiring harness is open-circuited".
GD535-5 (03)
40-47
Diagnosis of open harness in pressure sensor system
40 Troubleshooting
Measurement points of pressure sensor, and reference value list Sensor
Charge pressure sensor
Common rail pressure sensor
Sensor pins measured
Measured resistance inside of sensor (Reference value)
R2: Between pins (2) and (4)
Approx. 100 z
R1: Between pins (1) and (4)
Approx. 200 z
R2: Between pins (3) and (1)
Approx. 23 kz
R1: Between pins (1) (Positive) and (2) (Negative)
Remarks
Sensors are common to engines 107 and 114
Infinite resistance if polarity is reversed Approx. 10 Mz
* Unplug the following sensor connectors during R2' measurement. (See the related circuit diagrams of each code.) q When measuring the R2' resistance of charge pressure sensor (CA123): Connectors of atmospheric pressure sensor, CAM sensor, and crankcase pressure sensor q When measuring the R2' resistance of common rail pressure sensor (CA451): Because the 5V power is used exclusively, this power supply has no connector to be unplugged. Measurement note (See the related circuit diagrams of each code for the measurement point.) Sensor
Charge pressure sensor
Common rail pressure sensor
40-48
Sensor alone (Measurement point at sensor pin side)
Measured value
Sensor + Wiring harness Measured (Measurement point at harness side of value engine controller)
R2: Between pins (2) and (4)
R2': Between pins (78) and (54) (*)
R1: Between pins (1) and (4)
R1': Between pins (45) and (54)
R2: Between pins (3) and (1)
R2': Between pins (78) and (54) (*)
R1: Between pins (1) (Positive) and (2) (Negative)
R1': Between pins (58) (Positive) and (42) (Negative)
GD535-5 (03)
40 Troubleshooting
Connector list and layout
Connector list and layout
1
Connector No.
Connector type
Number of pins
A.PRESS.SEN.
FRAMATOME
3
Ambient pressure sensor
AK-3
AC1
YAZAKI
12
Air conditioner unit
BG-2
AC3
YAZAKI
14
Intermediate connector
BN-3
AC4
YAZAKI
6
Intermediate connector
BN-2
AC5
AMP
20
Air conditioner control panel
BK-9
AC6
AMP
16
Air conditioner control panel
BK-9
B.PRESS.TEMP.SEN.
SUMITOMO
4
Boost pressure and boost temperature sensor
AM-5
B11
DT
3
Articulation sensor
U-1,BF-1
B13
DT
2
Brake lamp switch
R-1,BB-1
B15
KES1
2
Window washer (door)
BE-1
B16
YAZAKI
2
Window washer (front)
BD-1
B17
YAZAKI
2
Window washer (rear)
BD-1
B19
DT
2
Power connector
B20
DT
2
Diode
BF-1
B21
DT
2
Diode
BE-1
B22
DT
2
Diode
BE-1
B25
DT
2
Diode
S-9,BE-9
BZ
DT
2
Backup alarm
L-7,AT-9
BZ1
DT
2
Intermediate connector
BD-1
BZ2
Relay
5
Differential lock buzzer relay
BB-9
BZ3
DT
2
Differential lock alarm buzzer
BA-8
C.RAIL.PRESS.SEN.
BOSCH
3
Common rail pressure sensor
AP-4
C1
DT
12
Intermediate connector
BN-2
C2
DT
12
Intermediate connector
BN-3
C3
DT
2
Room lamp
BI-8
C5
YAZAKI
9
RADIO
BJ-9
C6
DT
2
Speaker (R.H.)
BL-9
C7
DT
2
Speaker (L.H.)
BN-8
C11
M
4
Door wiper motor (L.H.)
BL-1
C12
Relay
6
Front wiper relay (Lo)
BG-8
C13
M
4
Door wiper motor (R.H.)
BI-3
C14
Relay
6
Front wiper relay (Hi)
BG-8
C15
DT
6
Front wiper motor
BJ-1
C16
M
4
Rear wiper motor
BG-8
C20
SWP
6
Yellow revolving warning lamp switch
BN-5
C21
SWP
6
Working lamp switch
BN-4
C22
Relay
4
Working lamp relay
BG-7
C23
DT
2
Working lamp (if equipped)
BI-4
GD535-5 (03)
Installation location
Layout address
W-2,BG-2
40-49
Connector list and layout
40 Troubleshooting
Connector No.
Connector type
Number of pins
C24
DT
2
Working lamp (if equipped)
BI-5
C25
DT
2
Working lamp (if equipped)
BI-6
C26
DT
2
Working lamp (if equipped)
BI-6
C27
M
3
Turn signal (Right) (If equipped)
BI-5
C28
M
3
Turn signal (Left) (If equipped)
BI-5
C29
DT
2
Intermediate connector
BI-6
C30
DT
2
Yellow revolving warning lamp
BI-7
C31
Relay
6
Yellow revolving warning lamp relay
BG-7
C32
DT
2
Buzzer
BM-9
C33
SWP
6
Brightness adjustment switch
BN-6
C38
DT
2
Diode
BI-2
C39
DT
2
Interlock solenoid
BI-2
C40
M
1
Door switch (R.H.)
BI-7
C41
M
1
Door switch (L.H.)
BJ-1
C42
Relay
5
Interlock solenoid relay
BI-2
C43
DT
12
Intermediate connector
BM-2
C46
DT
12
Intermediate connector
BM-2
C51
Relay
6
Rear wiper intermittent relay
BG-7
C53
YAZAKI
11
Rear wiper timer
BB-1
C54
YAZAKI
11
Door wiper timer
AY-2
CAN
DT
12
KOMNET service connector
CAN
DT
3
CAN
AL-2
CAN1
DT
3
CAN terminating resistor
AN-1
CON
DT
6
12V converter
BG-4
CT41
Terminal
1
Ground
J-3,AT-3
CT42
Terminal
1
Ground
BJ-9
E01
DT
2
Safety relay
AK-7
E02
Terminal
1
Alternator terminal R
AO-8
E07
Terminal
1
Grid heater
AM-5
E19
Terminal
1
Safety relay
AK-8
E20
Terminal
1
Safety relay
AK-7
E21
Terminal
1
Starting motor terminal C
AM-5
E29
Terminal
1
Alternator terminal B
AO-9
E30
Terminal
1
Starting motor terminal B
E31
Terminal
1
Slow-blow fuse
AN-5
E32
Terminal
1
Slow-blow fuse
AO-7
E33
Terminal
1
Slow-blow fuse
AO-7
EC2
DRC
50
Engine controller
AL-2
EC3
DTP
4
Engine controller
AM-1
ECM
DRC
60
Engine controller
AM-1
40-50
Installation location
Layout address
W-5,BG-5
J-3,AT-3
GD535-5 (03)
40 Troubleshooting
Connector list and layout
Connector No.
Connector type
Number of pins
ENG.PRESS.SW.
FRAMATOME
1
Engine oil pressure switch (low pressure)
AP-2
ENG.W.TEMP.SW.
PACKARD
2
Engine coolant temperature sensor
AK-4
ER1
DT
12
Intermediate connector
AO-6
ER2
DT
2
Intermediate connector
AO-7
ER3
DT
12
Intermediate connector
AO-6
ET39
DT
2
Fuel level sensor
L-5,AV-5
ET40B
Terminal
1
Ground
K-4,AU-4
ET41A
Terminal
1
Battery
L-2,AV-2
ET42
Terminal
1
Battery
L-2,AV-2
ET43
Terminal
1
Battery
L-3,AV-3
ET44
Terminal
1
Battery
K-3,AU-3
ET45
Terminal
1
Battery relay
J-3,AT-3
ET46
Terminal
1
Battery relay
J-3,AT-3
ET47
Terminal
1
Slow-blow fuse
K-3,AU-3
ET48
Terminal
1
Slow-blow fuse
L-3,AV-3
ET49
Terminal
1
Battery relay
J-2,AT-2
ET54
Terminal
1
Heater relay
AM-5
ET58
Terminal
1
Battery relay
J-2,AT-2
ET59
Terminal
1
Slow-blow fuse
L-1,AV-1
ET60
Terminal
1
Slow-blow fuse
L-2,AV-2
ET75
Terminal
1
Battery relay
J-2,AT-2
ET76
Terminal
1
Battery relay
J-2,AT-2
ET77
Terminal
1
Ground
J-3,AS-3
ET82
Terminal
1
Heater relay
AN-5
ET88
DT
2
Air conditioner compressor (if equipped)
AO-1
ET89
Terminal
1
Ground
H-2,AR-2
ET103A
Terminal
1
Ground
AO-2
ET103B
Terminal
1
Ground
AP-2
ET104
DT
2
Alternator terminal R
AK-6
FB1
―
15
Fuse box
W-6,BG-7
FB2
―
15
Fuse box
W-6,BG-6
FB3
―
15
Fuse box
BG-6
FL1
DT
3
Headlamp (R.H.)
A-3,AK-3
FL2
DT
3
Headlamp (L.H.)
A-1,AK-1
FL3
DT
3
Front combination lamp (R.H.)
AK-3
FL4
DT
3
Front combination lamp (L.H.)
AL-1
FL6
DT
3
Intermediate connector
I-9,AS-9
FL6
DT
3
Inching pedal
Q-1,BA-1
FL7
X
2
Horn
A-3
FL8
X
2
Horn
A-1,AK-1
GD535-5 (03)
Installation location
Layout address
40-51
Connector list and layout
40 Troubleshooting
Connector No.
Connector type
Number of pins
FL9
DT
2
Working lamp (R.H.)
D-8,AN-8
FL10
DT
2
Working lamp (L.H.)
F-9,AP-9
FL17
DT
12
Intermediate connector
P-1,AZ-1
FLG2
Terminal
1
Ground (ROPS frame)
E-8,AO-8
FP1
AMP070
12
Machine monitor
N-5,AX-5
FP3
DT
12
Monitor panel
O-9,AX-6
FP4
M
2
Alarm buzzer
N-4,AX-3
FP7
DT
6
Dimmer switch
N-5,AX-4
FP8
DT
3
Turn signal switch
O-9,AX-5
FP9
DT
2
Horn switch
M-7,AX-5
FP12
SWP
6
Differential lock switch
N-6,AX-6
FT11
Terminal
1
Ground
U-1,BF-11
FT12
Terminal
1
Ground
G-1,AQ-1
FT13
Terminal
1
Ground
I-3,AS-3
FT14
Terminal
1
Ground
BF-1
G SEN.
FRAMATOME
3
G sensor
AL-1
H10
YAZAKI
1
Rear window glass heating wire
BK-9
H11
YAZAKI
1
Rear window glass heating wire
BN-6
H12
SWP
6
Electrically heated rear window glass switch
BN-5
H13
DT
2
Rearview mirror heater (if equipped)
BI-4
H14
SWP
6
Heated rearview mirror switch
BN-5
H15
Relay
6
Rear line heater relay
GB-7
H17
AMP
8
Rear window glass heater timer
BG-3
IMA
BOSCH
2
IMA fuel pump actuator
AP-3
ING. #1,2
DTP
4
Injector #1, 2
AL-4
ING. #3,4
DTP
4
Injector #3, 4
AN-5
ING. #5,6
DTP
4
Injector #5, 6
AO-5
L21
S
10
Wiper switch
AX-5
L48
DT
6
Front wiper timer
BG-2
L80A
070
18
KOMTRAX controller
W-3,BG-6
L80B
070
12
KOMTRAX controller
W-4,BG-6
NE.SEN.
FRAMATOME
3
NE sensor
OPT2
DT
2
Power connector (ACC power supply)
V-1,BF-2
R1
DRC
70
Intermediate connector
T-1,BE-1
R4
DT
2
Intermediate connector
T-1,BC-1
R5
DTHD
1
Intermediate connector
S-1,BC1
R6
DTHD
1
Intermediate connector
S-1,BC-1
R7
DTP/DT
2
Intermediate connector
S-1,BC-1
R8
DT
2
Differential temperature sensor
K-4,AU-4
R9
DT
2
Differential lock solenoid
K-4,AT-3
40-52
Installation location
Layout address
AM-1
GD535-5 (03)
40 Troubleshooting
Connector list and layout
Connector No.
Connector type
Number of pins
R10
DT
2
Lifter solenoid
H-9,AR-9
R11
DT
2
Parking brake solenoid
G-9,AQ-9
R12
DT
2
Differential lock pressure switch
K-4,AU4
R15
DT
2
Accumulator oil pressure switch
J-1,AT-1
R16
DT
2
Accumulator oil pressure switch
J-1,AT-1
R17
DT
2
Hydraulic oil temperature sensor
AG-9
R18
DT
2
Diode
J-3,AT-3
R19
DT
2
Diode
K-3,AU-3
R28
DT
2
Diode
AL-5
R29
DT
2
Diode
AL-5
R31
DT
2
Diode
AK-5
R48
DT
6
Intermediate connector
L-5,AV-5
RL1
DT
12
Intermediate connector
L-6,AV-7
RL2
DT
6
Combination lamp (R.H.)
I-9,AT-9
RL3
DT
6
Combination lamp (L.H.)
K-9,AU-9
RL4
DT
2
Rear work equipment lamp (if equipped)
J-9,AS-9
RL5
DT
2
Rear work equipment lamp (if equipped)
L-8,AV-8
RL9
DT
2
Intermediate connector
J-9,AT-9
RL10
DT
2
License lamp (if equipped)
AS-9
SCT1
YAZAKI
2
12V power supply
BB-9
SCT2
YAZAKI
2
12V power supply
BB-9
SP11
Relay
5
Dimmer relay
W-7,BG-8
SP12
Relay
5
Small lamp relay
W-8,BF-9
SP13
Relay
6
Headlamp relay
V-9,BF-9
SP14
Relay
6
Front working lamp relay
U-9,BE-9
SP15
Relay
5
Rear working lamp relay
V-9,BE-9
SP16
Relay
5
Lamp relay
W-8,BF-9
SP17
Relay
5
Safety relay
U-9,BE-9
SP18
Relay
6
Hazard lamp relay 1
S-9,BD-9
SP19
Relay
5
Hazard lamp relay 2
T-9,BD-9
SP21
SWP
6
Accumulator switch (if equipped)
P-8,AZ-8
SP22
SWP
6
Head lamp switch
Q-8,BA-8
SP23
SWP
6
Front working lamp switch
R-8,BA-8
SP24
SWP
6
Rear working lamp switch
R-8,BA-8
SP25
SWP
6
Hazard lamp switch
P-8,AZ-7
SP26
Relay
4
Turn signal lamp relay
S-9,BC-9
SP27
Relay
6
Horn relay
W-7,BG-7
SP28
VC2 (CARLING TECHNOGIES)
10
Lifter lock switch
R-9,BB-9
SP29
YAZAKI
2
24V cigarette lighter
GD535-5 (03)
Installation location
Layout address
BG-3
40-53
Connector list and layout
40 Troubleshooting
Connector No.
Connector type
Number of pins
SP30
Relay
6
Cut-off relay 1
S-9,BC-9
SP31
Relay
6
Accumulator relay (if equipped)
T-9,BD-9
SP32
Relay
5
Personal lock relay
T-9,BE-9
SP35
DT
2
Diode
V-9,BF-9
SP36
DT
2
Diode
T-9,BE-9
SP37
DT
2
Diode
S-9,BC-9
SP38
DT
2
Diode
BD-9
SP40
Relay
5
Automatic preheater relay
W-8,BF-9
SP41
SWP
6
Parking lamp switch (if equipped)
R-9,BB-9
SP42
Relay
5
Parking lamp relay
W-8,BF-9
SP43
Relay
6
Self-holding relay
BC-9
SP46
DT
2
Diode
BC-9
ST1
Terminal
1
Horn switch
N-5,AX-4
ST6
Terminal
1
Starting switch B
N-4,AX-6
ST7
Terminal
1
Starting switch BR
P-7,AY-7
ST8
Terminal
1
Starting switch C
N-6,AX-7
ST9
Terminal
1
Starting switch ACC
N-6,AY-7
ST10
Terminal
1
Starting switch R1
N-3,AX-2
T9A
DT
6
Accelerator pedal
Q-1,BA-1
T9B
DT
2
Accelerator pedal
R-1,BB-1
T20
DT
12
Intermediate connector
AJ-7
T21
DT
12
Intermediate connector
AJ-7
T22
DT
12
Intermediate connector
AJ-6
TEL
DT/SWP
12
Intermediate connector
W-2,BG-5
TG1
Terminal
1
Ground
AJ-2
TM1
DT
2
FH clutch oil pressure switch
AE-7
TM2
DT
2
FH solenoid
AE-6
TM3
DT
2
FL clutch oil pressure switch
AE-6
TM4
DT
2
FL solenoid
AE-5
TM5
DT
2
2nd clutch oil pressure switch
AE-4
TM6
DT
2
2nd speed solenoid
AE-2
TM7
DT
2
3rd clutch oil pressure switch
AF-1
TM8
DT
2
3rd speed solenoid
AH-1
TM10
DT
2
1st clutch oil pressure switch
AE-8
TM11
DT
2
1st speed solenoid
AF-9
TM12
DT
2
R clutch oil pressure switch
AG-9
TM13
DT
2
R solenoid
AH-9
TM14
DT
2
4th clutch oil pressure switch
AI-9
TM15
DT
2
4th speed solenoid
AI-8
TM16
DT
2
L/U solenoid
AJ-8
40-54
Installation location
Layout address
GD535-5 (03)
40 Troubleshooting
Connector list and layout
Connector No.
Connector type
Number of pins
TM17
DT
2
Torque converter oil temperature sensor
AJ-5
TM18
TYCO AMP
3
Torque converter oil pressure sensor
AJ-6
TM19
DT
2
Transmission oil temperature sensor
AG-1
TM20
DT
2
Transmission input shaft speed sensor
AH-9
TM21
DT
2
Intermediate shaft speed sensor
AE-3
TM22
DT
2
Transmission output shaft speed sensor
AF-2
TM30
SWP
6
Transmission mode switch
Q-8,AZ-8
TM36
HD30
21
Gear shift lever
O-2,AY-1
TM37
SWP
6
RPM set mode switch
N-6,AX-6
TM38
VC2 (CARLING TECHNOGIES)
10
RPM set/resume switch
N-6,AY-7
TM39
DRC
24
Transmission controller
W-3,BG-4
TM40
DRC
40
Transmission controller
W-4,BG-4
TM41
DRC
40
Transmission controller
W-5,BG-5
TM42
Relay
5
Backup lamp relay
T-9,BD-9
TM43
Relay
5
Differential lock relay (if equipped)
W-7,BG-8
TM45
SWP
6
Engine mode switch
Q-8,AZ-8
WIF1
DT
2
Water-in-fuel sensor
AP-4
WIF2
DT
2
Intermediate connector
AO-1
GD535-5 (03)
Installation location
Layout address
40-55
Connector list and layout
40 Troubleshooting
Layout of connectors (1/11)
40-56
GD535-5 (03)
40 Troubleshooting
Connector list and layout
(2/11)
GD535-5 (03)
40-57
Connector list and layout
40 Troubleshooting
(3/11)
40-58
GD535-5 (03)
40 Troubleshooting
Connector list and layout
(4/11)
GD535-5 (03)
40-59
Connector list and layout
40 Troubleshooting
(5/11)
40-60
GD535-5 (03)
40 Troubleshooting
Connector list and layout
(6/11)
GD535-5 (03)
40-61
Connector list and layout
40 Troubleshooting
(7/11) (Cab specification)
40-62
GD535-5 (03)
40 Troubleshooting
Connector list and layout
(8/11) (Cab specification)
GD535-5 (03)
40-63
Connector list and layout
40 Troubleshooting
(9/11) (Cab specification)
40-64
GD535-5 (03)
40 Troubleshooting
Connector list and layout
(10/11) (Cab specification)
GD535-5 (03)
40-65
Connector list and layout
40 Troubleshooting
(11/11) (Cab specification)
40-66
GD535-5 (03)
40 Troubleshooting
Connector pin layout
Connector pin layout
1
a The "male" and "female" pins, and the convex and concave fittings (housing) are shown.
GD535-5 (03)
40-67
Connector pin layout
40-68
40 Troubleshooting
GD535-5 (03)
40 Troubleshooting
GD535-5 (03)
Connector pin layout
40-69
Connector pin layout
40-70
40 Troubleshooting
GD535-5 (03)
40 Troubleshooting
GD535-5 (03)
Connector pin layout
40-71
Connector pin layout
40-72
40 Troubleshooting
GD535-5 (03)
40 Troubleshooting
GD535-5 (03)
Connector pin layout
40-73
Connector pin layout
40-74
40 Troubleshooting
GD535-5 (03)
40 Troubleshooting
GD535-5 (03)
Connector pin layout
40-75
Connector pin layout
40-76
40 Troubleshooting
GD535-5 (03)
40 Troubleshooting
GD535-5 (03)
Connector pin layout
40-77
Connector pin layout
40-78
40 Troubleshooting
GD535-5 (03)
40 Troubleshooting
GD535-5 (03)
Connector pin layout
40-79
Connector pin layout
40-80
40 Troubleshooting
GD535-5 (03)
40 Troubleshooting
GD535-5 (03)
Connector pin layout
40-81
Connector pin layout
40-82
40 Troubleshooting
GD535-5 (03)
40 Troubleshooting
GD535-5 (03)
Connector pin layout
40-83
Connector pin layout
40-84
40 Troubleshooting
GD535-5 (03)
40 Troubleshooting
GD535-5 (03)
Connector pin layout
40-85
Connector pin layout
40-86
40 Troubleshooting
GD535-5 (03)
40 Troubleshooting
GD535-5 (03)
Connector pin layout
40-87
Connector pin layout
40-88
40 Troubleshooting
GD535-5 (03)
40 Troubleshooting
GD535-5 (03)
Connector pin layout
40-89
Connector pin layout
40-90
40 Troubleshooting
GD535-5 (03)
40 Troubleshooting
GD535-5 (03)
Connector pin layout
40-91
Connector pin layout
40-92
40 Troubleshooting
GD535-5 (03)
40 Troubleshooting
GD535-5 (03)
Connector pin layout
40-93
Connector pin layout
40-94
40 Troubleshooting
GD535-5 (03)
40 Troubleshooting
GD535-5 (03)
Connector pin layout
40-95
Connector pin layout
40-96
40 Troubleshooting
GD535-5 (03)
40 Troubleshooting
GD535-5 (03)
Connector pin layout
40-97
Connector pin layout
40-98
40 Troubleshooting
GD535-5 (03)
40 Troubleshooting
GD535-5 (03)
Connector pin layout
40-99
Connector pin layout
40-100
40 Troubleshooting
GD535-5 (03)
40 Troubleshooting
GD535-5 (03)
Connector pin layout
40-101
Connector pin layout
40-102
40 Troubleshooting
GD535-5 (03)
40 Troubleshooting
T-box and T-adapter list
T-box and T-adapter list
1
q
q
q q
q
799-601-2600
T-box (for ECONO)
21
799-601-3100
T-box (for MS)
37
q
799-601-3200
T-box (for MS)
37
q
799-601-3380
Plate for MS (14 pins)
799-601-3410
Adapter for BENDIX (MS)
24
MS-24P
q
799-601-3420
Adapter for BENDIX (MS)
24
MS-24P
q
799-601-3430
Adapter for BENDIX (MS)
17
MS-17P
q
799-601-3440
Adapter for BENDIX (MS)
17
MS-17P
q
799-601-3450
Adapter for BENDIX (MS)
5
MS-5P
q
799-601-3460
Adapter for BENDIX (MS)
10
MS-10P
q
799-601-3510
Adapter for BENDIX (MS)
5
MS-5P
q
799-601-3520
Adapter for BENDIX (MS)
17
MS-17P
q
799-601-3530
Adapter for BENDIX (MS)
19
MS-19P
q
799-601-2910
Adapter for BENDIX (MS)
14
MS-14P
q
799-601-3470
Case
799-601-2710
Adapter for MIC
5
MIC-5P
q q
q
799-601-2720
Adapter for MIC
13
MIC-13P q q
q
799-601-2730
Adapter for MIC
17
MIC-17P q q q
q q
q
799-601-2740
Adapter for MIC
21
MIC-21P q q q
q q
q
799-601-2950
Adapter for MIC
9
MIC-9P
q q q
q
799-601-2750
Adapter for ECONO
2
ECONO 2P
q q
799-601-2760
Adapter for ECONO
3
ECONO 3P
q q
799-601-2770
Adapter for ECONO
4
ECONO 4P
q q
799-601-2780
Adapter for ECONO
8
ECONO 8P
q q
799-601-2790
Adapter for ECONO
12
ECONO 12P
q q
799-601-2810
Adapter for DLI
8
DLI-8P
q q
799-601-2820
Adapter for DLI
12
DLI-12P
q q
799-601-2830
Adapter for DLI
16
DLI-16P
q q
GD535-5 (03)
Non-kit part
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
ID marking
799-601-2700
Part name
T-adapter kit 799-601-2500
Part No.
Number of pins
(Rev. 2009.3) a The part numbers of the T-boxes and T-adapters are listed in the vertical column, and the part numbers of harness checker assemblies are listed in the horizontal line.
q
q
40-103
T-box and T-adapter list
40 Troubleshooting
1
799-601-7020
Adapter for X
2
799-601-7030
Adapter for X
799-601-7040
q
q q
60
q q
q
X2P
q q q
q
3
X3P
q q q
q
Adapter for X
4
X4P
q q q
q
799-601-7050
Adapter for SWP
6
SW6P
q q q
799-601-7060
Adapter for SWP
8
SW8P
q q q
799-601-7310
Adapter for SWP
12
SW12P
799-601-7070
Adapter for SWP
14
SW14P
799-601-7320
Adapter for SWP
16
SW16P
799-601-7080
Adapter for M (T-adapter)
1
-
799-601-7090
Adapter for M
2
799-601-7110
Adapter for M
799-601-7120
q q
q q
q
q
M2P
q q q
q
3
M3P
q q q
q
Adapter for M
4
M4P
q q q
q
799-601-7130
Adapter for M
6
M6P
q q q
q
799-601-7340
Adapter for M
8
M8P
799-601-7140
Adapter for S
8
S8P
q q q
q
799-601-7150
Adapter for S (white)
10
S10P
q q q
q
799-601-7160
Adapter for S (blue)
12
S12P
q q q
799-601-7170
Adapter for S (blue)
16
S16P
q q q
799-601-7330
Adapter for S (white)
16
S16PW
799-601-7350
Adapter for S (white)
12
S12PW
799-601-7180
Adapter for AMP040
8
A8P
q
799-601-7190
Adapter for AMP040
12
A12P
q
q
799-601-7210
Adapter for AMP040
16
A16P
q q q
q
799-601-7220
Adapter for AMP040
20
A20P
q q q
q
799-601-7230
Short socket adapter for X
2
-
q q
q
799-601-7240
Case
799-601-7270
Case
799-601-7510
Adapter for 070
10
07-10
q
799-601-7520
Adapter for 070
12
07-12
q
799-601-7530
Adapter for 070
14
07-14
q
40-104
Non-kit part
Adapter for X (T-adapter)
799-601-4201
799-601-7010
799-601-4101
Case
799-601-9300
799-601-4360
799-601-9200
T-box (DRC60 or ECONO)
799-601-9100
799-601-4350
799-601-9000
Case
799-601-8000
799-601-2850
q q
799-601-7500
ECONO 12P
799-601-7400
12
799-601-7100
Extension cable (ECONO type)
799-601-7000
799-601-2840
799-601-2800
ID marking
799-601-2700
Part name
799-601-2500
Part No.
Number of pins
T-adapter kit
q
q q q
q q q
GD535-5 (03)
40 Troubleshooting
T-box and T-adapter list
REL-5P
q
799-601-7370
Adapter for relay
6
REL-6P
q
799-601-7380
Adapter for JFC
2
-
q
799-601-9010
Adapter for DTM
2
DTM2
q
q
799-601-9020
Adapter for DT
2
DT2
q
q
799-601-9030
Adapter for DT
3
DT3
q
q
799-601-9040
Adapter for DT
4
DT4
q
q
799-601-9050
Adapter for DT
6
DT6
q
q
799-601-9060
Adapter for DT (gray)
8
DT8GR
q
q
799-601-9070
Adapter for DT (black)
8
DT8B
q
q
799-601-9080
Adapter for DT (green)
8
DT8G
q
q
799-601-9090
Adapter for DT (brown)
8
DT8BR
q
q
799-601-9110
Adapter for DT (gray)
12
DT12GR
q
q
799-601-9120
Adapter for DT (black)
12
DT12B
q
q
799-601-9130
Adapter for DT (green)
12
DT12G
q
q
799-601-9140
Adapter for DT (brown)
12
DT12BR
q
q
799-601-9210
Adapter for HD30-18
8
D18-8
q q
799-601-9220
Adapter for HD30-18
14
D18-14
q q
799-601-9230
Adapter for HD30-18
20
D18-20
q q
799-601-9240
Adapter for HD30-18
21
D18-21
q q
799-601-9250
Adapter for HD30-24
9
D24-9
q q
799-601-9260
Adapter for HD30-24
16
D24-16
q q
799-601-9270
Adapter for HD30-24
21
D24-21
q q
799-601-9280
Adapter for HD30-24
23
D24-23
q q
799-601-9290
Adapter for HD30-24
31
D24-31
q q
799-601-9310
Plate for HD30 (24 pins)
799-601-9320
T-box (for ECONO)
799-601-9330
Case
799-601-9340
Case
799-601-9350
Adapter for DRC
40
DRC-40
q
799-601-9360
Adapter for DRC
24
DRC-24
q
2
G
799-601-9410* Socket for engine (CRI-T2)
GD535-5 (03)
24
Non-kit part
5
799-601-4201
Adapter for relay
799-601-4101
799-601-7360
799-601-9300
q
799-601-9200
07-20
799-601-9100
20
799-601-9000
Adapter for 070
799-601-8000
799-601-7550
799-601-7500 q
799-601-7400
07-18
799-601-7100
18
799-601-7000
Adapter for 070
799-601-2800
799-601-7540
Part name
799-601-2700
ID marking
Part No.
799-601-2500
Number of pins
T-adapter kit
q q
q q
q q
q
q q
q
q q
q
40-105
T-box and T-adapter list
40 Troubleshooting
S
q
Socket for engine (HPI-T2) 795-799-5530* Socket for engine (CRI-T3) Temperature sensor
2
C
q q
Socket for engine (HPI-T2) 795-799-5540* Socket TIM for engine (CRIT3)
2
A
q q
795-799-5460
Cable for engine (HPI-T2)
3
-
q
795-799-5470
Cable for engine (HPI-T2)
3
-
q
795-799-5480
Cable for engine (HPI-T2)
3
-
q
799-601-4110
Adapter PIM for engine (140T3)
4
ITT3N
q q
799-601-4130
Adapters NE and CAM for engine (CRI-T3)
3
FCIN
q q
799-601-4140
Adapter for engine (CRI-T3) Ambient pressure
3
FCIG
q q
799-601-4150
Adapter POIL for engine (CRIT3)
3
FCIB
q q
799-601-4160
Adapter for engine (CRI-T3) Oil pressure switch
2
4160
q q
799-601-4180
Adapter PEVA for engine (CRI-T3)
3
4180
q q
799-601-4190*
Socket for engine (CRI-T3) Common rail pressure
3
1, 2, 3L
q q
799-601-4230*
Socket for engine (CRI-T3) Intake pressure/temperature
4
1, 2, 3, 4C
q q
799-601-4240*
Socket PAMB for engine (CRIT3)
3
1, 2, 3A
q q
799-601-4250*
Socket PIM for engine (CRIT3)
3
1, 2, 3B
q q
3
1, 2, 3, G
q q
2
2, PA
q q
4
1, 2, 3, 4T
799-601-4330* Socket G for engine (CRI-T3) 799-601-4340*
Socket for engine (CRI-T3) Pump actuator
Socket for engine (CRI-T3) 799-601-4380* (95) Intake pressure/temperature
40-106
Non-kit part
2
799-601-4201
795-799-5520* Socket for engine (HPI-T2)
799-601-4101
q
799-601-9300
1, 2, 3
799-601-9200
3
799-601-9100
799-601-9440* Socket for engine (CRI-T2)
799-601-9000
q q
799-601-8000
P
799-601-7500
2
799-601-7400
Socket for engine (CRI-T2) 799-601-9430* Socket PCV for engine (CRIT3)
799-601-7100
q q
799-601-7000
A3
Adapter for engine (CRI-T2) Adapter PFUEL for engine (CRI-T3) Oil pressure sensor
799-601-2800
3
799-601-9420
Part name
799-601-2700
ID marking
Part No.
799-601-2500
Number of pins
T-adapter kit
q
GD535-5 (03)
40 Troubleshooting
T-box and T-adapter list
q
799-601-4390* Socket for controller (95ENG)
60
-
q
799-601-4280* Box for controller (PUMP)
121
-
q
799-601-9720
Adapter for controller (HST)
16
HST16A
q
799-601-9710
Adapter for controller (HST)
16
HST16B
q
799-601-9730
Adapter for controller (HST)
26
HST26A
q
799-601-9890
Multi-adapter for DT 2 to 4, DTM 2 pins
2, 3, 4
-
q
Non-kit part
DRC60
799-601-4201
60
799-601-4101
Adapter for controller (ENG)
799-601-9300
799-601-4220
799-601-9200
q
799-601-9100
DRC50
799-601-9000
50
799-601-8000
Adapter for controller (ENG)
799-601-7500
799-601-4211
799-601-7400
DTP4
799-601-7100
4
799-601-7000
Adapter for controller (ENG)
799-601-2800
799-601-4260
Part name
799-601-2700
ID marking
Part No.
799-601-2500
Number of pins
T-adapter kit
q q
*: These are not T-adapters but sockets.
GD535-5 (03)
40-107
Locations of fuses
40 Troubleshooting
Locations of fuses
1
Connection table of fuse box a This connection table shows the fuse box and the devices which receive power from the fuse box (A switched power supply is the power which is supplied while the starting switch is in ON position and an unswitched power supply is the power which is supplied while the starting switch is in OFF and ON positions). a When performing troubleshooting related to the electrical system, you should check the fuse box to see if the power is supplied normally. Fuse box 1 (FB1) Type of power supply
Slow-blow fuse for continuous power supply (30A)
Slow-blow fuse for switch power supply (60A)
Switch power start-up Switch ACC
40-108
Fuse No.
Fuse capacity
Destination of power
1
10A
Machine monitor
2
15A
Key switch (B)
3
10A
Continuous power supply for transmission controller
4
10A
Emergency flashing lights
5
-
6
10A
Turn signal lamp
7
15A
Solenoid
8
-
9
15A
Rear working lamp
10
15A
Front working lamp
11
10A
Transmission controller
12
15A
Headlamp
13
10A
Brake lamp, backup lamp
14
10A
Horn
15
5A
Engine controller, accessory
-
-
GD535-5 (03)
40 Troubleshooting
Locations of fuses
Fuse box 2 (Fuse box FB2) Type of power supply
Slow-blow fuse for continuous power supply (30A)
Slow-blow fuse for switch power supply (60A)
Fuse No.
Fuse capacity
Destination of power
1
20A
Air conditioner blower
2
10A
Continuous power supply for operator's cab
3
10A
Room lamp
4
30A
Continuous power supply for engine controller
5
-
6
10A
12V converter
7
5A
Radio
8
5A
Air conditioner compressor
9
10A
Illumination
10
10A
Spare
11
5A
Air conditioner control
12
15A
Cab mount working lamp
13
10A
Yellow rotation lamp
14
20A
Door wiper
15
20A
Front wiper, rear wiper
-
Fuse box 3 (Fuse box FB3) Type of power supply
Fuse No.
Fuse capacity
-
1
-
-
-
2
-
-
-
3
-
-
-
4
-
-
-
5
-
-
-
6
-
-
-
7
-
-
-
8
-
-
-
9
-
-
-
10
-
-
-
11
-
-
Slow-blow fuse for switch power supply (60A)
12
15A
-
13
-
-
-
14
-
-
-
15
-
-
GD535-5 (03)
Destination of power
Rear heating glass
40-109
Locations of fuses
40 Troubleshooting
Locations of fuse boxes and fuse No.
40-110
GD535-5 (03)
40 Troubleshooting
Failure code [1500L0] Double Engagement of T/M Clutches
Troubleshooting by failure code (display of code)
1
Failure code [1500L0] Double Engagement of T/M Clutches
1
Action code
Failure code
L04
1500L0
Failure
Double Engagement of T/M clutches (Transmission controller system)
Detail of failure Two Clutch Fill signals in erroneous combination were entered. q
Action of controller Problem on machine
q q
The machine stops if traveling, or it cannot start if stopped. q
Related information
No.
Flashes the centralized warning lamp and sounds the alarm buzzer. Holds the gear in neutral position. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
Input condition (ON/OFF) from ECMV fill switch of each clutch can be checked with monitoring function. (Code: 02216, 02217) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (at all gear shift positions).
Cause
Procedure, measuring location, criteria, and remarks
1
Failure of clutch ECMV system
If other failure codes are also displayed, perform troubleshooting for them.
2
Failure of transmission controller
If another failure code is not displayed at the same time, the controller may have failed. (Since this is an internal failure, troubleshooting cannot be performed.)
GD535-5 (03)
40-111
Failure code [15G0MW] Failure of R-Clutch System
40 Troubleshooting
Failure code [15G0MW] Failure of R-Clutch System Action code
Failure code
L03
15G0MW
Failure
1
Failure of R-clutch system (Transmission controller system)
During output to R-clutch ECMV solenoid, the value calculated either from the engine speed, transmission Detail of failure input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, or transmission output shaft speed sensor signal is abnormal. Action of controller Problem on machine
q q
None in particular q
Related information
No.
Flashes the centralized warning lamp and sounds the alarm buzzer. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
The output current command value to the R-clutch ECMV solenoid can be checked with monitoring function. (Code: 31606) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of R1 to R4 positions).
Cause
Procedure, measuring location, criteria, and remarks
1
Failure of R-clutch oil pressure or mechanical system
2
Failure of R-clutch ECMV Perform troubleshooting for failure code [DXH7KA], [DXH7KB] or [DXH7KY]. solenoid system
40-112
1. Check the transmission oil filter for clogging and other failure. 2. See the Testing and adjusting, "Testing power train oil pressure", and make sure that clutch oil pressure is normal.
GD535-5 (03)
40 Troubleshooting
Failure code [15H0MW] Failure of Clutch System (FH)
Failure code [15H0MW] Failure of Clutch System (FH) Action code
Failure code
L03
15H0MW
Failure
1
Failure of clutch system (FH) (Transmission controller system)
During output to FH-clutch ECMV solenoid, the value calculated either from the engine speed, transmission Detail of failure input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, or transmission output shaft speed sensor signal is abnormal. Action of controller Problem on machine
q q
The creep function does not work. q
Related information
No.
Flashes the centralized warning lamp and sounds the alarm buzzer. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
The output current command value to the FH-clutch ECMV solenoid can be checked with monitoring function. (Code: 31608) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of F2, F4, F6 or F8 position).
Cause
Procedure, measuring location, criteria, and remarks
1
Failure of FH-clutch oil pressure or mechanical system
1. Check the transmission oil filter for clogging and other failure. 2. See the Testing and adjusting, "Testing power train oil pressure", and make sure that clutch oil pressure is normal.
2
Failure of FH-clutch ECMV solenoid system
Perform troubleshooting for failure code [DXH2KA], [DXH2KB] or [DXH2KY].
GD535-5 (03)
40-113
Failure code [15J0MW] Failure of Clutch System (FL)
40 Troubleshooting
Failure code [15J0MW] Failure of Clutch System (FL) Action code
Failure code
L03
15J0MW
Failure
1
Failure of clutch system (FL) (Transmission controller system)
During output to FL-clutch ECMV solenoid, the value calculated either from the engine speed, transmission Detail of failure input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, or transmission output shaft speed sensor signal is abnormal. Action of controller Problem on machine
q q
The creep function does not work. q
Related information
No.
Flashes the centralized warning lamp and sounds the alarm buzzer. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
The output current command value to the FL-clutch ECMV solenoid can be checked with monitoring function. (Code: 31607) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of F1, F3, F5 or F7 position).
Cause
Procedure, measuring location, criteria, and remarks
1
Failure of FL-clutch oil pressure or mechanical system
1. Check the transmission oil filter for clogging and other failure. 2. See the Testing and adjusting, "Testing power train oil pressure", and make sure that clutch oil pressure is normal.
2
Failure of FL-clutch ECMV solenoid system
3. Perform troubleshooting for failure code [DXH3KA], [DXH3KB] or [DXH3KY].
40-114
GD535-5 (03)
40 Troubleshooting
Failure code [15K0MW] Failure of Clutch System (1st)
Failure code [15K0MW] Failure of Clutch System (1st) Action code
Failure code
L03
15K0MW
Failure
1
Failure of 1st clutch system (Transmission controller system)
During output to 1st clutch ECMV solenoid, the value calculated either from the engine speed, transmission Detail of failure input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, or transmission output shaft speed sensor signal is abnormal. Action of controller Problem on machine
q q
The creep function does not work. q
Related information
No.
Flashes the centralized warning lamp and sounds the alarm buzzer. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
The output current command value to the 1st clutch ECMV solenoid can be checked with monitoring function. (Code: 31602) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of F1, F2 or R1 position).
Cause
Procedure, measuring location, criteria, and remarks
1
Failure of 1st clutch oil pressure or mechanical system
1. Check the transmission oil filter for clogging and other failure. 2. See the Testing and adjusting, "Testing power train oil pressure", and make sure that clutch oil pressure is normal.
2
Failure of 1st clutch ECMV solenoid system
Perform troubleshooting for failure code [DXH4KA], [DXH4KB] or [DXH4KY].
3
1. Turn the starting switch to OFF position. Grounding of 2. Disconnect connectors TM40 and TM22, and connect T-adapter to either female side. transmission output shaft Between TM40 (female) (30) or TM22 (female) (1) and speed sensor circuit Resistance Min. 1 Mz ground
4
1. Turn the starting switch to OFF position. Hot short of transmission 2. Disconnect connector TM22, and connect T-adapter to female side. output shaft speed 3. Turn starting switch to ON position. sensor circuit Between TM22 (female) (1) and (2) Voltage
3 to 4V
Circuit diagram related to transmission output shaft speed sensor
GD535-5 (03)
40-115
Failure code [15L0MW] Failure of Clutch System (2nd)
40 Troubleshooting
Failure code [15L0MW] Failure of Clutch System (2nd) Action code
Failure code
L03
15L0MW
Failure
1
Failure of 2nd clutch system (Transmission controller system)
During output to 2nd clutch ECMV solenoid, the value calculated either from the engine speed, transmission Detail of failure input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, or transmission output shaft speed sensor signal is abnormal. Action of controller Problem on machine
q q
None in particular q
Related information
No.
Flashes the centralized warning lamp and sounds the alarm buzzer. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
The output current command value to the 2nd clutch ECMV solenoid can be checked with monitoring function. (Code: 31603) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of F3, F4, or R2 position).
Cause
Procedure, measuring location, criteria, and remarks
1
Failure of 2nd clutch oil pressure or mechanical system
1. Check the transmission oil filter for clogging and other failure. 2. See the Testing and adjusting, "Testing power train oil pressure", and make sure that clutch oil pressure is normal.
2
Failure of 2nd clutch ECMV solenoid system
Perform troubleshooting for failure code [DXH5KA], [DXH5KB] or [DXH5KY].
3
1. Turn the starting switch to OFF position. Grounding of 2. Disconnect connectors TM40 and TM22, and connect T-adapter to either female side. transmission output shaft Between TM40 (female) (30) or TM22 (female) (1) and speed sensor circuit Resistance Min. 1 Mz ground
4
1. Turn the starting switch to OFF position. Hot short of transmission 2. Disconnect connector TM22, and connect T-adapter to female side. output shaft speed 3. Turn starting switch to ON position. sensor circuit Between TM22 (female) (1) and (2) Voltage
3 to 4 V
Circuit diagram related to transmission output shaft speed sensor
40-116
GD535-5 (03)
40 Troubleshooting
Failure code [15M0MW] Failure of Clutch System (3rd)
Failure code [15M0MW] Failure of Clutch System (3rd) Action code
Failure code
L03
15M0MW
Failure
1
Failure of 3rd clutch system (Transmission controller system)
During output to 3rd clutch ECMV solenoid, the value calculated either from the engine speed, transmission Detail of failure input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, or transmission output shaft speed sensor signal is abnormal. Action of controller Problem on machine
q q
None in particular q
Related information
No.
Flashes the centralized warning lamp and sounds the alarm buzzer. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
The output current command value to the 3rd clutch ECMV solenoid can be checked with monitoring function. (Code: 31604) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of F5, F6 or R3 position).
Cause
Procedure, measuring location, criteria, and remarks
1
Failure of 3rd clutch oil pressure or mechanical system
1. Check the transmission oil filter for clogging and other failure. 2. See the Testing and adjusting, "Testing power train oil pressure", and make sure that clutch oil pressure is normal.
2
Failure of 3rd clutch ECMV solenoid system
Perform troubleshooting for failure code [DXH6KA], [DXH6KB] or [DXH6KY].
3
1. Turn the starting switch to OFF position. Grounding of 2. Disconnect connectors TM40 and TM22, and connect T-adapter to either female side. transmission output shaft Between TM40 (female) (30) or TM22 (female) (1) and speed sensor circuit Resistance Min. 1 Mz ground
4
1. Turn the starting switch to OFF position. Hot short of transmission 2. Disconnect connector TM22, and connect T-adapter to female side. output shaft speed 3. Turn starting switch to ON position. sensor circuit Between TM22 (female) (1) and (2) Voltage
3 to 4 V
Circuit diagram related to transmission output shaft speed sensor
GD535-5 (03)
40-117
Failure code [15N0MW] Failure of Clutch System (4th)
40 Troubleshooting
Failure code [15N0MW] Failure of Clutch System (4th) Action code
Failure code
L03
15N0MW
Failure
1
Failure of 4th clutch system (Transmission controller system)
During output to 4th clutch ECMV solenoid, the value calculated either from the engine speed, transmission Detail of failure input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, or transmission output shaft speed sensor signal is abnormal. Action of controller Problem on machine
q q
None in particular q
Related information
No.
Flashes the centralized warning lamp and sounds the alarm buzzer. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
The output current command value to the 4th clutch ECMV solenoid can be checked with monitoring function. (Code: 31605) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of F7, F8, or R4 position).
Cause
Procedure, measuring location, criteria, and remarks
1
Failure of 4th clutch oil pressure or mechanical system
1. Check the transmission oil filter for clogging and other failure. 2. See the Testing and adjusting, "Testing power train oil pressure", and make sure that clutch oil pressure is normal.
2
Failure of 4th clutch ECMV solenoid system
Perform troubleshooting for failure code [DXHHKA], [DXHHKB] or [DXHHKY].
3
1. Turn the starting switch to OFF position. Grounding of 2. Disconnect connectors TM40 and TM22, and connect T-adapter to either female side. transmission output shaft Between TM40 (female) (30) or TM22 (female) (1) and speed sensor circuit Resistance Min. 1 Mz ground
4
1. Turn the starting switch to OFF position. Hot short of transmission 2. Disconnect connector TM22, and connect T-adapter to female side. output shaft speed 3. Turn starting switch to ON position. sensor circuit Between TM22 (female) (1) and (2) Voltage
3 to 4 V
Circuit diagram related to transmission output shaft speed sensor
40-118
GD535-5 (03)
40 Troubleshooting
Failure code [15SBL1] Release Trouble of ECMV (R)
Failure code [15SBL1] Release Trouble of ECMV (R) Action code
Failure code
L01
15SBL1
Detail of failure Action of controller Problem on machine
No.
Release trouble of ECMV (R) (Transmission controller system)
Even if the output to the R-clutch ECMV solenoid is turned OFF, the signal from Fill switch is kept ON and the clutch is not released. q q
Particular action is not taken. (If double engagement is detected simultaneously, the gear speed is set to neutral.) If cause of failure disappears, machine becomes normal by itself.
Machine can move backward only. q
Related information
Failure
1
q q
The output current command value to the R-clutch ECMV solenoid can be checked with monitoring function. (Code: 31606) Input condition (ON/OFF) from ECMV fill switch of R-clutch can be checked with monitoring function. (Code: 02216, 02217) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine.
Cause
Procedure, measuring location, criteria, and remarks
1
Failure of R-clutch oil pressure or mechanical system
2
1. Turn the starting switch to OFF position. Failure of R-clutch ECMV 2. Disconnect connector TM12, and connect T-adapter to male side. fill switch Between TM12 (female) (1) and ground Resistance (Fill switch OFF)
3
4
5
Harness grounding or transmission controller failure
Ground fault in wiring harness
Failure of transmission controller
1. Check the transmission oil filter for clogging and other failure. 2. See the Testing and adjusting, "Testing power train oil pressure", and make sure that clutch oil pressure is normal.
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector TM12. 3. Start engine. If failure code [15SBL1] still continues, the wiring harness is grounded or the transmission controller has failed. (If failure code [15SBL1] is cleared, the R-clutch fill switch has failed.) If no failure is found by check on Cause 3, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40 and TM12, and connect T-adapter to either female side. Between TM40 (female) (27) or TM12 (female) (1) and ground
Resistance
Min. 1 Mz
If "Failure during check of cause 3" and "Normal during check of cause 4" occur, the transmission controller has failed. Reference: The following shows the criteria during normal. 1. Turn the starting switch to OFF position. 2. Lift the machine so that the drive wheels idle. 3. Insert T-adapter into connector TM12. 4. Start engine. Hold the shift lever to N position. Between TM40 (27) and ground
Voltage
7 to 11V
Steps 1 to 4 are the same as above. 5. Shift the lever (at travel speed) and diagnose it (while drive wheels are idling). Between TM40 (27) and ground
GD535-5 (03)
R1
Voltage
Max. 1 V
40-119
Failure code [15SBL1] Release Trouble of ECMV (R)
40 Troubleshooting
Circuit diagram related to reverse clutch ECMV solenoid
40-120
GD535-5 (03)
40 Troubleshooting
Failure code [15SBMA] Malfunction of ECMV (R)
Failure code [15SBMA] Malfunction of ECMV (R) Action code
Failure code
L03
15SBMA q
Detail of failure
q
q
Action of controller Problem on machine
q q
No. 1
Malfunction of ECMV (R) (Transmission controller system)
Even if signal is output to the R clutch ECMV solenoid, the clutch is not engaged when the signal from fill switch is OFF. During output to R-clutch ECMV solenoid, a clutch slipping is detected from either engine speed signal, transmission input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, or transmission output shaft speed sensor signal. Flashes the centralized warning lamp and sounds the alarm buzzer. Keeps to turn OFF the output to R-clutch ECMV solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
Machine can move forward only. q
Related information
Failure
1
q q
The output current command value to the R-clutch ECMV solenoid can be checked with monitoring function. (Code: 31606) Input condition (ON/OFF) from ECMV fill switch of R-clutch can be checked with monitoring function. (Code: 02216, 02217) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of R1 to R4 positions).
Cause Failure of R-clutch oil pressure or mechanical system
Procedure, measuring location, criteria, and remarks 1. Check the transmission oil filter for clogging and other failure. 2. See the Testing and adjusting, "Testing power train oil pressure", and make sure that clutch oil pressure is normal. 1. Turn the starting switch to OFF position. 2. Disconnect connector TM12, and connect T-adapter to male side. 3. Start engine. Hold the shift lever to N position.
2
Resistance Min. 1 Mz Failure of R-clutch ECMV Between TM12 (male) (1) and ground fill switch 1. Steps 1 to 2 are the same as above. 2. Lift the machine so that the drive wheels idle. 3. Start engine. 4. Shift the lever (at travel speed) and diagnose it (while drive wheels are idling). Between TM12 (male) (1) and ground
3
Open circuit in wiring harness
R1
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40 and TM12, and connect T-adapter to each female side. Between TM40 (female) (27) and TM12 (female) (1)
Resistance
Max. 1 z
Voltage
7 to 11 V
1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector TM40. 3. Start engine. Hold the shift lever to N position. 4
Failure of transmission controller
Between TM40 (27) and ground 1. 2. 3. 4.
Steps 1 to 2 are the same as above. Lift the machine so that the drive wheels idle. Start engine. Shift the lever (at travel speed) and diagnose it (while drive wheels are idling).
Between TM40 (27) and ground
GD535-5 (03)
R1
Voltage
Max. 1 V
40-121
Failure code [15SBMA] Malfunction of ECMV (R)
40 Troubleshooting
Circuit diagram related to reverse clutch ECMV solenoid
40-122
GD535-5 (03)
40 Troubleshooting
Failure code [15SCL1] Release Trouble of ECMV (FH)
Failure code [15SCL1] Release Trouble of ECMV (FH) Action code
Failure code
L01
15SCL1
Detail of failure Action of controller Problem on machine
No.
Release trouble of ECMV (FH) (Transmission controller system)
Even if the output to the FH-clutch ECMV solenoid is turned OFF, the clutch is not released if signal from Fill switch is kept ON. q q
Particular action is not taken. (If double engagement is detected simultaneously, the gear speed is set to neutral.) If cause of failure disappears, machine becomes normal by itself.
Machine can travel with F2, F4, F6 or F8 shift position. q
Related information
Failure
q q
The output current command value to the FH-clutch ECMV solenoid can be checked with monitoring function. (Code: 31608) Input condition (ON/OFF) from ECMV fill switch of FH-clutch can be checked with monitoring function. (Code: 02216, 02217) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine.
Cause
1
Failure of FH-clutch oil pressure or mechanical system
2
Failure of FH-clutch ECMV fill switch
3
Harness grounding or transmission controller failure
4
Ground fault in wiring harness
Procedure, measuring location, criteria, and remarks 1. Check the transmission oil filter for clogging and other failure. 2. See the Testing and adjusting, "Testing power train oil pressure", and make sure that clutch oil pressure is normal. 1. Turn the starting switch to OFF position. 2. Disconnect connector TM1, and connect T-adapter to male side. Between TM1 (male) (1) and ground (Fill switch OFF)
Resistance
Failure of transmission controller
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector TM1. 3. Start engine. If failure code [15SCL1] still continues, the wiring harness is grounded or the transmission controller has failed. (If failure code [15SCL1] is cleared, the FH-clutch fill switch has failed.) If no failure is found by check on Cause 3, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40 and TM1, and connect T-adapter to either female side. Between TM40 (female) (7) or TM1 (female) (1) and ground
5
1
Resistance
Min. 1 Mz
If "Failure during check of cause 3" and "Normal during check of cause 4" occur, the transmission controller has failed. Reference 1. Turn the starting switch to OFF position. 2. Lift the machine so that the drive wheels idle. 3. Insert T-adapter into connector TM40. 4. Start engine. Hold the shift lever to N position. Between TM40 (7) and ground
Voltage
7 to 11 V
Steps 1 to 4 are the same as above. 5. Shift the lever (at travel speed) and diagnose it (while drive wheels are idling). Between TM40 (7) and ground
GD535-5 (03)
F2
Voltage
Max. 1 V
40-123
Failure code [15SCL1] Release Trouble of ECMV (FH)
40 Troubleshooting
Circuit diagram related to FH-clutch ECMV solenoid
40-124
GD535-5 (03)
40 Troubleshooting
Failure code [15SCMA] Malfunction of ECMV (FH)
Failure code [15SCMA] Malfunction of ECMV (FH) Action code
Failure code
L03
15SCMA q
Detail of failure
q
q
Action of controller Problem on machine
q q
No. 1
Malfunction of ECMV (FH) (Transmission controller system)
Even if signal is output to the FH-clutch ECMV solenoid, the clutch is not engaged when the signal from fill switch is OFF. During output to FH-clutch ECMV solenoid, a clutch slipping is detected from either engine speed signal, transmission input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, or transmission output shaft speed sensor signal. Flashes the centralized warning lamp and sounds the alarm buzzer. Keeps to turn OFF the output to FH-clutch ECMV solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
Machine can travel at F1, F3, F5, F7, R1, R2, R3 or R4 gear position only. q
Related information
Failure
1
q q
The output current command value to the FH-clutch ECMV solenoid can be checked with monitoring function. (Code: 31608) Input condition (ON/OFF) from ECMV fill switch of FH-clutch can be checked with monitoring function. (Code: 02216, 02217) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of F2, F4, F6 or F8 position).
Cause Failure of FH-clutch oil pressure or mechanical system
Procedure, measuring location, criteria, and remarks 1. Check the transmission oil filter for clogging and other failure. 2. See the Testing and adjusting, "Testing power train oil pressure", and make sure that clutch oil pressure is normal. 1. Turn the starting switch to OFF position. 2. Disconnect connector TM1, and connect T-adapter to male side. 3. Start engine. Hold the shift lever to N position.
2
Failure of FH-clutch ECMV fill switch
Between TM1 (male) (1) and ground
Open circuit in wiring harness
Min. 1 Mz
Steps 1 to 2 are the same as above. 3. Lift the machine so that the drive wheels idle. 4. Start engine. 5. Shift the lever (at travel speed) and diagnose it (while drive wheels are idling). Between TM1 (male) (1) and ground
3
Resistance
F2
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40 and TM1, and connect T-adapter to each female side. Between TM40 (female) (7) and TM1 (female) (1)
Resistance
Max. 1 z
Voltage
7 to 11 V
1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector TM40. 3. Start engine. Hold the shift lever to N position. 4
Failure of transmission controller
Between TM40 (7) and ground
Steps 1 to 2 are the same as above. 3. Lift the machine so that the drive wheels idle. 4. Start engine. 5. Shift the lever (at travel speed) and diagnose it (while drive wheels are idling). Between TM40 (7) and ground
GD535-5 (03)
F2
Voltage
Max. 1 V
40-125
Failure code [15SCMA] Malfunction of ECMV (FH)
40 Troubleshooting
Circuit diagram related to FH-clutch ECMV solenoid
40-126
GD535-5 (03)
40 Troubleshooting
Failure code [15SDL1] Release Trouble of ECMV (FL)
Failure code [15SDL1] Release Trouble of ECMV (FL) Action code
Failure code
L01
15SDL1
Detail of failure Action of controller Problem on machine
No.
q q
Particular action is not taken. (If double engagement is detected simultaneously, the gear speed is set to neutral.) If cause of failure disappears, machine becomes normal by itself.
Machine can travel with F1, F3, F5 or F7 shift position.
q q
The output current command value to the FL-clutch ECMV solenoid can be checked with monitoring function. (Code: 31607) Input condition (ON/OFF) from ECMV fill switch of FL-clutch can be checked with monitoring function. (Code: 02216, 02217) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine.
Cause
1
Failure of FL-clutch oil pressure or mechanical system
2
Failure of FL-clutch ECMV fill switch
3
4
5
Release trouble of ECMV (FL) (Transmission controller system)
Even if the output to the FL-clutch ECMV solenoid is turned OFF, the clutch is not released when signal from Fill switch is kept ON.
q
Related information
Failure
1
Harness grounding or transmission controller failure
Ground fault in wiring harness
Failure of transmission controller
Procedure, measuring location, criteria, and remarks 1. Check the transmission oil filter for clogging and other failure. 2. See the Testing and adjusting, "Testing power train oil pressure", and make sure that clutch oil pressure is normal. 1. Turn the starting switch to OFF position. 2. Disconnect connector TM3, and connect T-adapter to male side. Between TM3 (male) (1) and ground (Fill switch OFF)
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector TM3. 3. Start engine. If failure code [15SDL1] still continues, the wiring harness is grounded or the transmission controller has failed. (If failure code [15SDL1] is cleared, the FL-clutch fill switch has failed.) If no failure is found by check on Cause 3, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40 and TM3, and connect T-adapter to either female side. Between TM40 (female) (17) or TM3 (female) (1) and ground
Resistance
Min. 1 Mz
If "Failure during check of cause 3" and "Normal during check of cause 4" occur, the transmission controller has failed. Reference 1. Turn the starting switch to OFF position. 2. Lift the machine so that the drive wheels idle. 3. Insert T-adapter into connector TM40. 4. Start engine. Hold the shift lever to N position. Between TM40 (17) and ground
Voltage
7 to 11 V
Steps 1 to 4 are the same as above. 5. Shift the lever (at travel speed) and diagnose it (while drive wheels are idling). Between TM40 (17) and ground
GD535-5 (03)
F1
Voltage
Max. 1 V
40-127
Failure code [15SDL1] Release Trouble of ECMV (FL)
40 Troubleshooting
Circuit diagram related to FL-clutch ECMV solenoid
40-128
GD535-5 (03)
40 Troubleshooting
Failure code [15SDMA] Malfunction of ECMV (FL)
Failure code [15SDMA] Malfunction of ECMV (FL) Action code
Failure code
L03
15SDMA q
Detail of failure
q
q
Action of controller Problem on machine
q q
No. 1
Malfunction of ECMV (FL) (Transmission controller system)
Even if signal is output to the FL-clutch ECMV solenoid, the clutch is not engaged when the signal from fill switch is OFF. During output to FL-clutch ECMV solenoid, a clutch slipping is detected from either engine speed signal, transmission input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, or transmission output shaft speed sensor signal. Flashes the centralized warning lamp and sounds the alarm buzzer. Keeps to turn OFF the output to FL-clutch ECMV solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
Machine can travel at F2, F4, F6, F8, R1, R2, R3 or R4 gear position only. q
Related information
Failure
1
q q
The output current command value to the FL-clutch ECMV solenoid can be checked with monitoring function. (Code: 31607) Input condition (ON/OFF) from ECMV fill switch of FL-clutch can be checked with monitoring function. (Code: 02216, 02217) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of F1, F3, F5 or F7 position).
Cause Failure of FL-clutch oil pressure or mechanical system
Procedure, measuring location, criteria, and remarks 1. Check the transmission oil filter for clogging and other failure. 2. See the Testing and adjusting, "Testing power train oil pressure", and make sure that clutch oil pressure is normal. 1. Turn the starting switch to OFF position. 2. Disconnect connector TM3, and connect T-adapter to male side. 3. Start engine. Hold the shift lever to N position.
2
Failure of FL-clutch ECMV fill switch
Between TM3 (male) (1) and ground
4
Open circuit in wiring harness
Failure of transmission controller
Min. 1 Mz
Steps 1 to 2 are the same as above. 3. Lift the machine so that the drive wheels idle. 4. Start engine. 5. Shift the lever (at travel speed) and diagnose it (while drive wheels are idling). Between TM3 (male) (1) and ground
3
Resistance
F1
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40 and TM3, and connect T-adapter to each female side. Between TM40 (female) (17) and TM3 (female) (1)
Resistance
Max. 1 z
Voltage
7 to 11 V
1. Turn the starting switch to OFF position. 2. Lift the machine so that the drive wheels idle. 3. Insert T-adapter into connector TM40. 4. Start engine. Hold the shift lever to N position. Between TM40 (17) and ground
Steps 1 to 4 are the same as above. 5. Shift the lever (at travel speed) and diagnose it (while drive wheels are idling). Between TM40 (17) and ground
GD535-5 (03)
F1
Voltage
Max. 1 V
40-129
Failure code [15SDMA] Malfunction of ECMV (FL)
40 Troubleshooting
Circuit diagram related to FL-clutch ECMV solenoid
40-130
GD535-5 (03)
40 Troubleshooting
Failure code [15SEL1] Release Trouble of ECMV (1st)
Failure code [15SEL1] Release Trouble of ECMV (1st) Action code
Failure code
L01
15SEL1
Detail of failure Action of controller Problem on machine
No.
Release trouble of ECMV (1st) (Transmission controller system)
Even if the output to the 1st clutch ECMV solenoid is turned OFF, the clutch is not released when signal from Fill switch is kept ON. q q
Particular action is not taken. (If double engagement is detected simultaneously, the gear speed is set to neutral.) If cause of failure disappears, machine becomes normal by itself.
Machine can travel in F1, F2 or R1 gear position only. q
Related information
Failure
1
q q
The output current command value to the 1st clutch ECMV solenoid can be checked with monitoring function. (Code: 31602) Input condition (ON/OFF) from ECMV fill switch of 1st clutch can be checked with monitoring function. (Code: 02216, 02217) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine.
Cause
Procedure, measuring location, criteria, and remarks
1
Failure of 1st clutch oil pressure or mechanical system
1. Check the transmission oil filter for clogging and other failure. 2. See the Testing and adjusting, "Testing power train oil pressure", and make sure that clutch oil pressure is normal.
2
Failure of 1st clutch ECMV fill switch
1. Turn the starting switch to OFF position. 2. Disconnect connector TM10, and connect T-adapter to male side. a Normal criteria when fill switch is OFF Between TM10 (male) (1) and ground
3
4
5
Harness grounding or transmission controller failure
Ground fault in wiring harness
Failure of transmission controller
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector TM10. 3. Start engine. If failure code [15SEL1] still continues, the wiring harness is grounded or the transmission controller has failed. (If failure code [15SEL1] is cleared, the 1st clutch fill switch has failed.) If no failure is found by check on Cause 3, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40 and TM10, and connect T-adapter to either female side. Between TM40 (female) (13) or TM10 (female) (1) and ground
Resistance
Min. 1 Mz
If "Failure during check of cause 3" and "Normal during check of cause 4" occur, the transmission controller has failed. Reference: The following shows the criteria during normal. 1. Turn the starting switch to OFF position. 2. Lift the machine so that the drive wheels idle. 3. Insert T-adapter into connector TM40. 4. Start engine. Hold the shift lever to N position. Between TM40 (13) and ground
Voltage
7 to 11 V
Steps 1 to 4 are the same as above. 5. Shift the lever (at travel speed) and diagnose it (while drive wheels are idling). Between TM40 (13) and ground
GD535-5 (03)
F1/R1
Voltage
Max. 1 V
40-131
Failure code [15SEL1] Release Trouble of ECMV (1st)
40 Troubleshooting
Circuit diagram related to 1st clutch ECMV solenoid
40-132
GD535-5 (03)
40 Troubleshooting
Failure code [15SEMA] Malfunction of ECMV (1st)
Failure code [15SEMA] Malfunction of ECMV (1st) Action code
Failure code
L03
15SEMA q
Detail of failure
q
q
Action of controller Problem on machine
q q
No. 1
Malfunction of 1st clutch ECMV solenoid (Transmission controller system)
Even if signal is output to the 1st clutch ECMV solenoid, the clutch is not engaged when the signal from fill switch is OFF. During output to 1st clutch ECMV solenoid, a clutch slipping is detected from either engine speed signal, transmission input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, or transmission output shaft speed sensor signal. Flashes the centralized warning lamp and sounds the alarm buzzer. Keeps to turn OFF the output to 1st clutch ECMV solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
Machine can travel in F3 to F8, or R2 to R4 positions only. q
Related information
Failure
1
q q
The output current command value to the 1st clutch ECMV solenoid can be checked with monitoring function. (Code: 31602) Input condition (ON/OFF) from ECMV fill switch of 1st clutch can be checked with monitoring function. (Code: 02216, 02217) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of F1, F2 or R1 position).
Cause Failure of 1st clutch oil pressure or mechanical system
Procedure, measuring location, criteria, and remarks 1. Check the transmission oil filter for clogging and other failure. 2. See the Testing and adjusting, "Testing power train oil pressure", and make sure that clutch oil pressure is normal. 1. Turn the starting switch to OFF position. 2. Disconnect connector TM10, and connect T-adapter to male side. 3. Start engine. Hold the shift lever to N position.
2
Failure of 1st clutch ECMV fill switch
Between TM10 (male) (1) and ground
Open circuit in wiring harness
Min. 1 Mz
Steps 1 to 2 are the same as above. 3. Lift the machine so that the drive wheels idle. 4. Start engine. 5. Shift the lever (at travel speed) and diagnose it (while drive wheels are idling). Between TM10 (male) (1) and ground
3
Resistance
F1/R1
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40 and TM10, and connect T-adapter to each female side. Between TM40 (female) (13) and TM10 (female) (1)
Resistance
Max. 1 z
Voltage
7 to 11 V
1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector TM40. 3. Start engine. Hold the shift lever to N position. 4
Failure of transmission controller
Between TM40 (13) and ground
Steps 1 to 2 are the same as above. 3. Lift the machine so that the drive wheels idle. 4. Start engine. 5. Shift the lever (at travel speed) and diagnose it (while drive wheels are idling). Between TM40 (13) and ground
GD535-5 (03)
F1/R1
Voltage
Max. 1 V
40-133
Failure code [15SEMA] Malfunction of ECMV (1st)
40 Troubleshooting
Circuit diagram related to 1st clutch ECMV solenoid
40-134
GD535-5 (03)
40 Troubleshooting
Failure code [15SFL1] Release Trouble of ECMV (2nd)
Failure code [15SFL1] Release Trouble of ECMV (2nd) Action code
Failure code
L01
15SFL1
Detail of failure Action of controller Problem on machine
No.
Release trouble of ECMV (2nd) (Transmission controller system)
Even if the output to the 2nd clutch ECMV solenoid is turned OFF, the clutch is not released when signal from Fill switch is kept ON. q q
Particular action is not taken. (If double engagement is detected simultaneously, the gear speed is set to neutral.) If cause of failure disappears, machine becomes normal by itself.
Machine can travel in F3, F4 or R2 gear position only. q
Related information
Failure
1
q q
The output current command value to the 2nd clutch ECMV solenoid can be checked with monitoring function. (Code: 31603) Input condition (ON/OFF) from ECMV fill switch of 2nd clutch can be checked with monitoring function. (Code: 02216, 02217) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine.
Cause
Procedure, measuring location, criteria, and remarks
1
Failure of 2nd clutch oil pressure or mechanical system
1. Check the transmission oil filter for clogging and other failure. 2. See the Testing and adjusting, "Testing power train oil pressure", and make sure that clutch oil pressure is normal.
2
Failure of 2nd clutch ECMV fill switch
1. Turn the starting switch to OFF position. 2. Disconnect connector TM5, and connect T-adapter to male side. a Normal criteria when fill switch is OFF Between TM5 (male) (1) and ground
3
Harness grounding or transmission controller failure
4
Ground fault in wiring harness
Resistance
1. Turn the starting switch to OFF position. 2. Disconnect connector TM5. 3. Start engine. If failure code [15SFL1] still continues, the wiring harness is grounded or the transmission controller has failed. (If failure code [15SFL1] is cleared, the 2nd clutch fill switch has failed.) If no failure is found by check on Cause 3, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40 and TM5, and connect T-adapter to either female side. Between TM40 (female) (3) or TM5 (female) (1) and ground
5
Failure of transmission controller
Min. 1 Mz
Resistance
Min. 1 Mz
If "Failure during check of cause 3" and "Normal during check of cause 4" occur, the transmission controller has failed. Reference: The following shows the criteria during normal. 1. Turn the starting switch to OFF position. 2. Lift the machine so that the drive wheels idle. 3. Insert T-adapter into connector TM40. 4. Start engine. Hold the shift lever to N position. Between TM40 (3) and ground
Voltage
7 to 11 V
Steps 1 to 4 are the same as above. 5. Shift the lever (at travel speed) and diagnose it (while drive wheels are idling). Between TM40 (3) and ground
GD535-5 (03)
F3
Voltage
Max. 1 V
40-135
Failure code [15SFL1] Release Trouble of ECMV (2nd)
40 Troubleshooting
Circuit diagram related to 2nd clutch ECMV solenoid
40-136
GD535-5 (03)
40 Troubleshooting
Failure code [15SFMA] Malfunction of ECMV (2nd)
Failure code [15SFMA] Malfunction of ECMV (2nd) Action code
Failure code
L03
15SFMA q
Detail of failure
q
q
Action of controller Problem on machine
q q
No. 1
Malfunction of 2nd clutch ECMV solenoid (Transmission controller system)
Even if signal is output to the 2nd clutch ECMV solenoid, the clutch is not engaged when the signal from fill switch is OFF. During output to 2nd clutch ECMV solenoid, a clutch slipping is detected from either engine speed signal, transmission input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, or transmission output shaft speed sensor signal. Flashes the centralized warning lamp and sounds the alarm buzzer. Keeps to turn OFF the output to 2nd clutch ECMV solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
Machine can travel in F1, F2, F5 to F8, R1, R3, or R4 gear position only. q
Related information
Failure
1
q q
The output current command value to the 2nd clutch ECMV solenoid can be checked with monitoring function. (Code: 31603) Input condition (ON/OFF) from ECMV fill switch of 2nd clutch can be checked with monitoring function. (Code: 02216, 02217) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of F3, F4 or R2 position).
Cause Failure of 2nd clutch oil pressure or mechanical system
Procedure, measuring location, criteria, and remarks 1. Check the transmission oil filter for clogging and other failure. 2. See the Testing and adjusting, "Testing power train oil pressure", and make sure that clutch oil pressure is normal. 1. Turn the starting switch to OFF position. 2. Disconnect connector TM5, and connect T-adapter to male side. 3. Start engine. Hold the shift lever to N position.
2
Failure of 2nd clutch ECMV fill switch
Between TM5 (male) (1) and ground
Open circuit in wiring harness
Min. 1 Mz
Steps 1 to 2 are the same as above. 3. Lift the machine so that the drive wheels idle. 4. Start engine. 5. Shift the lever (at travel speed) and diagnose it (while drive wheels are idling). Between TM5 (male) (1) and ground
3
Resistance
F3
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40 and TM5, and connect T-adapter to each female side. Between TM40 (female) (3) and TM5 (female) (1)
Resistance
Max. 1 z
Voltage
7 to 11 V
1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector TM40. 3. Start engine. Hold the shift lever to N position. 4
Failure of transmission controller
Between TM40 (3) and ground
Steps 1 to 2 are the same as above. 3. Lift the machine so that the drive wheels idle. 4. Start engine. 5. Shift the lever (at travel speed) and diagnose it (while drive wheels are idling). Between TM40 (3) and ground
GD535-5 (03)
F3
Voltage
Max. 1 V
40-137
Failure code [15SFMA] Malfunction of ECMV (2nd)
40 Troubleshooting
Circuit diagram related to 2nd clutch ECMV solenoid
40-138
GD535-5 (03)
40 Troubleshooting
Failure code [15SGL1] Release Trouble of ECMV (3rd)
Failure code [15SGL1] Release Trouble of ECMV (3rd) Action code
Failure code
L01
15SGL1
Detail of failure Action of controller Problem on machine
No.
Release trouble of ECMV (3rd) (Transmission controller system)
Even if the output to the 3rd clutch ECMV solenoid is turned OFF, the clutch is not released when signal from Fill switch is kept ON. q q
Particular action is not taken. (If double engagement is detected simultaneously, the gear speed is set to neutral.) If cause of failure disappears, machine becomes normal by itself.
Machine can travel in F5, F6 or R3 gear position only. q
Related information
Failure
1
q q
The output current command value to the 3rd clutch ECMV solenoid can be checked with monitoring function. (Code: 31604) Input condition (ON/OFF) from ECMV fill switch of 3rd clutch can be checked with monitoring function. (Code: 02216, 02217) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine.
Cause
Procedure, measuring location, criteria, and remarks
1
Failure of 3rd clutch oil pressure or mechanical system
1. Check the transmission oil filter for clogging and other failure. 2. See the Testing and adjusting, "Testing power train oil pressure", and make sure that clutch oil pressure is normal.
2
Failure of 3rd clutch ECMV fill switch
1. Turn the starting switch to OFF position. 2. Disconnect connector TM7, and connect T-adapter to male side. a Normal criteria when fill switch is OFF Between TM7 (male) (1) and ground
3
Harness grounding or transmission controller failure
4
Ground fault in wiring harness
Resistance
1. Turn the starting switch to OFF position. 2. Disconnect connector TM7. 3. Start engine. If failure code [15SGL1] still continues, the wiring harness is grounded or the transmission controller has failed. (If failure code [15SGL1] is cleared, the 3rd clutch fill switch has failed.) If no failure is found by check on Cause 3, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40 and TM7, and connect T-adapter to either female side. Between TM40 (female) (2) or TM7 (female) (1) and ground
5
Failure of transmission controller
Min. 1 Mz
Resistance
Min. 1 Mz
If "Failure during check of cause 3" and "Normal during check of cause 4" occur, the transmission controller has failed. Reference 1. Turn the starting switch to OFF position. 2. Lift the machine so that the drive wheels idle. 3. Insert T-adapter into connector TM40. 4. Start engine. Hold the shift lever to N position. Between TM40 (2) and ground
Voltage
7 to 11 V
Steps 1 to 4 are the same as above. 5. Shift the lever (at travel speed) and diagnose it (while drive wheels are idling). Between TM40 (2) and ground
GD535-5 (03)
F5
Voltage
Max. 1 V
40-139
Failure code [15SGL1] Release Trouble of ECMV (3rd)
40 Troubleshooting
Circuit diagram related to 3rd clutch ECMV solenoid
40-140
GD535-5 (03)
40 Troubleshooting
Failure code [15SGMA] Malfunction of ECMV (3rd)
Failure code [15SGMA] Malfunction of ECMV (3rd) Action code
Failure code
L03
15SGMA q
Detail of failure
q
q
Action of controller Problem on machine
q q
No. 1
Malfunction of ECMV (3rd) (Transmission controller system)
Even if signal is output to the 3rd clutch ECMV solenoid, the clutch is not engaged when the signal from fill switch is OFF. During output to 3rd clutch ECMV solenoid, a clutch slipping is detected from either engine speed signal, transmission input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, or transmission output shaft speed sensor signal. Flashes the centralized warning lamp and sounds the alarm buzzer. Keeps to turn OFF the output to 3rd clutch ECMV solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
Machine can travel in F1 to F4, F7, F8, R1, R2, or R4 gear position only. q
Related information
Failure
1
q q
The output current command value to the 3rd clutch ECMV solenoid can be checked with monitoring function. (Code: 31603) Input condition (ON/OFF) from ECMV fill switch of 3rd clutch can be checked with monitoring function. (Code: 02216, 02217) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of F5, F6 or R3 position).
Cause Failure of 3rd clutch oil pressure or mechanical system
Procedure, measuring location, criteria, and remarks 1. Check the transmission oil filter for clogging and other failure. 2. See the Testing and adjusting, "Testing power train oil pressure", and make sure that clutch oil pressure is normal. 1. Turn the starting switch to OFF position. 2. Disconnect connector TM7, and connect T-adapter to male side. 3. Start engine. Hold the shift lever to N position.
2
Failure of 3rd clutch ECMV fill switch
Between TM7 (male) (1) and ground
Open circuit in wiring harness
Min. 1 Mz
Steps 1 to 2 are the same as above. 3. Lift the machine so that the drive wheels idle. 4. Start engine. 5. Shift the lever (at travel speed) and diagnose it (while drive wheels are idling). Between TM7 (male) (1) and ground
3
Resistance
F5
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40 and TM7, and connect T-adapter to each female side. Between TM40 (female) (2) and TM7 (female) (1)
Resistance
Max. 1 z
Voltage
7 to 11 V
1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector TM40. 3. Start engine. Hold the shift lever to N position. 4
Failure of transmission controller
Between TM40 (2) and ground
Steps 1 to 2 are the same as above. 3. Lift the machine so that the drive wheels idle. 4. Start engine. 5. Shift the lever (at travel speed) and diagnose it (while drive wheels are idling). Between TM40 (2) and ground
GD535-5 (03)
F5
Voltage
Max. 1 V
40-141
Failure code [15SGMA] Malfunction of ECMV (3rd)
40 Troubleshooting
Circuit diagram related to 3rd clutch ECMV solenoid
40-142
GD535-5 (03)
40 Troubleshooting
Failure code [15SHL1] Release Trouble of ECMV (4th)
Failure code [15SHL1] Release Trouble of ECMV (4th) Action code
Failure code
L01
15SHL1
Detail of failure Action of controller Problem on machine
No.
Release trouble of ECMV (4th) (Transmission controller system)
Even if the output to the 4th clutch ECMV solenoid is turned OFF, the clutch is not released when signal from fill switch is kept ON. q q
Particular action is not taken. (If double engagement is detected simultaneously, the gear speed is set to neutral.) If cause of failure disappears, machine becomes normal by itself.
Machine can travel in F7, F8 or R4 gear position only. q
Related information
Failure
1
q q
The output current command value to the 4th clutch ECMV solenoid can be checked with monitoring function. (Code: 31605) Input condition (ON/OFF) from ECMV fill switch of 4th clutch can be checked with monitoring function. (Code: 02216, 02217) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine.
Cause
Procedure, measuring location, criteria, and remarks
1
Failure of 4th clutch oil pressure or mechanical system
1. Check the transmission oil filter for clogging and other failure. 2. See the Testing and adjusting, "Testing power train oil pressure", and make sure that clutch oil pressure is normal.
2
Failure of 4th clutch ECMV fill switch
1. Turn the starting switch to OFF position. 2. Disconnect connector TM14, and connect T-adapter to male side. a Normal criteria when fill switch is OFF Between TM14 (male) (1) and ground
3
4
5
Harness grounding or transmission controller failure
Ground fault in wiring harness
Failure of transmission controller
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector TM14. 3. Start engine. If failure code [15SHL1] still continues, the wiring harness is grounded or the transmission controller has failed. (If failure code [15SHL1] is cleared, the 4th clutch fill switch has failed.) If no failure is found by check on Cause 3, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40 and TM14, and connect T-adapter to either female side. Between TM40 (female) (38) or TM14 (female) (1) and ground
Resistance
Min. 1 Mz
If "Failure during check of cause 3" and "Normal during check of cause 4" occur, the transmission controller has failed. Reference: The following shows the criteria during normal. 1. Turn the starting switch to OFF position. 2. Lift the machine so that the drive wheels idle. 3. Insert T-adapter into connector TM40. 4. Start engine. Hold the shift lever to N position. Between TM40 (38) and ground
Voltage
7 to 11 V
Steps 1 to 4 are the same as above. 5. Shift the lever (at travel speed) and diagnose it (while drive wheels are idling). Between TM40 (38) and ground
GD535-5 (03)
F7
Voltage
Max. 1 V
40-143
Failure code [15SHL1] Release Trouble of ECMV (4th)
40 Troubleshooting
Circuit diagram related to 4th clutch ECMV solenoid
40-144
GD535-5 (03)
40 Troubleshooting
Failure code [15SHMA] Malfunction of ECMV (4th)
Failure code [15SHMA] Malfunction of ECMV (4th) Action code
Failure code
L03
15SHMA q
Detail of failure
q
q
Action of controller Problem on machine
q q
No. 1
Malfunction of 4th clutch ECMV solenoid (Transmission controller system)
Even if signal is output to the 4th clutch ECMV solenoid, the clutch is not engaged when the signal from fill switch is OFF. During output to 4th clutch ECMV solenoid, a clutch slipping is detected from either engine speed signal, transmission input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, or transmission output shaft speed sensor signal. Flashes the centralized warning lamp and sounds the alarm buzzer. Keeps to turn OFF the output to 4th clutch ECMV solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
Machine can travel in F1 to F6, or R1 to R3 positions only. q
Related information
Failure
1
q q
The output current command value to the 4th clutch ECMV solenoid can be checked with monitoring function. (Code: 31605) Input condition (ON/OFF) from ECMV fill switch of 4th clutch can be checked with monitoring function. (Code: 02216, 02217) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of F7, F8 or R4 position).
Cause Failure of 4th clutch oil pressure or mechanical system
Procedure, measuring location, criteria, and remarks 1. Check the transmission oil filter for clogging and other failure. 2. See the Testing and adjusting, "Testing power train oil pressure", and make sure that clutch oil pressure is normal. 1. Turn the starting switch to OFF position. 2. Disconnect connector TM14, and connect T-adapter to male side. 3. Start engine. Hold the shift lever to N position.
2
Failure of 4th clutch ECMV fill switch
Between TM14 (male) (1) and ground
Open circuit in wiring harness
Min. 1 Mz
Steps 1 to 2 are the same as above. 3. Lift the machine so that the drive wheels idle. 4. Start engine. 5. Shift the lever (at travel speed) and diagnose it (while drive wheels are idling). Between TM14 (male) (1) and ground
3
Resistance
F7
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40 and TM14, and connect T-adapter to each female side. Between TM40 (female) (38) and TM14 (female) (1)
Resistance
Max. 1 z
Voltage
7 to 11 V
1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector TM40. 3. Start engine. Hold the shift lever to N position. 4
Failure of transmission controller
Between TM40 (38) and ground
Steps 1 to 2 are the same as above. 3. Lift the machine so that the drive wheels idle. 4. Start engine. 5. Shift the lever (at travel speed) and diagnose it (while drive wheels are idling). Between TM40 (38) and ground
GD535-5 (03)
F7
Voltage
Max. 1 V
40-145
Failure code [15SHMA] Malfunction of ECMV (4th)
40 Troubleshooting
Circuit diagram related to 4th clutch ECMV solenoid
40-146
GD535-5 (03)
40 Troubleshooting
Failure code [15SJMA] Malfunction of ECMV (L/U)
Failure code [15SJMA] Malfunction of ECMV (L/U) Action code
Failure code
L03
15SJMA
Failure
1
Malfunction of ECMV (L/U) (Transmission controller system)
During output to lockup clutch ECMV solenoid, a clutch slipping is detected from either engine speed signal, Detail of failure transmission input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, or transmission output shaft speed sensor signal. q
Action of controller Problem on machine
q q
Even if the MANUAL mode is selected by the transmission mode switch, the AUTO mode (Torque Converter mode) is always selected. q
Related information
No.
Flashes the centralized warning lamp and sounds the alarm buzzer. Keeps to turn OFF the output to lockup clutch ECMV solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
The output current command value to the lockup clutch ECMV solenoid can be checked with monitoring function. (Code: 31609) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Operate the transmission mode selector switch (MANUAL mode).
Cause
Procedure, measuring location, criteria, and remarks
1
Failure of lockup clutch oil pressure or mechanical system
1. Check the transmission oil filter for clogging and other failure. 2. See the Testing and adjusting, "Testing power train oil pressure", and make sure that clutch oil pressure is normal.
2
Failure of lockup clutch ECMV solenoid system
Perform troubleshooting for failure code [DXH1KA], [DXH1KB] or [DXH1KY].
GD535-5 (03)
40-147
Failure code [15U0NT] Overload of Inching Clutch
40 Troubleshooting
Failure code [15U0NT] Overload of Inching Clutch Action code
Failure code
L02
15U0NT
Detail of failure Action of controller
Failure
1
Inching clutch overload (Transmission controller system)
The clutch temperature, that is estimated based on the inching clutch oil temp sensor, has exceeded 200 °C q q
Flashes the centralized warning lamp, and sounds the alarm buzzer 2 seconds. Then, it turns OFF the lockup clutch. If cause of failure disappears, machine becomes normal by itself.
Problem on machine
The lockup clutch is turned OFF.
Related information
After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
No.
Cause
Procedure, measuring location, criteria, and remarks As an event to detect an overheating of inching clutch has occurred at present or in the past, locate the failure cause and damage and repair it (including inappropriate inching operation).
1
Inching clutch overload
2
Failure of transmission oil temperature sensor Perform troubleshooting for failure code [DGF1KX]. system
40-148
GD535-5 (03)
40 Troubleshooting
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front)
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) Action code
Failure code
L03
2G42ZG
Detail of failure Action of controller Problem on machine
No.
Accumulator oil pressure low (front) (Machine monitor system)
When engine is running, the dropped pressure of front accumulator was detected by the front brake oil pressure switch. q q
Lights the centralized warning lamp and sounds the alarm buzzer. If cause of failure disappears, machine becomes normal by itself.
When engine is running, the brake oil pressure caution lamp turns ON. q
Related information
Failure
q
Input condition (ON/OFF) from front brake oil pressure switch can be checked with monitoring function. (Code: 04510). After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine.
Cause
1
Dropped oil pressure of front brake accumulator
2
Failure of front brake oil pressure switch
Procedure, measuring location, criteria, and remarks Check the oil pressure of front brake accumulator (see the Testing and Adjusting). 1. Turn the starting switch to OFF position. 2. Disconnect connector R15, and connect T-adapter to male side. 3. Start engine. Between R15 (male) (1) and (2)
3
Open circuit in wiring harness
5
Short circuit or ground fault in wiring harness Failure of transmission controller
GD535-5 (03)
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM39 and R15, and connect T-adapter to each female side. Between TM39 (female) (6) and R15 (female) (1) Between R15 (female) (2) and ground
4
1
Resistance
Max. 1 z Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM39 and R15, and connect T-adapter to female side of R15. Between R15 (female) (1) and (2)
Resistance
Min. 1 Mz
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-149
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front)
40 Troubleshooting
Circuit diagram related to the brake accumulator
40-150
GD535-5 (03)
40 Troubleshooting
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear)
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) Action code
Failure code
L03
2G43ZG
Detail of failure Action of controller Problem on machine
No.
Accumulator oil pressure low (rear) (Machine monitor system)
When engine is running, the dropped pressure of rear accumulator was detected by the rear brake oil pressure switch. q q
Lights the centralized warning lamp and sounds the alarm buzzer. If cause of failure disappears, machine becomes normal by itself.
When engine is running, the brake oil pressure caution lamp turns ON. q
Related information
Failure
q
Input condition (ON/OFF) from front brake oil pressure switch can be checked with monitoring function. (Code: 04510) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine.
Cause
1
Dropped oil pressure of rear brake accumulator
2
Defective rear brake oil pressure switch
Procedure, measuring location, criteria, and remarks Check the oil pressure of rear brake accumulator (see the Testing and Adjusting). 1. Turn the starting switch to OFF position. 2. Disconnect connector R16, and connect T-adapter to male side. 3. Start engine. Between R16 (male) (1) and (2)
3
Open circuit in wiring harness
5
Short circuit or ground fault in wiring harness Failure of transmission controller
GD535-5 (03)
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40 and R16, and connect T-adapter to each female side. Between TM40 (female) (37) and R16 (female) (1) Between R16 (female) (2) and ground
4
1
Resistance
Max. 1 z Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40 and R16, and connect T-adapter to female side of R16. Between R16 (female) (1) and (2)
Resistance
Min. 1 Mz
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-151
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear)
40 Troubleshooting
Circuit diagram related to the brake accumulator
40-152
GD535-5 (03)
40 Troubleshooting
Failure code [989L00] Engine Controller Lock Caution 1
Failure code [989L00] Engine Controller Lock Caution 1 Action code
Failure code
-
989L00
Failure
1
Engine controller lock caution 1 (Machine monitor system)
Detail of failure Engine controller lock failure is detected (Factor 1). Action of controller Problem on machine
q q
Engine does not start. q
Related information
No. 1
None in particular If cause of failure disappears, machine becomes normal by itself.
q
If this failure code occurs after replacement of machine monitor, you need to change the current password back to the password you used before panel replacement. After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause The machine monitor was replaced.
GD535-5 (03)
Procedure, measuring location, criteria, and remarks This error may occur if the machine monitor is replaced.
40-153
Failure code [989M00] Engine Controller Lock Caution 2
40 Troubleshooting
Failure code [989M00] Engine Controller Lock Caution 2 Action code
Failure code
-
989M00
Failure
1
Engine controller lock caution 2 (Machine monitor system)
Detail of failure Abnormal status of engine controller lock was detected (Factor 2). Action of controller Problem on machine
q q
Engine does not start. q
Related information
q q
No.
None in particular If cause of failure disappears, machine becomes normal by itself.
If this failure code occurs after replacement of machine monitor, you need to change the current password back to the password you used before panel replacement. After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause
Procedure, measuring location, criteria, and remarks
1
The machine monitor was replaced.
This error may occur if the machine monitor is replaced.
2
Defective machine monitor
If the machine monitor is not replaced and if this failure code occurs, the machine monitor may have failed. (Since this is an internal defect, troubleshooting cannot be performed.)
40-154
GD535-5 (03)
40 Troubleshooting
Failure code [989N00] Engine Controller Lock Caution 3
Failure code [989N00] Engine Controller Lock Caution 3 Action code
Failure code
-
989N00
Failure
1
Engine controller lock caution 3 (Machine monitor system)
Detail of failure Abnormal status of engine controller lock was detected (Factor 3). Action of controller Problem on machine Related information
No. 1
q q
Automatic recovery is attempted. If cause of failure disappears, machine becomes normal by itself.
Engine does not start. q q
After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: System is recovered automatically, and the error is not reproduced.
Cause Defective engine controller
GD535-5 (03)
Procedure, measuring location, criteria, and remarks If this failure recurs, the engine controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-155
Failure code [AB00KE] Charge Voltage Low
40 Troubleshooting
Failure code [AB00KE] Charge Voltage Low Action code
Failure code
L03
AB00KE
Failure
1
Charge Voltage Low (Machine monitor system)
Detail of failure Power generation signal is not entered from alternator when engine is running. Action of controller
Lights the centralized warning lamp and sounds the alarm buzzer.
Problem on machine
If it is continued, the power voltage drops and machine may fail to travel.
Related information
The battery charge voltage can be checked with monitoring function. (Code: 04306)
No.
1
Cause
Defective alternator
Procedure, measuring location, criteria, and remarks 1. 2. 3. a
Turn the starting switch to OFF position. Disconnect cable from R terminal of alternator. Start engine. If a deteriorated battery is used or if machine is operated in cold climates, the voltage may not rise for a while after engine startup.
Between alternator terminals R and E 2
3
Open circuit in wiring harness Failure of transmission controller
Voltage
24 to 30 V
1. Turn the starting switch to OFF position. 2. Disconnect connector TM39, and connect T-adapter to female side. Between TM39 (female) (15) and alternator R terminal
Resistance
Max. 1 z
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to alternator
40-156
GD535-5 (03)
40 Troubleshooting
Failure code [AB00KY] Hot Short of Alternator R Terminal
Failure code [AB00KY] Hot Short of Alternator R Terminal Action code
Failure code
L03
AB00KY
Failure
1
Hot short of alternator R terminal (Transmission controller system)
Detail of failure The signal of alternator R terminal is ON when power supply is OFF. Action of controller
Lights the centralized warning lamp and sounds the alarm buzzer when power supply is turned ON the next time.
Problem on machine
If it is continued, the power voltage drops and machine may fail to travel.
Related information
The battery charge voltage can be checked with monitoring function. (Code: 04306)
No.
1
Cause
Defective alternator
Procedure, measuring location, criteria, and remarks 1. 2. 3. a
Turn the starting switch to OFF position. Disconnect cable from R terminal of alternator. Start engine. If a deteriorated battery is used or if machine is operated in cold climates, the voltage may not rise for a while after engine startup.
Between alternator terminals R and E
2
Hot short circuit in wiring harness Failure of transmission controller
24 to 30 V
1. Turn the starting switch to OFF position. 2. Disconnect connector TM39, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between TM39 (female) (15) and ground
3
Voltage
Voltage
Max. 1 V
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to alternator
GD535-5 (03)
40-157
Failure code [B@BAZG] Derating in speed due to engine oil pressure drop
40 Troubleshooting
Failure code [B@BAZG] Derating in speed due to engine oil pressure drop1 Action code
Failure code
L03
B@BAZG
Detail of failure Action of controller Problem on machine
No.
Engine Oil Pressure Low (Engine controller system)
When engine was running, the voltage from engine oil pressure switch dropped to GND, and the engine controller detected the abnormal drop of engine oil pressure. q q
Lights the engine oil pressure caution lamp on the machine monitor. Lights the centralized warning lamp and sounds the alarm buzzer.
If machine is used as it is, engine may be seized. q
Related information
Failure
q q
The signal of engine oil pressure switch is entered in the engine controller, and this code is transmitted to the machine monitor through CAN communication. For the diagnosis of engine oil pressure switch during engine stopping, see Failure code [CA435]. After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine.
Cause
Procedure, measuring location, criteria, and remarks
1
Engine oil pressure dropped. (When system works properly)
Engine oil pressure may drops. Check it and remove cause of failure if oil pressure is low.
2
Defective engine oil pressure sensor system
If no failure is found in cause 1, engine oil pressure sensor system may be defective. Perform troubleshooting for failure code [CA435].
40-158
GD535-5 (03)
40 Troubleshooting
Failure code [B@BCNS] Engine Overheat
Failure code [B@BCNS] Engine Overheat Action code
Failure code
L02
B@BCNS
Failure
1
Engine Water Overheat (Engine controller system)
Detail of failure The engine coolant temperature exceeds its operating range when engine is running. Action of controller Problem on machine
q q
If machine is used as it is, engine may be seized. q q
Related information
q q
No.
Lights the engine coolant caution lamp on the machine monitor. Lights the centralized warning lamp and sounds the alarm buzzer.
The signal voltage of engine coolant temperature sensor is entered in engine controller, and this data is transmitted to the machine monitor through CAN communication. Input voltage from engine coolant sensor can be checked with monitoring function. (Code: 04105) Temperature detected by engine coolant temperature sensor can be checked with monitoring function. (Code: 04107) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine.
Cause
Procedure, measuring location, criteria, and remarks
1
Overheating of engine coolant (When system works properly)
Engine coolant may overheat. Check coolant temperature and remove cause of failure if coolant overheats.
2
Defective engine coolant temperature sensor system
If no failure is found by check on cause 1, engine coolant temperature sensor system may be defective. Perform troubleshooting for failure codes [CA144] and [CA145].
GD535-5 (03)
40-159
Failure code [B@CENS] T/C Oil Temp. Overheat
40 Troubleshooting
Failure code [B@CENS] T/C Oil Temp. Overheat Action code
Failure code
L02
B@CENS
Detail of failure Action of controller Problem on machine
No.
Overheat of torque converter oil temperature (Machine monitor system)
The voltage of torque converter oil temperature sensor dropped during engine running, and the transmission controller detected an overheat of torque converter oil temperature (approximately 120°C or above). q q q
Lights the torque converter oil temperature caution lamp on the machine monitor. If cause of failure disappears, machine becomes normal by itself. Lights the centralized warning lamp and sounds the alarm buzzer.
If machine is used as it is, the torque converter may seize. q
Related information
Failure
q q
Signal from torque converter oil temperature is entered in the transmission controller, and its data is transmitted to machine monitor through CAN communication. The input voltage and temperature sent from the torque converter oil temperature sensor can be checked by the monitoring function. (Code: 30101, 30100) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine.
Cause
Procedure, measuring location, criteria, and remarks
1
Overheat of torque converter oil temperature The torque converter oil may overheat. If overheated, repair it. (when system works properly)
2
Failure of torque converter oil temperature Perform troubleshooting for failure code [DGT1KX]. sensor system
40-160
1
GD535-5 (03)
40 Troubleshooting
Failure code [B@CKNS] DIFF Oil Temp. Overheat
Failure code [B@CKNS] DIFF Oil Temp. Overheat Action code
Failure code
L02
B@CKNS
Failure
1
Overheat of differential gear oil (Machine monitor system)
Detail of failure Differential gear oil temperature caution occurred. (Differential gear oil temperature exceeded 120°C) Action of controller Problem on machine
q q q
If machine is used as it is, the differential gear may seize. q
Related information
No.
1
Lights the centralized warning lamp and sounds the alarm buzzer. If cause of failure disappears, machine becomes normal by itself. Lights the differential gear oil temperature caution lamp.
q
The input voltage and temperature sent from the differential gear oil temperature sensor can be checked by the monitoring function. (Code: 31910, 31909) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause
Procedure, measuring location, criteria, and remarks
Overheat of differential gear case oil temperature As an event to detect an overheating of differential gear case oil has occurred at present or (When system works in the past, locate the failure cause and damage and repair it. properly) 1. Turn the starting switch to OFF position. 2. Disconnect connector R8, and connect T-adapter to male side.
2
Between R8 (male) (1) and (2) Failure of differential gear (Temperature characteristics of oil oil temperature sensor temperature sensor) Between R8 (male) (1) and ground, and between R8 (male) (2) and ground
3
Open or short circuit in wiring harness
25°C
Resistance
38 to 49 kz
100°C
Resistance
3.7 to 4.0 kz
All ranges
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector TM39, and connect T-adapter to female side. a The resistance is the same as for the temperature characteristics table of oil temperature sensor in cause 1 (25°C to 100°C) Between TM39 (female) (14) and ground
4
5
6
Open circuit in wiring harness
Ground fault in wiring harness
Hot short or short circuit of wiring harness Failure of transmission controller
GD535-5 (03)
3.7 to 49 kz
If no failure is found by check on cause 2, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors TM39 and R8, and connect T-adapter to each female side. Between TM39 (female) (14) and R8 (female) (1)
Resistance
Max. 1 z
Between TM39 (female) (21) and R8 (female) (2)
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors R8 and TM39, and connect T-adapter to either female side. Between R8 (female) (1) or TM39 (female) (14) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector R8, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between R8 (female) (1) and (2)
7
Resistance
Voltage
Approx. 5 V
If no failure is found by above checks, the transmission controller has failed. (Since this is an internal defect, troubleshooting cannot be performed.)
40-161
Failure code [B@CKNS] DIFF Oil Temp. Overheat
40 Troubleshooting
Circuit diagram related to differential gear oil temperature sensor
40-162
GD535-5 (03)
40 Troubleshooting
Failure code [B@HANS] HYD Oil Temp. Overheat
Failure code [B@HANS] HYD Oil Temp. Overheat Action code
Failure code
L02
B@HANS
Detail of failure Action of controller Problem on machine
Hydraulic Oil Temperature Overheat (Machine monitor system)
The voltage of hydraulic oil temperature sensor dropped, and the machine monitor detected an overheat of hydraulic oil temperature (approximately 100°C or more) while engine is running. q q q
Lights the hydraulic oil temperature caution lamp on the machine monitor. If cause of failure disappears, machine becomes normal by itself. Lights the centralized warning lamp and sounds the alarm buzzer.
If machine is used as it is, hydraulic system components may be damaged. q
Related information
Failure
1
q q
Signal from hydraulic system oil temperature is entered in the transmission controller, and its data is transmitted to machine monitor through CAN communication. The input voltage and temperature sent from the hydraulic oil temperature sensor can be checked by the monitoring function. (Code: 04404, 04401) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine.
No.
Cause
1
Overheat of hydraulic oil temperature (when system works properly)
Procedure, measuring location, criteria, and remarks Hydraulic oil may be overheated. Check hydraulic oil temperature, and remove cause of failure if hydraulic oil overheats. 1. Turn the starting switch to OFF position. 2. Disconnect connector R17, and connect T-adapter to male side.
2
Failure of hydraulic oil temperature sensor
Between R17 (male) (1) and (2) (Temperature characteristics of oil temperature sensor) Between R17 (male) (1) and ground, and between R17 (male) (2) and ground
3
Open or short circuit in wiring harness
25°C
Resistance
38 to 49 kz
100°C
Resistance
3.7 to 4.0 kz
All ranges
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector TM39, and connect T-adapter to female side. a The resistance is the same as for the temperature characteristics table of oil temperature sensor in cause 1 (25°C to 100°C) Between TM39 (female) (20) and (21)
4
5
6
Open circuit in wiring harness
Ground fault in wiring harness
Hot short or short circuit of wiring harness Failure of transmission controller
GD535-5 (03)
3.7 to 49 kz
If no failure is found by check on cause 2, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors TM39 and R17, and connect T-adapter to each female side. Between TM39 (female) (20) and R17 (female) (1)
Resistance
Max. 1 z
Between TM39 (female) (21) and R17 (female) (2)
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors R17 and TM39, and connect T-adapter to either female sidev. Between R17 (female) (1) or TM39 (female) (20) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector R17, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between R17 (female) (1) and (2)
7
Resistance
Voltage
Approx. 5 V
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-163
Failure code [B@HANS] HYD Oil Temp. Overheat
40 Troubleshooting
Circuit diagram related to hydraulic oil temperature sensor
40-164
GD535-5 (03)
40 Troubleshooting
Failure code [CA111] Engine NE, controller internal error
Failure code [CA111] Engine NE, controller internal error Action code
Failure code
L03
CA111
Failure
1
Engine controller internal failure (Engine controller system)
Detail of failure Internal memory of engine controller or internal power supply circuit has failed. Action of controller Problem on machine Related information
No.
None in particular q q
Engine may stop during running, or engine may not start again. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting).
After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective relevant system
If other failure codes are also displayed, perform troubleshooting for them.
2
Defective engine controller system
Perform troubleshooting for failure code [CA441].
GD535-5 (03)
40-165
Failure code [CA115] Engine NE, Bkup speed sensor error
40 Troubleshooting
Failure code [CA115] Engine NE, Bkup speed sensor error Action code
Failure code
L03
CA115
Failure
1
Failure of engine NE or Backup speed sensor (Engine controller system)
Detail of failure Both signals of engine Ne speed sensor and engine backup speed sensor are abnormal. Action of controller
None in particular q
Problem on machine
Related information
No.
q q
Engine stops. Engine does not start. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting).
After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine.
Cause
Procedure, measuring location, criteria, and remarks
1
Poor connection of sensor connector
The Ne speed sensor cable and the backup speed sensor cable may not be connected securely (or incorrectly connected).
2
Failure of Ne speed sensor system
Perform troubleshooting for failure code [CA689], Steps 1 to 10).
3
Failure of Bkup speed sensor system
Perform troubleshooting for failure code [CA778].
4
Defective engine controller
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-166
GD535-5 (03)
40 Troubleshooting
Failure code [CA122] Charge pressure sensor high error
Failure code [CA122] Charge pressure sensor high error Action code
Failure code
L03
CA122
Detail of failure Action of controller Problem on machine
Charge pressure sensor high error (Engine controller system)
High voltage was detected in the pressure signal circuit of charge (boost) pressure and temperature sensors. Runs engine with the fixed charge pressure. q q
q q
Related information
Failure
1
q
q
Engine output lowers. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting). The input voltage from charge pressure sensor (boost pressure sensor) can be checked with monitoring function. (Code: 36501) The input voltage from charge pressure sensor (boost pressure sensor) can be checked with monitoring function. (Code: 36500) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position. If the sensor connector is unplugged, alarm [CA123] is output even in the normal state.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it.
2
Failure of dual system sensor power supply 2 system
If failure code [CA227] is also displayed, perform troubleshooting for it first.
3
1. Turn the starting switch to OFF position. 2. Disconnect the BOOST PRESS & IMT connector. Failure of boost pressure 3. Turn starting switch to ON position. and temperature sensor If failure code [CA122] changes to [CA123], the boost pressure sensor has failed. Temperature sensor failure code [CA153] is also displayed simultaneously. Ignore this code. This code is output because the sensor connector is being unplugged.
4
Short circuit in wiring harness
1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and BOOST PRESS & IMT, and connect T-adapter to female side of ECM. Between ECM (female) (37) and (44)
5
Hot short circuit in wiring harness Defective engine controller
GD535-5 (03)
Min. 100 kz
1. Turn the starting switch to OFF position. 2. Disconnect connector BOOST PRESS & IMT, and insert T-adapter into connector ECM. 3. Turn starting switch ON (with connector BOOST PRESS & IMT disconnected). Between ECM (44) and (47)
6
Resistance
Voltage
Max. 1 V
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-167
Failure code [CA122] Charge pressure sensor high error
40 Troubleshooting
Circuit diagram related to charge pressure sensor
40-168
GD535-5 (03)
40 Troubleshooting
Failure code [CA123] Charge pressure sensor low error
Failure code [CA123] Charge pressure sensor low error Action code
Failure code
L03
CA123
Detail of failure Action of controller Problem on machine
Charge pressure sensor low error (Engine controller system)
Low voltage was detected in the pressure signal circuit of charge (boost) pressure and temperature sensors. Runs engine with the fixed charge pressure. q q
q q
Related information
Failure
1
q
q q
Engine output lowers. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting). The input voltage from charge pressure sensor (boost pressure sensor) can be checked with monitoring function. (Code: 36501) The input voltage from charge pressure sensor (boost pressure sensor) can be checked with monitoring function. (Code: 36500) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position. Because the T-adapter for sensor connection is a socket, the voltage cannot be checked by checking the disconnection of wiring harness and sensor connector. If the sensor connector is disconnected, this code is output.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it.
2
Defective power supply system of charge (boost) If failure code [CA187] or [CA227] is also displayed, perform troubleshooting for it first. pressure sensor
3
4
Short circuit in wiring harness
Ground fault in wiring harness
1. Turn the starting switch to OFF position. 2. Disconnect connectors CAM SENSOR, FUEL RAIL PRESS, BOOST PRESS & IMT, and ECM. 3. Connect T-adapter to female side of ECM. Between ECM (female) (37) and (47)
Resistance
Min. 100 kz
Between ECM (female) (44) and (47)
Resistance
Min. 100 kz
1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and BOOST PRESS & IMT, and connect T-adapter to female side of ECM. Between ECM (female) (44) and ground
Resistance
Min. 100 kz
5
Open circuit in wiring harness
6
If failure is not found by check on causes 1 to 5, but found by check on cause 6, the sensor is defective. Failure of boost pressure 1. Turn the starting switch to OFF position. and temperature sensor 2. Insert T-adapter into connector ECM. (Incorrect input voltage of 3. Turn starting switch to ON position. engine controller) Sensor Min. 0.3 to Between ECM (44) and (47) Voltage output 4.7 V
7
Defective engine controller
If no failure is found by above checks, wiring harness may have open circuit. (*)
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
* See the "Diagnosis of open harness in pressure sensor system" of "Related information on troubleshooting".
GD535-5 (03)
40-169
Failure code [CA123] Charge pressure sensor low error
40 Troubleshooting
Circuit diagram related to charge pressure sensor
40-170
GD535-5 (03)
40 Troubleshooting
Failure code [CA131] Throttle sensor high error
Failure code [CA131] Throttle sensor high error Action code
Failure code
L03
CA131
Failure
1
Throttle position sensor high error (Engine controller system)
Detail of failure High voltage appears in throttle position sensor signal circuit. Action of controller Problem on machine
Turn the accelerator pedal OFF, and set the throttle opening to 0%. Then, turn the accelerator pedal ON, set the throttle opening to 50%, and run the engine. q q
q q
Related information
q
Full throttle position cannot be set. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting). Input voltage from throttle position sensor can be checked with monitoring function. (Code: 03000) The opening of accelerator pedal, detected by throttle position sensor, can be checked with monitoring function. (Code: 31701) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it.
2
Defective throttle sensor power supply system
If failure code [CA2185] is also displayed, perform troubleshooting for it first.
3
Short circuit in wiring harness
4
Hot short circuit in wiring harness
1. Turn the starting switch to OFF position. 2. Disconnect connectors EC2 and T9A, and connect T-adapter to either female side. Between EC2 (female) (9) and (22), or between T9A (female) (1) and (2)
6
Failure of accelerator pedal (throttle position sensor)
Defective engine controller
Voltage
Max. 1 V
Depress the accelerator pedal.
Voltage
3.7 to 4.0 V
When accelerator pedal is released
Voltage
0.5 to 0.8 V
1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector T9A. 3. Turn starting switch to ON position.
Between T9A (2) and (3)
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) Reference 1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector EC2. 3. Turn starting switch to ON position. 4. Operate the accelerator pedal and perform troubleshooting. Between EC2 (22) and (23)
Between EC2 (9) and (23)
GD535-5 (03)
Min. 100 kz
1. Turn the starting switch to OFF position. 2. Disconnect connector T9A, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between T9A (female) (2) and ground
5
Resistance
Power supply
Voltage
4.75 to 5.25 V
Depress the accelerator pedal.
Voltage
3.7 to 4.0 V
When accelerator pedal is released
Voltage
0.5 to 0.8 V
40-171
Failure code [CA131] Throttle sensor high error
40 Troubleshooting
Circuit diagram related to throttle sensor
40-172
GD535-5 (03)
40 Troubleshooting
Failure code [CA132] Throttle sensor low error
Failure code [CA132] Throttle sensor low error Action code
Failure code
L03
CA132
Failure
1
Throttle position sensor low error (Engine controller system)
Detail of failure Low voltage appears in throttle position sensor signal circuit. Action of controller Problem on machine
Turn the accelerator pedal OFF, and set the throttle opening to 0%. Then, turn the accelerator pedal ON, set the throttle opening to 50%, and run the engine. q q
q q
Related information
q
Full throttle position cannot be set. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting). Input voltage from throttle position sensor can be checked with monitoring function. (Code: 03000) The opening of accelerator pedal, detected by throttle position sensor, can be checked with monitoring function. (Code: 31701) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it. If failure code [CA2186] is also displayed, perform troubleshooting for it first.
2
Defective throttle sensor power supply system
1. 2. 3. 4. 5.
Turn the starting switch to OFF position. Disconnect cable from negative (-) battery terminal. Disconnect connectors T9A and T9B, and connect T-adapter to female side. Connect negative (-) battery terminal. Turn starting switch to ON position.
Between T9A (female) (1) and (3)
Voltage
4.75 to 5.25 V
Between T9B (female) (1) and (2)
Voltage
4.75 to 5.25 V
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors EC2, T9A, T9B, TM39, and TM40, and connect T-adapter to each female side.
3
4
Open circuit in wiring harness
Short circuit in wiring harness
GD535-5 (03)
If no failure is found by check on cause 2, this check is not required. Between EC2 (female) (22) and T9A (female) (1)
Resistance
Min. 100 kz
If no failure is found by check on cause 2, this check is not required. Between EC2 (female) (23) and T9A (female) (3)
Resistance
Max. 10 z
Between EC2 (female) (9) and T9A (female) (2)
Resistance
Max. 10 z
Between TM39 (female) (4) and T9B (2)
Resistance
Max. 10 z
Between TM40 (female) (1) and T9B (1)
Resistance
Max. 10 z
If no failure is found by check on cause 2, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors EC2 and T9A, and connect T-adapter to either female side.4 Between EC2 (female) (9) and (23), or between T9A (female) (2) and (3)
Resistance
Min. 100 kz
40-173
Failure code [CA132] Throttle sensor low error
No. 5
6
7
Cause Ground fault in wiring harness
Failure of accelerator pedal (throttle position sensor)
Defective engine controller
40 Troubleshooting
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connectors EC2 and T9A, and connect T-adapter to either female side. Between EC2 (female) (9) or T9A (female) (2) and ground
Min. 100 kz
Depress the accelerator pedal.
Voltage
3.7 to 4.0 V
When accelerator pedal is released
Voltage
0.5 to 0.8 V
1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector T9A. 3. Turn starting switch to ON position.
Between T9A (2) and (3)
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) Reference 1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector EC2. 3. Turn starting switch to ON position. 4. Operate the accelerator pedal and perform troubleshooting. Between EC2 (22) and (23)
Between EC2 (9) and (23)
40-174
Resistance
Power supply
Voltage
4.75 to 5.25 V
Depress the accelerator pedal.
Voltage
3.7 to 4.0 V
When accelerator pedal is released
Voltage
0.5 to 0.8 V
GD535-5 (03)
40 Troubleshooting
Failure code [CA132] Throttle sensor low error
Circuit diagram related to throttle sensor
GD535-5 (03)
40-175
Failure code [CA144] Coolant sensor high error
40 Troubleshooting
Failure code [CA144] Coolant sensor high error Action code
Failure code
L01
CA144
Failure
1
Coolant temperature sensor high error (Engine controller system)
Detail of failure High voltage appears in the engine coolant sensor signal circuit. Action of controller Problem on machine
Runs engine with the fixed coolant temperature. q q q q
Related information
q
q q
Engine startability is poor in low temperature. The overheat prevention function does not work. Input voltage from engine coolant sensor can be checked with monitoring function. (Code: 04105) Temperature detected by engine coolant temperature sensor can be checked with monitoring function. (Code: 04107) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position. If the temperature sensor connector is unplugged, this code is output. Because the T-adapter for sensor connection is a socket, the T-adapter cannot be connected to the wiring harness.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it. 1. Turn the starting switch to OFF position. 2. Disconnect connector COOLANT TEMP, and connect socket to male side. Regard coolant temperature sensor as normal if its resistance is 700 z to 37 kz when coolant temperature is 0°C or more.
2
3
Defective coolant temperature sensor
Open or short circuit in wiring harness
Between COOLANT TEMP (male) (A) and (B) (Coolant temperature characteristics)
0°C
Resistance
30 to 37 kz
25°C
Resistance
9.3 to 10. 7 kz
50°C
Resistance
3.2 to 3.8 kz
80°C
Resistance
1.0 to 1.3 kz
95°C
Resistance
700 to 800 z
1. Turn the starting switch to OFF position. 2. Disconnect connector ECM, and connect T-adapter to female side. a Use temperature sensor resistance characteristics table for check on cause 2 as resistance criteria. Between ECM (female) (15) and (38) (when coolant temperature is 0°C or more)
4
Defective engine controller
40-176
Resistance
700 z to 37 kz
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [CA144] Coolant sensor high error
Circuit diagram related to coolant temperature sensor
GD535-5 (03)
40-177
Failure code [CA145] Coolant sensor low error
40 Troubleshooting
Failure code [CA145] Coolant sensor low error Action code
Failure code
L01
CA145
Failure
1
Coolant temperature sensor low error (Engine controller system)
Detail of failure Low voltage appears in the engine coolant sensor signal circuit. Action of controller Problem on machine
Runs engine with the fixed coolant temperature. q q q q
Related information
q
q
Engine startability is poor in low temperature. The overheat prevention function does not work. Input voltage from engine coolant sensor can be checked with monitoring function. (Code: 04105) Temperature detected by engine coolant temperature sensor can be checked with monitoring function. (Code: 04107) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position. If the temperature sensor connector is disconnected, the high error code is output instead of this code.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it. 1. Turn the starting switch to OFF position. 2. Disconnect connector COOLANT TEMP, and connect socket to male side. Regard coolant temperature sensor as normal if its resistance is 700 z to 37 kz when coolant temperature is 0°C or more.
2
Defective coolant temperature sensor
Between COOLANT TEMP (male) (A) and (B) (Coolant temperature characteristics)
Between (B) and ground
3
Short circuit in wiring harness
0°C
Resistance
30 to 37 kz
25°C
Resistance
9.3 to 10.7 kz
50°C
Resistance
3.2 to 3.8 kz
80°C
Resistance
1.0 to 1.3 kz
95°C
Resistance
700 to 800 z
Entire coolant temperature range
Resistance
Min. 100 kz
1. Turn the starting switch to OFF position. 2. Disconnect connector ECM, and connect T-adapter to female side. a Use temperature sensor resistance characteristics table for check on cause 2 as resistance criteria. Between ECM (female) (15) and (38) (when coolant temperature is 0°C or more)
4
Ground fault in wiring harness Defective engine controller
40-178
700 z to 37 kz
1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and COOLANT TEMP, and connect T-adapter to female side of ECM. Between ECM (female) (15) and ground
5
Resistance
Resistance
Min. 100 kz
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [CA145] Coolant sensor low error
Circuit diagram related to coolant temperature sensor
GD535-5 (03)
40-179
Failure code [CA153] Charge temperature sensor high error
40 Troubleshooting
Failure code [CA153] Charge temperature sensor high error Action code
Failure code
L01
CA153
Detail of failure Action of controller Problem on machine
Charge air temperature sensor high error (Engine controller system)
High voltage was detected in the temperature signal circuit of charge (boost) pressure and temperature sensors. Runs engine with the fixed charge temperature. The engine protection function does not work at the boost temperature. q q
Related information
Failure
1
q
q q
The input voltage from charge temperature sensor (boost temperature sensor) can be checked with monitoring function. (Code: 18501) Temperature sensed by charge temperature sensor (boost temperature sensor) can be checked with monitoring function. (Code: 18500) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position. Because the T-adapter for sensor connection is a socket, the T-adapter cannot be connected to the wiring harness. If the temperature sensor connector is disconnected, this code is output.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it. 1. Turn the starting switch to OFF position. 2. Disconnect connector BOOST PRESS & IMT, and connect socket to male side.
2
3
Defective charge temperature sensor
Open or short circuit in wiring harness
Between BOOST PRESS & IMT (male) (3) and (4) Charge temperature characteristics
Defective engine controller
40-180
Resistance
41 kz to 48 kz
-20°C
Resistance
14 kz to 16 kz
0°C
Resistance
5.4 kz to 6.1 kz
30°C
Resistance
1.6 kz to 1.8 kz
60°C
Resistance
560 to 600 z
90°C
Resistance
30 to 250 z
130°C
Resistance
80 to 90 z
1. Turn the starting switch to OFF position. 2. Disconnect connector ECM, and connect T-adapter to female side. a Use the charge temperature and resistance characteristics table of charge temperature sensor for check on cause 2 as resistance criteria. Between ECM (female) (23) and (47)
4
-40°C
Resistance
80 z to 48 kz
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [CA153] Charge temperature sensor high error
Circuit diagram related to charge temperature sensor
GD535-5 (03)
40-181
Failure code [CA154] Charge temperature sensor low error
40 Troubleshooting
Failure code [CA154] Charge temperature sensor low error Action code
Failure code
L01
CA154
Detail of failure Action of controller Problem on machine
Charge air temperature sensor low error (Engine controller system)
Low voltage was detected in the temperature signal circuit of charge (boost) pressure and temperature sensors. Runs engine with the fixed charge temperature. The engine protection function does not work at the boost temperature. q q
Related information
Failure
1
q q
The input voltage from charge temperature sensor (boost temperature sensor) can be checked with monitoring function. (Code: 18501) Temperature sensed by charge temperature sensor (boost temperature sensor) can be checked with monitoring function. (Code: 18500) If the temperature sensor connector is disconnected, the high error code is output instead of this code. After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it. 1. Turn the starting switch to OFF position. 2. Disconnect connector BOOST PRESS & IMT, and connect socket to male side.
2
3
Defective charge temperature sensor
Short circuit in wiring harness
Between BOOST PRESS & IMT (male) (3) and (4) (Charge temperature characteristics)
Ground fault in wiring harness
Defective engine controller
40-182
41 kz to 48 kz
-20°C
Resistance
14 kz to 16 kz
0°C
Resistance
5.4 kz to 6.1 kz
30°C
Resistance
1.6 kz to 1.8 kz
60°C
Resistance
560 to 600 z
90°C
Resistance
30 to 250 z
130°C
Resistance
80 to 90 z
Resistance
80 z to 48 kz
If no failure is found by check on cause 3, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and BOOST PRESS & IMT, and connect T-adapter to female side of ECM. Between ECM (female) (23) and ground
5
Resistance
1. Turn the starting switch to OFF position. 2. Disconnect connector ECM, and connect T-adapter to female side. a Use the charge temperature and resistance characteristics table of charge temperature sensor for check on cause 2 as resistance criteria. Between ECM (female) (23) and (47)
4
-40°C
Resistance
Min. 100 kz
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [CA154] Charge temperature sensor low error
Circuit diagram related to charge temperature sensor
GD535-5 (03)
40-183
Failure code [CA155] Speed derating error by high charge temperature
40 Troubleshooting
Failure code [CA155] Speed derating error by high charge temperature Action code
Failure code
L03
CA155
Detail of failure Action of controller
Limits engine output and runs engine.
q q
q
Related information
No.
Speed derating error by high charge temperature (Engine controller system)
The charge (boost) pressure and temperature sensor detects the temperature above the upper limit of control.
q
Problem on machine
Failure
q
Engine output lowers. Engine stops. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting). Temperature sensed by charge temperature sensor (boost temperature sensor) can be checked with monitoring function. (Code: 18500) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine.
Cause
Procedure, measuring location, criteria, and remarks As the cooling performance of aftercooler may have dropped, check the following points. Looseness or damage of fan belt q Insufficient cooling air volume q Clogging of aftercooler fins
1
Dropped cooling performance of aftercooler
2
Abnormal increase of turbocharger outlet temperature
As the turbocharger outlet temperature may have increased abnormally, inspect the related parts.
3
Failure of charge temperature sensor system
If no failure is found by above checks, the charge temperature system may have failed. Perform troubleshooting for failure codes [CA153] and [CA154].
40-184
1
q
GD535-5 (03)
40 Troubleshooting
Failure code [CA187] Sensor power supply 2 low error
Failure code [CA187] Sensor power supply 2 low error Action code
Failure code
L03
CA187
Failure
1
Sensor power supply 2 voltage low error (Engine controller system)
Detail of failure Low voltage appears in the sensor power supply 2 circuit. Action of controller
q q q
Problem on machine
Related information
q q
q
Runs engine with the fixed charge (boost) pressure and charge (boost) temperature. Limits engine output and runs engine. Engine output lowers. Deteriorated startability Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting). After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it. 1. Turn the starting switch to OFF position. 2. Disconnect following connectors one by one in order, and turn starting switch ON each time.
2
3
Defective sensor or wiring harness
Defective engine controller
If this failure code is not displayed, disconnected sensor or engine wiring harness is defective. a Other (many) failure codes are output simultaneously. This is because connector is disconnected. Ignore failure codes other than this [CA187]. Sensor and wiring harness
Connector
Boost pressure and temperature sensor
BOOST PRESS & IMT
Common rail pressure sensor
FUEL RAIL PRESS
Bkup sensor
CAM SENSOR
Engine harness
ECM
1. Turn the starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to male side. 3. Turn starting switch ON with engine wiring harness disconnected. Between ECM (male) (37) and (47)
GD535-5 (03)
Voltage
4.75 to 5.25 V
40-185
Failure code [CA187] Sensor power supply 2 low error
40 Troubleshooting
Circuit diagram related to sensor power supply 2 circuit
40-186
GD535-5 (03)
40 Troubleshooting
Failure code [CA221] Atmospheric pressure sensor high error
Failure code [CA221] Atmospheric pressure sensor high error Action code
Failure code
L01
CA221
Failure
1
Atmospheric pressure sensor high error (Engine controller system)
Detail of failure High voltage appears in atmospheric pressure sensor signal circuit. Action of controller Problem on machine
Runs engine with the fixed atmospheric pressure. q q q q
Related information
q
Engine output lowers. Deteriorated startability Input voltage from atmospheric pressure sensor can be checked with monitoring function. (Code: 37401) The atmospheric pressure detected by atmospheric pressure sensor can be checked with monitoring function. (Code: 37400) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it.
2
Failure of sensor power supply 1 system
If failure code [CA352] or [CA386] is also displayed, perform troubleshooting for it first.
3
Defective atmospheric pressure sensor
1. Turn the starting switch to OFF position. 2. Disconnect connector AMB. AIR PRESSURE. 3. Turn starting switch to ON position. If failure code [CA221] changes to [CA222], the sensor is defective.
4
5
Short circuit in wiring harness
Hot short circuit in wiring harness
1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and AMB. AIR PRESSURE, and connect T-adapter to either female side. Between ECM (female) (33) and (3), or between AMB. AIRPRESSURE (female) (1) and (3)
Defective engine controller
GD535-5 (03)
Min. 100 kz
1. Turn the starting switch to OFF position. 2. Disconnect connector AMB. AIR PRESSURE. 3. Connect T-adapter to female side of connector AMB. AIR PRESSURE, or insert Tadapter into connector ECM. 4. Turn starting switch ON (with connector AMB. AIR PRESSURE disconnected). Between ECM (3) to (38), or between AMB. AIR PRESSURE (female) (3) and (2)
6
Resistance
Voltage
Max. 1 V
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-187
Failure code [CA221] Atmospheric pressure sensor high error
40 Troubleshooting
Circuit diagram related to atmospheric pressure sensor
40-188
GD535-5 (03)
40 Troubleshooting
Failure code [CA222] Atmospheric pressure sensor low error
Failure code [CA222] Atmospheric pressure sensor low error Action code
Failure code
L01
CA222
Failure
1
Atmospheric pressure sensor low error (Engine controller system)
Detail of failure Low voltage appears in atmospheric pressure sensor signal circuit. Action of controller Problem on machine
Runs engine with the fixed atmospheric pressure. q q q q
Related information
q
Engine output lowers. Deteriorated startability Input voltage from atmospheric pressure sensor can be checked with monitoring function. (Code: 37401) The atmospheric pressure detected by atmospheric pressure sensor can be checked with monitoring function. (Code: 37400) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it. If failure code [CA352] or [CA386] is also displayed, perform troubleshooting for it first.
2
Failure of atmospheric pressure sensor power supply system
1. Turn the starting switch to OFF position. 2. Disconnect connector AMB. AIR PRESSURE, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between AMB. AIR PRESSURE (female) (1) Power supply and (2) input
Voltage
4.75 to 5.25 V
1. Turn the starting switch to OFF position. 2. Disconnect connectors AMB. AIR PRESSURE and ECM, and connect T-adapters to each female side.
3
4
5
Short circuit in wiring harness
Ground fault in wiring harness
Short circuit in wiring harness
GD535-5 (03)
If the power input on cause 2 is normal, this check is not required. Between ECM (female) (33) and AMB. AIR PRESSURE (female) (1)
Resistance
Max. 10 z
If the power input on cause 2 is normal, this check is not required. Between ECM (female) (38) and AMB. AIR PRESSURE (female) (2)
Resistance
Max. 10 z
Between ECM (female) (3) and AMB. AIR PRESSURE (female) (3) (sensor output)
Resistance
Max. 10 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and AMB. AIR PRESSURE, and connect T-adapter to either female side. Between ECM (female) (3) and ground, or between AMB. AIR PRESSURE (female) (3) and ground
Resistance
Min. 100 kz
1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and AMB. AIR PRESSURE, and connect T-adapter to either female side. Between ECM (female) (3) and (38), or between AMB. AIR PRESSURE (female) (2) and (3)
Resistance
Min. 100 kz
40-189
Failure code [CA222] Atmospheric pressure sensor low error
No.
6
Cause
Defective atmospheric pressure sensor ((Incorrect input voltage at engine controller)
Procedure, measuring location, criteria, and remarks If failure is not found by check on causes 1 to 5, but found by check on cause 6, the sensor is defective. 1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector ECM. 3. Turn starting switch to ON position. Between ECM (3) and (38)
7
Defective engine controller
40 Troubleshooting
Sensor output
Voltage
0.5 to 4.5 V
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to atmospheric pressure sensor
40-190
GD535-5 (03)
40 Troubleshooting
Failure code [CA227] Sensor power supply 2 high error
Failure code [CA227] Sensor power supply 2 high error Action code
Failure code
L03
CA227
Failure
1
Sensor power supply 2 high error (Engine controller system)
Detail of failure High voltage appears in the sensor power supply 2 circuit. Action of controller
q q q
Problem on machine
Related information
No. 1
q q
Runs engine with the fixed charge pressure and charge temperature. Limits engine output and runs engine. Engine output lowers. Deteriorated startability Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting).
After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause Failure of sensor power supply 2 system
GD535-5 (03)
Procedure, measuring location, criteria, and remarks Perform troubleshooting for failure code [CA187].
40-191
Failure code [CA234] Engine overspeed
40 Troubleshooting
Failure code [CA234] Engine overspeed Action code
Failure code
L02
CA234
Failure
1
Engine Overspeed (Engine controller system)
Detail of failure The engine speed exceeded the limit of control speed. Action of controller Problem on machine
Stops fuel injection until the engine drops below the normal speed. q q
q
Related information
No.
q
Engine speed fluctuates. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting). Engine speed can be checked with monitoring function. (Code: 01002) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Idle the engine at high speed.
Cause
Procedure, measuring location, criteria, and remarks
1
Improper fuel is used.
Fuel used may be improper. Check it.
2
Improper machine usage
As the installed equipment may be operated incorrectly, instruct operator on how to use the equipment properly.
3
Defective engine controller
If no failure is found by checks on causes 1 and 2, engine controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-192
GD535-5 (03)
40 Troubleshooting
Failure code [CA238] Ne speed sensor power supply error
Failure code [CA238] Ne speed sensor power supply error Action code
Failure code
L03
CA238
Failure
1
Ne speed sensor power supply error (Engine controller system)
Detail of failure Low voltage appears in the engine Ne speed sensor power circuit. Action of controller
Controls the engine using the Bkup speed sensor signals. q q
Problem on machine
q q q
Related information
The engine stops (when Bkup speed sensor is also defective). The engine does not start (when Bkup speed sensor is also defective). Engine startability is poor. Engine rotation is hunting. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting).
After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it. 1. Turn the starting switch to OFF position. 2. Disconnect following connectors one by one in order and turn starting switch ON each time.
2
3
Defective sensor or wiring harness
Defective engine controller
a If this failure code is not displayed, disconnected sensor or engine wiring harness is defective.Other (many) failure codes are output simultaneously. This is because connector is disconnected. Ignore failure codes other than this [CA238]. Sensor and wiring harness
Connector
Ne speed sensor
CRANK SENSOR
Engine harness
ECM
1. Turn the starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to male side. 3. Turn starting switch ON with engine wiring harness disconnected. Between ECM (male) (16) and (48)
Voltage
4.75 to 5.25 V
Circuit diagram related to Ne speed sensor
GD535-5 (03)
40-193
Failure code [CA271] IMV short-circuit error
40 Troubleshooting
Failure code [CA271] IMV short-circuit error Action code
Failure code
L03
CA271
Failure
1
IMV short-circuit error (Engine controller system)
Detail of failure The drive circuit of supply pump actuator has shorted. Action of controller
None in particular q
Problem on machine
Related information
q q q
The engine speed does not increase from low idle speed. Engine output lowers. The common rail system fuel pressure is higher than the command value. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting).
After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it.
2
Failure of supply pump actuator
1. Turn the starting switch to OFF position. 2. Disconnect connector CP3 PUMP REGULATOR. 3. Turn starting switch to ON position. If failure code [CA271] changes to [CA272], the supply pump actuator is defective.
3
4
Short circuit or ground fault in wiring harness
Short circuit in wiring harness
1. Turn the starting switch to OFF position. 2. Disconnect connector ECM, and connect T-adapter to female side. Between ECM (female) (2) and (32)
Resistance
1 to 5 z
Between ECM (female) (2) and ground
Resistance
Min. 100 kz
If no failure is found by check on cause 3, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and CP3 PUMP REGULATOR, and connect T-adapter to female side of either ECM or CP3 PUMP REGULATOR. Between ECM (female) (2) and (3) or between CP3 PUMP REGULATOR (female) (1) and (2)
5
Ground fault in wiring harness
Defective engine controller
40-194
Min. 100 kz
If no failure is found by check on cause 3, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and CP3 PUMP REGULATOR, and connect T-adapter to female side of either ECM or CP3 PUMP REGULATOR. Between ECM (female) (2) and ground, or between CP3 PUMP REGULATOR (female) (1) and ground
6
Resistance
Resistance
Min. 100 kz
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [CA271] IMV short-circuit error
Circuit diagram related to IMV/IMA
GD535-5 (03)
40-195
Failure code [CA272] IMV open circuit
40 Troubleshooting
Failure code [CA272] IMV open circuit Action code
Failure code
L03
CA272
Failure
1
IMV open circuit (Engine controller system)
Detail of failure The drive circuit of supply pump actuator has opened. Action of controller
None in particular q
Problem on machine
Related information
q q
Although the engine starts, it is unstable. The common rail system fuel pressure is higher than the command value. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting).
After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it.
2
Failure of supply pump actuator
3
4
5
Open or short circuit in wiring harness
Open circuit in wiring harness
Hot short circuit in wiring harness
1. Turn the starting switch to OFF position. 2. Disconnect connector CP3 PUMP REGULATOR. Between CP3 PUMP REGULATOR (female) (1) and (2)
Defective engine controller
40-196
Max. 5 z
1. Turn the starting switch to OFF position. 2. Disconnect connector ECM, and connect T-adapter to female side. Between ECM (female) (2) and (32)
Resistance
Max. 5 z
If no failure is found by check on cause 3, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and CP3 PUMP REGULATOR, and connect T-adapters to each female side. Between ECM (female) (2) and CP3 PUMP REGULATOR (1)
Resistance
Max. 10 z
Between ECM (female) (32) and CP3 PUMP REGULATOR (2)
Resistance
Max. 10 z
1. Turn the starting switch to OFF position. 2. Disconnect connector CP3 PUMP REGULATOR. 3. Insert T-adapter into connector ECM, or connect T-adapter to female side of connector CP3 PUMP REGULATOR. 4. Turn starting switch to ON position (keep connector CP3 PUMP REGULATOR disconnected), and measure the resistance when one minute or more have passed. a As they are pulse voltages, the average voltage is displayed on the multimeter. Between ECM (2) and (32) or between CP3 PUMP REGULATOR (female) (1) and (2)
6
Resistance
Voltage
Max. 3V
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [CA272] IMV open circuit
Circuit diagram related to IMV/IMA
GD535-5 (03)
40-197
Failure code [CA322] Injector #1 (L/B #1) open/short
40 Troubleshooting
Failure code [CA322] Injector #1 (L/B #1) open/short Action code
Failure code
L03
CA322
Failure
1
Injector #1 (L/B #1) circuit has opened or shorted. (Engine controller system)
Detail of failure The drive circuit of injector No. 1 has opened or shorted. Action of controller
None in particular q
Problem on machine
q q
q
Related information
q
Poor engine combustion or hunting occurs. Engine output lowers. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting). After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. While engine is running normally, approximately 65 V of pulse voltage is supplied to injector (+) side. Because it is pulse voltage, it cannot be measured by using multimeter.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it. 1. Turn the starting switch to OFF position. 2. Disconnect connectors INJECTOR CYL 1&2, and connect T-adapter to male side.
2
3
4
5
Defective injector No. 1
Open circuit or ground fault in wiring harness
Open circuit in wiring harness
Ground fault in wiring harness
Between INJECTOR CYL 1&2 (male) (3) and (4)
Resistance
Max. 2 z
Between INJECTOR CYL 1&2 (male) (3) and ground
Resistance
Min. 100 kz
1. Turn the starting switch to OFF position. 2. Disconnect connector ECM, and connect T-adapter to female side. Between ECM (female) (45) and (53)
Resistance
Max. 2 z
Between ECM (female) (45) and ground
Resistance
Min. 100 kz
If no failure is found by check on cause 3, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 1&2, and connect T-adapter to each female side. Between ECM (female) (45) and INJECTOR CYL 1&2 (female) (3)
Resistance
Max. 2 z
Between ECM (female) (53) and INJECTOR CYL 1&2 (female) (4)
Resistance
Max. 2 z
If no failure is found by check on cause 3, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 1&2, and connect T-adapter to either female side. Between ECM (female) (45) or INJECTOR CYL 1&2 (female) (3) and ground
40-198
Resistance
Min. 100 kz
GD535-5 (03)
40 Troubleshooting
No.
6
7
Failure code [CA322] Injector #1 (L/B #1) open/short
Cause
Short circuit in wiring harness
Defective engine controller
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 1&2, and connect T-adapter to female side of ECM. Check by using multimeter in continuity mode. Between ECM (female) (45) and each pin other than pin (45)
No conductivity (No sound is heard.)
Between ECM (female) (53) and each pin other than pin (53)
No conductivity (No sound is heard.)
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to injector #1
GD535-5 (03)
40-199
Failure code [CA323] Injector #5 (L/B #5) open/short
40 Troubleshooting
Failure code [CA323] Injector #5 (L/B #5) open/short Action code
Failure code
L03
CA323
Failure
1
Injector #5 (L/B #5) circuit has opened or shorted. (Engine controller system)
Detail of failure The drive circuit of injector No. 5 has opened or shorted. Action of controller
None in particular q
Problem on machine
q q
q
Related information
q
Poor engine combustion or hunting occurs. Engine output lowers. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting). After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. While engine is running normally, approximately 65 V of pulse voltage is supplied to injector (+) side. Because it is pulse voltage, it cannot be measured by using multimeter.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it. 1. Turn the starting switch to OFF position. 2. Disconnect connectors INJECTOR CYL 5&6, and connect T-adapter to male side.
2
3
4
5
Defective injector No. 5
Open circuit or ground fault in wiring harness
Open circuit in wiring harness
Ground fault in wiring harness
Between INJECTOR CYL 5&6 (male) (3) and (4)
Resistance
Max. 2 z
Between INJECTOR CYL 5&6 (male) (3) and ground
Resistance
Min. 100 kz
1. Turn the starting switch to OFF position. 2. Disconnect connector ECM, and connect T-adapter to female side. Between ECM (female) (46) and (60)
Resistance
Max. 2 z
Between ECM (female) (46) and ground
Resistance
Min. 100 kz
If no failure is found by check on cause 3, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 5&6, and connect T-adapter to each female side. Between ECM (female) (46) and INJECTOR CYL 5&6 (female) (3)
Resistance
Max. 2 z
Between ECM (female) (60) and INJECTOR CYL 5&6 (female) (4)
Resistance
Max. 2 z
If no failure is found by check on cause 3, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 5&6, and connect T-adapter to either female side. Between ECM (female) (46) or INJECTOR CYL 5&6 (female) (3) and ground
40-200
Resistance
Min. 100 kz
GD535-5 (03)
40 Troubleshooting
No.
6
7
Failure code [CA323] Injector #5 (L/B #5) open/short
Cause
Short circuit in wiring harness
Defective engine controller
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 5&6, and connect T-adapter to female side of ECM. Check by using multimeter in continuity mode. Between ECM (female) (46) and each pin other than pin (46)
No conductivity (No sound is heard.)
Between ECM (female) (60) and each pin other than pin (60)
No conductivity (No sound is heard.)
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to injector #5
GD535-5 (03)
40-201
Failure code [CA324] Injector #3 (L/B #3) open/short
40 Troubleshooting
Failure code [CA324] Injector #3 (L/B #3) open/short Action Code
Failure code
L03
CA324
Failure
1
Injector #3 (L/B #3) circuit has opened or shorted. (Engine controller system)
Detail of failure The drive circuit of injector No. 3 has opened or shorted. Action of controller
None in particular q
Problem on machine
q q
q
Related information
q
Poor engine combustion or hunting occurs. Engine output lowers. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting). After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. While engine is running normally, approximately 65 V of pulse voltage is supplied to injector (+) side. Because it is pulse voltage, it cannot be measured by using multimeter.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it. 1. Turn the starting switch to OFF position. 2. Disconnect connectors INJECTOR CYL 3&4, and connect T-adapter to male side.
2
3
4
5
Defective injector No. 3
Open circuit or ground fault in wiring harness
Open circuit in wiring harness
Ground fault in wiring harness
Between INJECTOR CYL 3&4 (male) (3) and (4)
Resistance
Max. 2 z
Between INJECTOR CYL 3&4 (male) (3) and ground
Resistance
Min. 100 kz
1. Turn the starting switch to OFF position. 2. Disconnect connector ECM, and connect T-adapter to female side. Between ECM (female) (55) and (52)
Resistance
Max. 2 z
Between ECM (female) (55) and ground
Resistance
Min. 100 kz
If no failure is found by check on cause 3, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 3&4, and connect T-adapters to each female side. Between ECM (female) (55) and INJECTOR CYL 3&4 (female) (3)
Resistance
Max. 2 z
Between ECM (female) (52) and INJECTOR CYL 3&4 (female) (4)
Resistance
Max. 2 z
If no failure is found by check on cause 3, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 3&4, and connect T-adapter to either female side. Between ECM (female) (55) or INJECTOR CYL 3&4 (female) (3) and ground
40-202
Resistance
Min. 100 kz
GD535-5 (03)
40 Troubleshooting
No.
6
7
Failure code [CA324] Injector #3 (L/B #3) open/short
Cause
Short circuit in wiring harness
Defective engine controller
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 3&4, and connect T-adapter to female side of ECM. Check by using multimeter in continuity mode. Between ECM (female) (55) and each pin other than pin (55)
No conductivity (No sound is heard.)
Between ECM (female) (52) and each pin other than pin (52)
No conductivity (No sound is heard.)
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to injector #3
GD535-5 (03)
40-203
Failure code [CA325] Injector #6 (L/B #6) open/short
40 Troubleshooting
Failure code [CA325] Injector #6 (L/B #6) open/short Action code
Failure code
L03
CA325
Failure
1
Injector #6 (L/B #6) circuit has opened or shorted. (Engine controller system)
Detail of failure The drive circuit of injector No. 6 has opened or shorted. Action of controller
None in particular q
Problem on machine
q q
q
Related information
q
Poor engine combustion or hunting occurs. Engine output lowers. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting). After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. While engine is running normally, approximately 65 V of pulse voltage is supplied to injector (+) side. Because it is pulse voltage, it cannot be measured by using multimeter.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it. 1. Turn the starting switch to OFF position. 2. Disconnect connectors INJECTOR CYL 5&6, and connect T-adapter to male side.
2
3
4
5
Defective injector No. 6
Open circuit or ground fault in wiring harness
Open circuit in wiring harness
Ground fault in wiring harness
Between INJECTOR CYL 5&6 (male) (1) and (2)
Resistance
Max. 2 z
Between INJECTOR CYL 5&6 (male) (1) and ground
Resistance
Min. 100 kz
1. Turn the starting switch to OFF position. 2. Disconnect connector ECM, and connect T-adapter to female side. Between ECM (female) (57) and (59)
Resistance
Max. 2 z
Between ECM (female) (57) and ground
Resistance
Min. 100 kz
If no failure is found by check on cause 3, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 5&6, and connect T-adapter to either female side. Between ECM (female) (57) and INJECTOR CYL 5&6 (female) (1)
Resistance
Max. 2 z
Between ECM (female) (59) and INJECTOR CYL 5&6 (female) (2)
Resistance
Max. 2 z
If no failure is found by check on cause 3, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 5&6, and connect T-adapter to either female side. Between ECM (female) (57) or INJECTOR CYL 5&6 (female) (1) and ground
40-204
Resistance
Min. 100 kz
GD535-5 (03)
40 Troubleshooting
No.
6
7
Failure code [CA325] Injector #6 (L/B #6) open/short
Cause
Short circuit in wiring harness
Defective engine controller
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 5&6, and connect T-adapter to female side of ECM. Check by using multimeter in continuity mode. Between ECM (female) (57) and each pin other than pin (57)
No conductivity (No sound is heard.)
Between ECM (female) (59) and each pin other than pin (59)
No conductivity (No sound is heard.)
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to injector #6
GD535-5 (03)
40-205
Failure code [CA331] Injector #2 (L/B #2) open/short
40 Troubleshooting
Failure code [CA331] Injector #2 (L/B #2) open/short Action code
Failure code
L03
CA331
Failure
1
Injector #2 (L/B #2) circuit has opened or shorted. (Engine controller system)
Detail of failure The drive circuit of injector No. 2 has opened or shorted. Action of controller
None in particular q
Problem on machine
q q
q
Related information
q
Poor engine combustion or hunting occurs. Engine output lowers. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting). After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. While engine is running normally, approximately 65 V of pulse voltage is supplied to injector (+) side. Because it is pulse voltage, it cannot be measured by using multimeter.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it. 1. Turn the starting switch to OFF position. 2. Disconnect connectors INJECTOR CYL 1&2, and connect T-adapter to male side.
2
3
4
5
Defective injector No. 2
Open circuit or ground fault in wiring harness
Open circuit in wiring harness
Ground fault in wiring harness
Between INJECTOR CYL 1&2 (male) (1) and (2)
Resistance
Max. 2 z
Between INJECTOR CYL 1&2 (male) (2) and ground
Resistance
Min. 100 kz
1. Turn the starting switch to OFF position. 2. Disconnect connector ECM, and connect T-adapter to female side. Between ECM (female) (54) and (51)
Resistance
Max. 2 z
Between ECM (female) (54) and ground
Resistance
Min. 100 kz
If no failure is found by check on cause 3, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 1&2, and connect T-adapters to each female side. Between ECM (female) (54) and INJECTOR CYL 1&2 (female) (2)
Resistance
Max. 2 z
Between ECM (female) (51) and INJECTOR CYL 1&2 (female) (1)
Resistance
Max. 2 z
If no failure is found by check on cause 3, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 1&2, and connect T-adapter to either female side. Between ECM (female) (54) or INJECTOR CYL 1&2 (female) (2) and ground
40-206
Resistance
Min. 100 kz
GD535-5 (03)
40 Troubleshooting
No.
6
7
Failure code [CA331] Injector #2 (L/B #2) open/short
Cause
Short circuit in wiring harness
Defective engine controller
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 1&2, and connect T-adapter to female side of ECM. Check by using multimeter in continuity mode. Between ECM (female) (54) and each pin other than pin (54)
No conductivity (No sound is heard.)
Between ECM (female) (51) and each pin other than pin (51)
No conductivity (No sound is heard.)
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to injector #2
GD535-5 (03)
40-207
Failure code [CA332] Injector #4 (L/B #4) open/short
40 Troubleshooting
Failure code [CA332] Injector #4 (L/B #4) open/short Action code
Failure code
L03
CA332
Failure
1
Injector #4 (L/B #4) circuit has opened or shorted. (Engine controller system)
Detail of failure The drive circuit of injector No. 4 has opened or shorted. Action of controller
None in particular q
Problem on machine
q q
q
Related information
q
Poor engine combustion or hunting occurs. Engine output lowers. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting). After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. While engine is running normally, approximately 65 V of pulse voltage is supplied to injector (+) side. Because it is pulse voltage, it cannot be measured by using multimeter.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it. 1. Turn the starting switch to OFF position. 2. Disconnect connectors INJECTOR CYL 3&4, and connect T-adapter to male side.
2
3
4
5
Defective injector No. 4
Open circuit or ground fault in wiring harness
Open circuit in wiring harness
Ground fault in wiring harness
Between INJECTOR CYL 3&4 (male) (1) and (2)
Resistance
Max. 2 z
Between INJECTOR CYL 3&4 (male) (2) and ground
Resistance
Min. 100 kz
1. Turn the starting switch to OFF position. 2. Disconnect connector ECM, and connect T-adapter to female side. Between ECM (female) (56) and (58)
Resistance
Max. 2 z
Between ECM (female) (56) and ground
Resistance
Min. 100 kz
If no failure is found by check on cause 3, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 3&4, and connect T-adapters to each female side. Between ECM (female) (56) and INJECTOR CYL 3&4 (female) (2)
Resistance
Max. 2 z
Between ECM (female) (58) and INJECTOR CYL 3&4 (female) (1)
Resistance
Max. 2 z
If no failure is found by check on cause 3, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 3&4, and connect T-adapter to either female side. Between ECM (female) (56) or INJECTOR CYL 3&4 (female) (2) and ground
40-208
Resistance
Min. 100 kz
GD535-5 (03)
40 Troubleshooting
No.
6
7
Failure code [CA332] Injector #4 (L/B #4) open/short
Cause
Short circuit in wiring harness
Defective engine controller
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 3&4, and connect T-adapter to female side of ECM. Check by using multimeter in continuity mode. Between ECM (female) (56) and each pin other than pin (56)
No conductivity (No sound is heard.)
Between ECM (female) (58) and each pin other than pin (58)
No conductivity (No sound is heard.)
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to injector #4
GD535-5 (03)
40-209
Failure code [CA342] Data compatibility error in engine controller
40 Troubleshooting
Failure code [CA342] Data compatibility error in engine controller Action code
Failure code
L03
CA342
Failure
1
Data compatibility error in engine controller (Engine controller system)
Detail of failure A data compatibility error has occurred in engine controller. Action of controller Problem on machine Related information
No.
None in particular q q
The engine may run normally, may stop, or may fail to start. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting).
After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective relevant system
If other failure codes are also displayed, perform troubleshooting for them.
2
Failure of power voltage system
Perform troubleshooting for failure code [CA441].
40-210
GD535-5 (03)
40 Troubleshooting
Failure code [CA351] Injector drive circuit error
Failure code [CA351] Injector drive circuit error Action code
Failure code
L03
CA351
Failure
1
Injector drive circuit error (Engine controller system)
Detail of failure The drive power supply circuit of injector has failed. Action of controller
Limits engine output and runs engine. q q
Problem on machine
q q q
Related information
No.
Exhaust smoke is black. Unstable combustion occurs. Engine output lowers. Engine does not start. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting).
After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective relevant system
If other failure codes are also displayed, perform troubleshooting for them.
2
Failure of power voltage system
Perform troubleshooting for failure code [CA441].
GD535-5 (03)
40-211
Failure code [CA352] Sensor power supply 1 low error
40 Troubleshooting
Failure code [CA352] Sensor power supply 1 low error Action code
Failure code
L03
CA352
Failure
1
Sensor power supply 1 voltage low error (Engine controller system)
Detail of failure Low voltage appears in the sensor power supply 1 circuit. Action of controller
Runs engine with the fixed atmospheric pressure. q
Problem on machine
Related information
q q
Engine output lowers. Deteriorated startability Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting).
After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it. 1. Turn the starting switch to OFF position. 2. Disconnect following connectors one by one in order and turn starting switch ON each time. 3. Each time troubleshooting is finished, return to step 1.
2
3
Defective sensor or wiring harness
Defective engine controller
If this failure code is not displayed, disconnected sensor or engine wiring harness is defective. a Other (many) failure codes are output simultaneously. This is because connector is disconnected. Ignore failure codes other than this [CA352]. Sensor and wiring harness
Connector
Ambient pressure sensor
AMB. AIR PRESSURE
Engine harness
ECM
1. Turn the starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to male side. 3. Turn starting switch ON with engine wiring harness disconnected. Between ECM (male) (33) and (38)
40-212
Voltage
4.75 to 5.25 V
GD535-5 (03)
40 Troubleshooting
Failure code [CA352] Sensor power supply 1 low error
Circuit diagram related to sensor power supply 1 circuit
GD535-5 (03)
40-213
Failure code [CA386] Sensor power supply 1 high error
40 Troubleshooting
Failure code [CA386] Sensor power supply 1 high error Action code
Failure code
L03
CA386
Failure
1
Sensor power supply 1 voltage high error (Engine controller system)
Detail of failure High voltage appears in the sensor power supply 1 circuit. Action of controller
Runs engine with the fixed atmospheric pressure. q
Problem on machine
Related information
No. 1
q q
Engine output lowers. Deteriorated startability Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting).
After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause Failure of sensor power supply 1 system
40-214
Procedure, measuring location, criteria, and remarks Perform troubleshooting for failure code [CA352].
GD535-5 (03)
40 Troubleshooting
Failure code [CA428] Water-in-fuel sensor high error
Failure code [CA428] Water-in-fuel sensor high error Action code
Failure code
L01
CA428
Failure
1
Water-in-fuel sensor high error (Engine controller system)
Detail of failure High voltage appears in signal circuit of water-in-fuel sensor at fuel prefilter. Action of controller Problem on machine
None in particular Water separator monitor does not work normally. q
Related information
q
The signal status (ON or OFF) of water-in-fuel sensor (of fuel prefilter) can be checked with monitoring function. (Code: 18800) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it.
Failure of water-in-fuel sensor at fuel prefilter
1. Turn the starting switch to OFF position. 2. Disconnect connector WIF1, and connect T-adapter to female side. If water is in fuel prefilter, drain it.
2
Between WIF1 (female) (1) and (2)
3
4
5
6
Open or short circuit in wiring harness
Open circuit in wiring harness
Short circuit in wiring harness
Defective engine controller
GD535-5 (03)
Resistance
Min. 100 kz
1. Turn the starting switch to OFF position. 2. Disconnect connector ECM, and connect T-adapter to female side. Between ECM (female) (14) and (47) (Resistance of water-in-fuel sensor)
Resistance
Min. 100 kz
If no failure is found by check on cause 3, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and WIF1, and connect T-adapters to each female side. Between ECM (female) (14) and WIF1 (female) (1)
Resistance
Max. 10 z
Between ECM (female) (47) and WIF1 (female) (2)
Resistance
Max. 10 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and WIF1, and connect T-adapter to female side of ECM. Check by using multimeter in continuity mode. Between ECM (female) (14) and each pin other than pin (14)
No conductivity (No sound is heard.)
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-215
Failure code [CA428] Water-in-fuel sensor high error
40 Troubleshooting
Circuit diagram related to water-in-fuel sensor
40-216
GD535-5 (03)
40 Troubleshooting
Failure code [CA429] Water-in-fuel sensor low error
Failure code [CA429] Water-in-fuel sensor low error Action code
Failure code
L01
CA429
Failure
1
Water-in-fuel sensor low error (Engine controller system)
Detail of failure Low voltage appears in signal circuit of water-in-fuel sensor at fuel prefilter. Action of controller Problem on machine
None in particular Water separator monitor does not work normally. q
Related information
q
The signal status (ON or OFF) of water-in-fuel sensor (of fuel prefilter) can be checked with monitoring function. (Code: 18800) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it.
2
Failure of water-in-fuel sensor at fuel prefilter
1. Turn the starting switch to OFF position. 2. Disconnect connector WIF1, and connect T-adapter to female side. If water is in fuel prefilter, drain it. Between WIF1 (female) (1) and (2)
Resistance
Min. 100 kz
Between WIF1 (female) (1) and ground
Resistance
Min. 100 kz
1. Turn the starting switch to OFF position. 2. Disconnect connector ECM, and connect T-adapter to female side. 3
4
5
6
Short circuit or ground fault in wiring harness
Short circuit in wiring harness
Ground fault in wiring harness
Defective engine controller
GD535-5 (03)
Between ECM (female) (14) and (47) (Resistance of water-in-fuel sensor)
Resistance
Min. 100 kz
Between ECM (female) (14) and ground
Resistance
Min. 100 kz
1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and WIF1, and connect T-adapter to female side of ECM. Check by using multimeter in continuity mode. Between ECM (female) (14) and each pin other than pin (14)
No conductivity (No sound is heard.)
If no failure is found by check on cause 3, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and WIF1, and connect T-adapter to either female side. Between ECM (female) (14) or WIF1 (female) (1) and ground
Resistance
Min. 100 kz
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-217
Failure code [CA429] Water-in-fuel sensor low error
40 Troubleshooting
Circuit diagram related to water-in-fuel sensor
40-218
GD535-5 (03)
40 Troubleshooting
Failure code [CA431] Idle validation switch error
Failure code [CA431] Idle validation switch error Action code
Failure code
L01
CA431
Failure
1
Idle validation switch error (Engine controller system)
Detail of failure An error occurred in Idle Validation Switch signal 1 or 2 (IVS1 or IVS2). Action of controller
Runs the engine with throttle opening detected by the throttle position sensor.
Problem on machine q
Related information
q q
The input condition (ON/OFF status) of Idle Validation signal 1 can be checked by using the monitoring function (Code: 18300). The input condition (ON/OFF status) of Idle Validation signal 2 can be checked by using the monitoring function (Code: 18301). After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it.
Defective power supply system
1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector T9B. 3. Turn starting switch to ON position. If voltage is abnormal, go to check on cause 4.
2
Between T9B (1) and (2)
3
Defective accelerator pedal
Voltage
4.75 to 5.25 V
1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector T9A. 3. Turn starting switch to ON position. If abnormal, diagnose the wiring harness on causes 4 and 5. If the harness is normal, the accelerator pedal is defective. Between T9A (5) and (4)
See the IVS1 of Figure 1.
Between T9A (6) and (4)
See the IVS2 of Figure 1.
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors T9A, T9B, EC2, TM39, and TM40, and connect T-adapters to each female side. 4
5
Open circuit in wiring harness
Short circuit in wiring harness
GD535-5 (03)
Between EC2 (female) (32) and T9A (female) (4)
Resistance
Max. 10 z
Between EC2 (female) (11) and T9A (female) (5)
Resistance
Max. 10 z
Between EC2 (female) (1) and T9A (female) (6)
Resistance
Max. 10 z
Between TM40 (female) (1) and T9B (female) (1)
Resistance
Max. 10 z
Between TM39 (female) (4) and T9B (female) (2)
Resistance
Max. 10 z
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors T9A and EC2, and connect T-adapter to female side of EC2. Between EC2 (female) (1) and each pin other than (1)
Resistance
Min. 100 kz
Between EC2 (female) (11) and each pin other than (11)
Resistance
Min. 100 kz
40-219
Failure code [CA431] Idle validation switch error
No.
6
Cause
Failure of transmission controller
40 Troubleshooting
Procedure, measuring location, criteria, and remarks 1. 2. 3. 4. 5.
Turn the starting switch to OFF position. Disconnect cable from negative (-) battery terminal. Insert T-adapters into connectors TM39 and TM40. Connect negative (-) battery terminal. Turn starting switch to ON position.
Between TM40 (1) and TM39 (4)
7
Defective engine controller
Voltage
4.75 to 5.25 V
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) Reference 1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector EC2. 3. Turn starting switch to ON position. Between EC2 (11) and (32)
See the IVS1 of Figure 1.
Between EC2 (1) and (32)
See the IVS2 of Figure 1.
Circuit diagram related to Idle Validation circuit
40-220
GD535-5 (03)
40 Troubleshooting
Failure code [CA431] Idle validation switch error
Fig. 1 Pedal stroke: Stroke of accelerator pedal Output voltage: Output voltages (at pin 2 of connector T9A, and pin 9 of EC2) IVS1: Signal voltage of Idle Validation switch 1 IVS2: Signal voltage of Idle Validation switch 2 Switch gap: Area where both IVS1 and IVS2 signals are turned OFF
GD535-5 (03)
40-221
Failure code [CA432] Idle validation action error
40 Troubleshooting
Failure code [CA432] Idle validation action error Action code
Failure code
L03
CA432
Failure
1
Idle validation action error (Engine controller system)
Detail of failure The idle validation switch signal does not match the throttle sensor signal (signal inconsistency).
Action of controller
Problem on machine
1. If the idle validation switch signal shows that the accelerator pedal is OFF, and if the throttle sensor signal shows that the accelerator pedal is ON: the throttle opening is controlled to 0% when the idle validation signal shows that the accelerator pedal is OFF. Also, the throttle opening is controlled to 50% when the accelerator pedal is shown to be ON. 2. If idle validation switch signal indicates that the accelerator pedal is ON, and if the throttle sensor signal shows that the accelerator pedal is OFF: the throttle opening is controlled to 0% (and the engine speed is fixed to the low idle speed). q q
q q
Related information
q q q
No. 1
2
The engine speed does not increase from low idling speed. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting). The input condition (ON/OFF status) of Idle Validation signal 1 can be checked by using the monitoring function (Code: 18300). The input condition (ON/OFF status) of Idle Validation signal 2 can be checked by using the monitoring function (Code: 18301). Input voltage from throttle position sensor can be checked with monitoring function. (Code: 03000) The opening of accelerator pedal, detected by throttle position sensor, can be checked with monitoring function. (Code: 31701) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause
Procedure, measuring location, criteria, and remarks
Idle validation switch signal error
If an error occurs in idle validation switch signal, perform troubleshooting for failure code [CA431] (Perform troubleshooting for cause 2 and later for the throttle position sensor).
Defective power supply system
1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector T9A. 3. Turn starting switch to ON position. If abnormal, go to check on cause 4. Between T9A (1) and (3)
3
Defective accelerator pedal
Voltage
4.75 to 5.25 V
1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector T9A. 3. Turn starting switch to ON position. If abnormal, diagnose the wiring harness on causes 4 and 5. If the harness is normal, the accelerator pedal is defective. Between T9A (2) and (3)
See the output voltage of Figure 1.
1. Turn the starting switch to OFF position. 2. Disconnect connectors T9A and EC2, and connect T-adapters to each female side. 4
5
Open circuit in wiring harness
Short circuit in wiring harness
40-222
Between EC2 (female) (22) and T9A (female) (1)
Resistance
Max. 10 z
Between EC2 (female) (9) and T9A (female) (2)
Resistance
Max. 10 z
Between EC2 (female) (23) and T9A (female) (3)
Resistance
Max. 10 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors T9A and EC2, and connect T-adapter to female side of EC2. Between EC2 (female) (9) and each pin other than (9)
Resistance
Min. 100 kz
GD535-5 (03)
40 Troubleshooting
No.
6
Cause
Defective engine controller
Failure code [CA432] Idle validation action error
Procedure, measuring location, criteria, and remarks If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) Reference 1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector EC2. 3. Turn starting switch to ON position. Between EC2 (9) and (23)
See the output voltage of Figure 1 on the next page.
Circuit diagram related to Idle Validation circuit
GD535-5 (03)
40-223
Failure code [CA432] Idle validation action error
40 Troubleshooting
Fig. 1 Pedal stroke: Stroke of accelerator pedal Output voltage: Output voltages (at pin 2 of connector T9A, and pin 9 of EC2) IVS1: Signal voltage of Idle Validation switch 1 IVS2: Signal voltage of Idle Validation switch 2 Switch gap: Area where both IVS1 and IVS2 signals are turned OFF
40-224
GD535-5 (03)
40 Troubleshooting
Failure code [CA435] Engine oil pressure switch error
Failure code [CA435] Engine oil pressure switch error Action code
Failure code
L01
CA435
Failure
1
Engine oil pressure switch error (Engine controller system)
Detail of failure An error occurred in the engine oil pressure switch signal circuit. Action of controller Problem on machine
None in particular q q q
Related information
q q
q
The engine protect function by hydraulic pressure does not work. The engine oil pressure is not displayed normally. After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position, or start engine. When oil pressure is low (when engine is stopped), the engine oil pressure switch is closed (turned ON). When oil pressure is high (when engine is running), the switch is opened (turned OFF). If this failure code is output, the engine controller checks if the oil pressure switch is closed (ON), that is, the voltage is set to the "GND level" or not only when the engine is stopped. When engine is running, an error of the engine oil pressure switch is checked with failure code [B@BAZG].
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it.
2
Defective engine oil pressure switch
3
4
Open or short circuit in wiring harness Defective engine controller
1. Turn the starting switch to OFF position. 2. Disconnect connector OIL PRESSURE SWITCH, and connect T-adapter to male side. Between OIL PRESSURE SWITCH (male) (1) and ground
Resistance
Max. 10 z
1. Turn the starting switch to OFF position. 2. Disconnect connector ECM, and connect T-adapter to female side. Between ECM (female) (17) and ground
Resistance
Max. 10 z
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to engine oil pressure switch
GD535-5 (03)
40-225
Failure code [CA441] Power supply voltage low error
40 Troubleshooting
Failure code [CA441] Power supply voltage low error Action code
Failure code
L01
CA441
Failure
1
Battery Voltage Low Error (Engine controller system)
Detail of failure Low voltage occurs in engine controller power circuit. Action of controller
None in particular q
Problem on machine
Related information
No.
q q
q
Engine stops. Engine startability is poor. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting). After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause
Procedure, measuring location, criteria, and remarks
1
Loose or corroded battery terminals
2
Loose terminal or partial open circuit at terminal
1. Turn the starting switch to OFF position.
3
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it.
4
Improper battery power supply
5
Defective alternator
As battery terminals may be loose or corroded, check them.
Check terminals of alternator, battery relay, ground terminal (ET103), etc.
1. Turn the starting switch to OFF position. 2. Perform troubleshooting with starting switch at OFF position and when starting engine. Between positive (+) and negative (-) battery terminals
Defective engine controller
40-226
20 to 30 V
Voltage
27.5 to 29.5 V
1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector ET104. 3. Start engine. (Engine speed: Middle or faster) Between ET104 (1) and ground
6
Voltage
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) Reference 1. Turn starting switch to OFF position, and disconnect battery ground. 2. Insert T-adapter into connector EC3. 3. Connection battery ground. 4. Measure the voltage when the starting switch is OFF and when engine is started. Between EC3 (3) and (1)
Voltage
20 to 30 V
Between EC3 (4) and (2)
Voltage
20 to 30 V
GD535-5 (03)
40 Troubleshooting
Failure code [CA441] Power supply voltage low error
Circuit diagram related to power supply voltage
GD535-5 (03)
40-227
Failure code [CA442] Power supply voltage high error
40 Troubleshooting
Failure code [CA442] Power supply voltage high error Action code
Failure code
L03
CA442
Failure
1
Power supply voltage high error (Engine controller system)
Detail of failure High voltage (Min. 36 V) is generated in controller power supply voltage circuit. Action of controller Problem on machine Related information
No. 1
None in particular q q
Engine may stop. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting).
After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause Defective engine controller power supply system
40-228
Procedure, measuring location, criteria, and remarks Perform troubleshooting for failure code [CA441].
GD535-5 (03)
40 Troubleshooting
Failure code [CA449] Common rail pressure high error 2
Failure code [CA449] Common rail pressure high error 2 Action code
Failure code
L03
CA449
Failure
1
Common rail pressure high error 2 (Engine controller system)
Detail of failure A high voltage error (2) occurred in the common rail system circuit. Action of controller
Limits engine output and runs engine. q
Problem on machine
q q
q
Related information
No.
q q
The engine sound level increases during no loading or during low loading. Engine output lowers. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting). Signal voltage from common rail pressure sensor can be checked with monitoring function. (Code: 36401) The common rail pressure detected by the common rail pressure sensor can be checked with monitoring function. (Code: 36400) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective relevant system
If other failure codes are also displayed, perform troubleshooting for them.
2
Air insertion into lowpressure circuit
Air may be in low-pressure circuit. Check it according to the following procedure. 1. Remove the pressure inspection plug (at outlet side) of fuel main filter. 2. Operate the feed pump of fuel prefilter. 3. Check the fuel and air leakage from the pressure inspection plug.
3
Failure of fuel return circuit devices
4
Failure of common rail pressure sensor
5
6
Defective pressure limiter
Defective supply pump
GD535-5 (03)
For check of fuel return circuit pressure, see Testing and adjusting, "Testing fuel pressure". Pressure of fuel return circuit
During low idle or during cranking
Max. 0.02 MPa {Max. 0.19 kg/cm2}
Perform troubleshooting for failure codes [CA451] and [CA452]. For check of leakage from pressure limiter, see Testing and adjusting, "Testing fuel return rate and leakage". Leakage from pressure limiter
At low idle
0 cc (No leakage)
If no failure is found by preceding checks, the supply pump may be defective.
40-229
Failure code [CA451] Common rail pressure sensor high error
40 Troubleshooting
Failure code [CA451] Common rail pressure sensor high error Action code
Failure code
L03
CA451
Failure
1
Common rail pressure sensor high error (Engine controller system)
Detail of failure High voltage appears in signal circuit of common rail pressure sensor. Action of controller
Limits engine output and runs engine. q
Problem on machine
q q
q q
Related information
q
q q
Engine speed or output drops. Engine does not start. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting). Signal voltage from common rail pressure sensor can be checked with monitoring function. (Code: 36401) The common rail pressure detected by the common rail pressure sensor can be checked with monitoring function. (Code: 36400) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position. If the connector of common rail pressure sensor is disconnected, this code is output. Because the T-adapter for sensor connection is a socket, the voltage cannot be checked by checking the disconnection of wiring harness and sensor connector.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it.
2
Failure of common rail pressure sensor power supply
If failure code [CA227] or [CA187] is also displayed, perform troubleshooting for it first.
3
Short circuit in wiring harness
1. Turn the starting switch to OFF position. 2. Disconnect connectors CAM SENSOR, FUEL RAIL PRESS, BOOST PRESS & IMT, and ECM. 3. Connect T-adapter to female side of ECM. Between ECM (female) (25) and (37)
4
Hot short circuit in wiring harness
1. 2. 3. a
Resistance
Min. 100 kz
Turn the starting switch to OFF position. Disconnect connector FUEL RAIL PRESS, and insert T-adapter into connector ECM. Turn starting switch ON (with connector FUEL RAIL PRESS disconnected). ECM (25) pin is connected to the 5V power via the resistance in engine controller.
Between ECM (25) and (47)
Voltage
Approx. 5 V
5
Open circuit in wiring harness
6
If failure is not found by check on causes 1 to 5, but found by check on cause 6, the sensor is defective. Failure of common rail 1. Turn the starting switch to OFF position. pressure sensor 2. Insert T-adapter into connector ECM. (Incorrect input voltage of 3. Turn starting switch to ON position. engine controller) Sensor Between ECM (25) and (47) Voltage 0.2 to 4.6 V output
7
Defective engine controller
If no failure is found by above checks, wiring harness may have open circuit. (*)
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
* See the "Diagnosis of open harness in pressure sensor system" of "Related information on troubleshooting".
40-230
GD535-5 (03)
40 Troubleshooting
Failure code [CA451] Common rail pressure sensor high error
Circuit diagram related to common rail pressure sensor
GD535-5 (03)
40-231
Failure code [CA452] Common rail pressure sensor low error
40 Troubleshooting
Failure code [CA452] Common rail pressure sensor low error Action code
Failure code
L03
CA452
Failure
1
Common rail pressure sensor low error (Engine controller system)
Detail of failure Low voltage appears in signal circuit of common rail pressure sensor. Action of controller
Limits engine output and runs engine. q
Problem on machine
q q
q q
Related information
q
q
Engine speed or output drops. Engine does not start. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting). Signal voltage from common rail pressure sensor can be checked with monitoring function. (Code: 36401) The common rail injection pressure detected by the common rail pressure sensor can be checked with monitoring function. (Code: 36400) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position. If the sensor connector is disconnected, [CA451] is output even in the normal state.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it.
2
Failure of common rail pressure sensor power supply
If failure code [CA187] or [CA227] is also displayed, perform troubleshooting for it first.
3
Failure of common rail pressure sensor
Make sure that failure code [CA187] is not output. 1. Turn the starting switch to OFF position. 2. Disconnect connector FUEL RAIL PRESS. 3. Turn starting switch to ON position. If failure code [CA452] changes to [CA451], the sensor is defective.
4
Ground fault in wiring harness
1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and FUEL RAIL PRESS, and connect T-adapter to female side of ECM. Between ECM (female) (25) and ground
5
Short circuit in wiring harness Defective engine controller
40-232
Min. 100 kz
1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and FUEL RAIL PRESS, and connect T-adapter to female side of ECM. Between ECM (female) (25) and (47)
6
Resistance
Resistance
Min. 100 kz
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [CA452] Common rail pressure sensor low error
Circuit diagram related to common rail pressure sensor
GD535-5 (03)
40-233
Failure code [CA488] Torque derating error by high charge temperature
40 Troubleshooting
Failure code [CA488] Torque derating error by high charge temperature Action code
Failure code
L03
CA488
Failure
1
Torque derating error by high charge temperature (Engine controller system)
Detail of failure The temperature signal of the boost pressure and temperature sensor exceeded the upper limit of control. Action of controller Problem on machine
Limits engine output and runs engine. q q
q
Related information
No.
q
Engine output lowers. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting). The boost temperature can be checked with monitoring function. (Code: 18500) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine.
Cause
Procedure, measuring location, criteria, and remarks
1
Dropped cooling performance of aftercooler
q
2
Abnormal increase of turbocharger outlet temperature
As the turbocharger outlet temperature may have increased abnormally, inspect the related parts.
3
Failure of charge temperature sensor system
Perform troubleshooting for failure codes [CA153] and [CA154].
40-234
As the cooling performance of aftercooler may have dropped, check the following points. Insufficient cooling air volume q Clogging of aftercooler fins
GD535-5 (03)
40 Troubleshooting
Failure code [CA553] Common rail pressure high error 1
Failure code [CA553] Common rail pressure high error 1 Action code
Failure code
L03
CA553
Failure
1
Common rail pressure high error 1 (Engine controller system)
Detail of failure A high voltage error (1) occurred in the common rail injection circuit. Action of controller
None in particular q
Problem on machine
q q
q
Related information
No. 1
q q
The engine sound level increases during no loading or during low loading. Engine output lowers. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting). Signal voltage from common rail pressure sensor can be checked with monitoring function. (Code: 36401) The common rail injection pressure detected by the common rail pressure sensor can be checked with monitoring function. (Code: 36400) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine.
Cause Defective relevant system
Procedure, measuring location, criteria, and remarks If other failure codes are also displayed, perform troubleshooting for them. As the ground terminal connection may be poor, check the following terminals. Ground terminal of machine (Negative (-) terminal of battery) q Ground terminal of engine q Ground terminal of engine controller q Ground terminal of starting switch q
2
Poor connection of ground terminal
3
Damaged O-ring of supply pump actuator
As the O-ring of supply pump actuator may be damaged, check it.
4
Failure of common rail pressure sensor
Perform troubleshooting for failure codes [CA451] and [CA452].
GD535-5 (03)
40-235
Failure code [CA559] Supply pump pressure low error 1
40 Troubleshooting
Failure code [CA559] Supply pump pressure low error 1 Action code
Failure code
L03
CA559
Failure
1
Supply pump pressure low error 1 (Engine controller system)
Detail of failure A low voltage error (1) occurred in the common rail injection circuit. Action of controller
None in particular q
Problem on machine
q q q
q
Related information
No.
q
Engine cannot start or engine is hard to start. Exhaust smoke is black. Engine output lowers. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting). Common rail injection pressure can be checked with monitoring function. (Code: 36400) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine.
Cause
Procedure, measuring location, criteria, and remarks
1
Improper fuel is used.
As the fuel used may be improper, check it.
2
External leakage of fuel
As the fuel may leak externally, check it. (Visually inspect it while engine is low idle.) See Note 1 for troubleshooting. For check of fuel low pressure circuit, see Testing and adjusting, "Testing fuel pressure".
3
Failure of low pressure circuit devices
Negative inlet pressure of fuel supply pump (at outlet side of fuel prefilter) Pressure of fuel lowpressure circuit (inlet pressure of fuel main filter)
4
Defective pressure limiter
At high idle (When engine can start)
Max. -50.7 MPa {Max. -380 mmHg}
At cranking (When engine cannot start)
0.3 to 1.1 MPa {3.1 to 11.3 kg/cm2}
At low idle (When engine can start)
0.5 to 1.3 MPa {5.1 to 13.3 kg/cm2}
For check of leakage from pressure limiter, see Testing and adjusting, "Testing fuel return rate and leakage". Leakage from pressure limiter
At low idle
0 cc (No leakage)
For check of fuel return rate from injector, see Testing and adjusting, "Testing fuel discharge, return and leakage". 5
Defective injector Return rate from injector
At cranking (When engine cannot start)
Max. 90 cc/min
At low idle (When engine can start)
Max. 180 cc/min
For check of fuel return rate from supply pump, see Testing and adjusting, "Testing fuel discharge, return and leakage". 6
7
Defective supply pump
Failure of common rail pressure sensor
40-236
Return rate from supply pump
At cranking (When engine cannot start)
Max. 140 cc/min
At low idle (When engine can start)
Max. 1000 cc/min
Perform troubleshooting for failure codes [CA451] and [CA452].
GD535-5 (03)
40 Troubleshooting
Failure code [CA559] Supply pump pressure low error 1
Note 1: Check low-pressure fuel circuit devices for following items. 1) Remaining quantity of fuel 2) Clogging of fuel tank breather 3) Leakage from or clogging of low-pressure fuel piping 4) Clogging of fuel prefilter 5) Clogging of fuel main filter 6) Replace fuel filter when problem is not removed even if no clogging is found.
GD535-5 (03)
40-237
Failure code [CA689] Engine Ne speed sensor error
40 Troubleshooting
Failure code [CA689] Engine Ne speed sensor error Action code
Failure code
L03
CA689
Failure
1
Failure of engine Ne speed sensor (Engine controller system)
Detail of failure An error occurred in a signal from engine Ne speed sensor. Action of controller
Uses signals from engine Bkup speed sensor, and continues to control. q
Problem on machine
q q q
q
q
Related information q q
Engine rotation is hunting. Engine startability is poor. Engine output lowers. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting). After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. As the speed sensor consists of a wheel sensor and electronic circuit (but not coils), you cannot determine the normal sensor operation by simply measuring the resistance of speed sensor using a multimeter. Under normal conditions, the 5V pulse voltage is output from the speed sensor, and you cannot measure it using a multimeter. A speed sensing wheel is installed inside of vibration damper of crankshaft. The hole of this wheel is detected when the crankshaft rotates.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it.
2
Failure of Ne speed sensor power system
If failure code [CA238] is also displayed, perform troubleshooting for it first.
3
Failure or incorrect mounting (such as loose mounting) of engine Ne speed sensor
As the engine Ne speed sensor may be broken or may be installed improperly (loosened), check it.
4
Input failure of Ne speed sensor power
1. Turn the starting switch to OFF position. 2. Disconnect connector CRANK SENSOR, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between CRANK SENSOR (female) (1) and Power supply (2) input
Voltage
4.75 to 5.25 V
If no failure is found by check on cause 4, this check is not required. Between ECM (female) (16) and CRANK SENSOR (female) (1)
Resistance
Max. 10 z
If no failure is found by check on cause 4, this check is not required. Between ECM (female) (48) and CRANK SENSOR (female) (2)
Resistance
Max. 10 z
Between ECM (female) (27) and CRANK SENSOR (female) (3)
Resistance
Max. 10 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and CRANK SENSOR.
5
Open circuit in wiring harness
40-238
GD535-5 (03)
40 Troubleshooting
No.
Cause
Failure code [CA689] Engine Ne speed sensor error
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and CRANK SENSOR.
6
7
8
Short circuit in wiring harness
Ground fault in wiring harness
Hot short circuit in wiring harness
Between ECM (female) (16) and (27), or between CRANK SENSOR (female) (1) and (3)
Resistance
Min. 100 kz
Between ECM (female) (27) and (48), or between CRANK SENSOR (female) (2) and (3)
Resistance
Min. 100 kz
Resistance
Min. 100 kz
Voltage
Max. 1 V
1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and CRANK SENSOR. Between ECM (female) (27) or CRANK SENSOR (female) (3) and ground Turn the starting switch to OFF position. Disconnect connector CRANK SENSOR. Turn starting switch to ON position. Between CRANK SENSOR (female) (3) and ground
9
Damaged or loosened speed sensing ring
Check the speed sensing ring.
10
Failure of Ne speed sensor
If no failure is found in above checks, Ne speed sensor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
11
Defective engine controller
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to engine Ne speed sensor
GD535-5 (03)
40-239
Failure code [CA731] Engine Bkup speed sensor phase error
40 Troubleshooting
Failure code [CA731] Engine Bkup speed sensor phase error Action code
Failure code
L03
CA731
Failure
1
Engine Bkup speed sensor phase error (Engine controller system)
Detail of failure A phase error was detected from signals of engine Ne speed sensor and engine backup speed sensor. Action of controller
Continues to control by using engine Ne sensor signals. q
Problem on machine
Related information
No.
q q q
Engine cannot start or engine is hard to start. Idling speed is unstable. Exhaust smoke is black. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting).
After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine.
Cause
Procedure, measuring location, criteria, and remarks
1
Damaged engine Ne speed sensor
As the engine Ne speed sensor may be broken, check it.
2
Damaged engine Bkup speed sensor
As the engine Bkup speed sensor may be broken, check it.
3
Improper mounting or damage of speed sensing wheel on crankshaft side
Speed sensing wheel on crankshaft side may be installed improperly or damaged. Check it according to the following procedure. 1. Align the paint mark (M1) of damper with the top surface (M2) of Ne speed sensor. a It is not the compression top dead center of cylinder No. 1. (Approximately 80° before compression top dead center) 2. Installation is correct if the center of oval hole (WS) of speed sensing wheel locates on the top surface (M2) of Ne speed sensor.
4
Speed detection ring on camshaft side may be installed improperly or damaged. Check it according to the following procedure. Improper installation or 1. Align the paint mark (M1) of damper with the top surface (M2) of Ne speed sensor. damage of speed a It is not the compression top dead center of cylinder No. 1. (Approximately 80° sensing ring on camshaft before compression top dead center) side 2. Remove the Bkup speed sensor. 3. Installation is correct if twin groove (single rib) (B) of speed sensing ring is visible through sensor mounting hole (H).
5
Incorrect timing between crankshaft and camshaft
6
Poor connection of ground terminal
40-240
As the timing may be incorrect between crankshaft and camshaft, check this timing. As the ground terminal connection may be poor, check the following terminals. Ground terminal of machine (Negative (-) terminal of battery) q Ground terminal of engine q Ground terminal of engine controller q Ground terminal of starting switch q
GD535-5 (03)
40 Troubleshooting
GD535-5 (03)
Failure code [CA731] Engine Bkup speed sensor phase error
40-241
Failure code [CA757] All continuous data lost error
40 Troubleshooting
Failure code [CA757] All continuous data lost error Action code
Failure code
L03
CA757
Failure
1
All continuous data lost error (Engine controller system)
Detail of failure The entire data of engine controller has been lost. Action of controller
None in particular q
Problem on machine
Related information
No.
q q
Engine may stop, and it may fail to start again. The monitoring function (engine controller system) of machine monitor may not operate normally. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting).
After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective relevant system
If other failure codes are also displayed, perform troubleshooting for them.
2
Failure of power supply circuit
Perform troubleshooting for failure code [CA441].
40-242
GD535-5 (03)
40 Troubleshooting
Failure code [CA778] Engine Bkup speed sensor error
Failure code [CA778] Engine Bkup speed sensor error Action code
Failure code
L03
CA778
Failure
1
Engine Bkup speed sensor error (Engine controller system)
Detail of failure An error was detected in engine Bkup speed (CAM) sensor signal. Action of controller
Continues to control by using engine Ne speed sensor signals. q
Problem on machine
q q
q
q
Related information q q
Engine startability is poor. Engine output lowers. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting). After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. As the speed sensor consists of a wheel sensor and electronic circuit (but not coils), you cannot determine the normal sensor operation by simply measuring the resistance of speed sensor using a multimeter. Under normal conditions, the 5V pulse voltage is output from the speed sensor, you cannot measure it using a multimeter. The speed sensor detects a groove of speed sensing ring (during rotation) that is mounted on the camshaft.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it.
2
Failure of sensor power supply 2 system
If failure code [CA187] or [CA227] is also displayed, perform troubleshooting for it first.
3
Damage or incorrect mounting (such as loose mounting) of engine Bkup speed (CAM) sensor
Engine Bkup speed (CAM) sensor may be damaged or installed improperly (loosened). Check it.
4
Input failure of engine Bkup speed sensor power
1. Turn the starting switch to OFF position. 2. Disconnect connector CAM SENSOR , and connect T-adapter to female side. 3. Turn starting switch to ON position. Between CAM SENSOR (female) (1) and (2) Power supply
Voltage
4.75 to 5.25 V
1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and CAM SENSOR, and connect T-adapters to each female side. 5
Open circuit in wiring harness
GD535-5 (03)
Between ECM (female) (37) and CAM SENSOR (female) (1)
Resistance
Max. 10 z
Between ECM (female) (47) and CAM SENSOR (female) (2)
Resistance
Max. 10 z
Between ECM (female) (26) and CAM SENSOR (female) (3)
Resistance
Max. 10 z
40-243
Failure code [CA778] Engine Bkup speed sensor error
No.
Cause
40 Troubleshooting
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and CAM SENSOR, and connect T-adapter to either female side.
6
7
8
Short circuit in wiring harness
Ground fault in wiring harness
Hot short circuit in wiring harness
Between ECM (female) (26) and (37), or between CAM SENSOR (female) (1) and (3)
Resistance
Min. 100 kz
Between ECM (female) (26) and (47), or between CAM SENSOR (female) (2) and (3)
Resistance
Min. 100 kz
1. Turn the starting switch to OFF position. 2. Disconnect connectors ECM and CAM SENSOR, and connect T-adapter to either female side. Between ECM (female) (26) or CAM SENSOR (female) (3) and ground
Resistance
Min. 100 kz
1. Turn the starting switch to OFF position. 2. Disconnect connector CAM SENSOR, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between CAM SENSOR (female) (3) and ground
Voltage
Max. 1 V
9
Loose mounting of speed Remove the engine Bkup speed (CAM) sensor, and check it through hole (H). sensing ring a If the speed sensing ring (B) is loosely mounted, follow the "Reference" instructions.
10
Failure of engine Bkup speed (CAM) sensor
If no abnormality is found by above checks, engine Bkup speed (CAM) sensor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
11
Defective engine controller
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-244
GD535-5 (03)
40 Troubleshooting
Failure code [CA778] Engine Bkup speed sensor error
Circuit diagram related to engine Bkup speed sensor
Reference: CA778 (107 series engine) Check the camshaft ring for looseness. Remove the front cover, and check the camshaft ring for looseness. See "Removal and installation of engine front seal" of "Disassembly and assembly". Prepare the front seal, LG-7 liquid gasket, and front seal tool (795-799-6400)
3. Remove front cover (2). 4. Remove front seal (3). (RING): Ring
Removal 1. Remove the fan belt. For details, see "Removal and installation of fan belt" of "Disassembly and assembly". 2. Remove damper assembly (1). (DP): Dowel pin 5. Check mounting bolts (4) of camshaft ring (5) for looseness. 3 Mounting bolts (4): 10 ± 2 Nm (DP): Dowel pin
GD535-5 (03)
40-245
Failure code [CA778] Engine Bkup speed sensor error
40 Troubleshooting
Installation For the drawing, see the "Removal" section. 1. Install front cover (2). 2 Front cover: LG-7 liquid gasket 2. See "Removal and installation of engine front seal" of "Disassembly and assembly". 1) Install front seal (3). 2) Install Dowel pin (DP), and install the damper assembly. 3) Install fan belt and fan. 4) Install the cooling assembly.
40-246
GD535-5 (03)
40 Troubleshooting
Failure code [CA1633] KOMNET (CAN communication) error
Failure code [CA1633] KOMNET (CAN communication) error Action code
Failure code
L03
CA1633
Detail of failure Action of controller
Related information
No. 1
2
KOMNET (CAN communication) error (Engine controller system)
The engine controller has detected a communication error in the CAN (KOMNET) communication circuit between engine controller and transmission controller or machine monitor. q q q
Problem on machine
Failure
q
Operates the machine in default mode, or holds the status of error occurrence. If cause of failure disappears, machine becomes normal by itself. Information passed through CAN (KOMNET) communication may not be transmitted normally, and the machine may not operate normally. (Failure status varies depending on the failure location.) Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting).
After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause Blown fuse
Defective engine controller
Procedure, measuring location, criteria, and remarks If fuse No. 4 of FB2 fuse box is blown, the circuit may be shorted in the controller. If fuse is not burnt out, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connector EC3 and connect T-adapter to male side. q Measured value: Approx. 9 to 20 kz q If it is 10 z or less, the engine controller may have failed (internal short circuit). Between EC3 (male) (3) and (1)
3
4
5
Defective power supply to engine controller
Blown fuse
Defective CAN terminating resistor
GD535-5 (03)
1
Resistance
Min. 10 z
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connector EC3, and connect T-adapter to female side. 4. If fuse is blown, replace it in advance. 5. Connect negative (-) battery terminal. 6. Turn the starting switch to ON position. Perform troubleshooting for failure code [DB2RKR], cause 2). Between EC3 (female) (3) and (1) or ground
Voltage
20 to 30 V
Between EC3 (female) (4) and (2) or ground
Voltage
20 to 30 V
If fuse No. 15 of FB1 fuse box is blown, the circuit may be grounded. In this case, perform check on cause 9 first. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors CAN1 and FP1, and connect T-adapter to male side. Between CAN1 (male) (A) and (B)
Resistance
120 ± 12 z
Between FP1 (male) (11) and (12)
Resistance
120 ± 12 z
40-247
Failure code [CA1633] KOMNET (CAN communication) error
No.
6
Cause
Open or short circuit in wiring harness
40 Troubleshooting
Procedure, measuring location, criteria, and remarks CAN communication line a The 120 z CAN terminating resistor is also located in machine monitor. That is, 2 CAN terminating resistors of 120 z are connected in parallel. When circuit resistance is measured at connector of controller other than machine monitor, if combined resistance is 60 z, wiring harness does not have open circuit. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors EC2, TM40, L80A, CAN1, and FP1 one by one, and connect Tadapter to female side of its connector. a If circuit is shorted (resistance between terminals is 10 z or below), disconnect all of terminals EC2, TM40, L80A, CAN1, and FP2, and check them again. Locate the short circuit between wiring harnesses or the short circuit in the controller. Between EC2 (female) (46) and (47)
Resistance
Approx. 60 z
Between TM40 (female) (32) and (22)
Resistance
Approx. 60 z
Between L80A (female) (10) and (11)
Resistance
Approx. 60 z
Between CAN1 (female) (A) and (B)
Resistance
Approx. 120 z
Between FP1 (female) (11) and (12)
Resistance
Approx. 120 z
If no failure is found by check on cause 6, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors EC2, TM40, L80A, CAN1, and FP1, and connect T-adapters to female side of each connector.
7
8
9
Between TM40 (female) (32) and FP1 (female) (11)
Resistance
Max. 10 z
Between TM40 (female) (22) and FP1 (female) (12) Locate the open circuit of Between TM40 (female) (32) and EC2 (female) (46) wiring harness.
Resistance
Max. 10 z
Resistance
Max. 10 z
Between TM40 (female) (22) and EC2 (female) (47)
Resistance
Max. 10 z
Between TM40 (female) (32) and L80A (female) (10)
Resistance
Max. 10 z
Between TM40 (female) (22) and L80A (female) (11)
Resistance
Max. 10 z
Between EC2 (female) (46) and CAN1 (female) (A)
Resistance
Max. 10 z
Between EC2 (female) (47) and CAN1 (female) (B)
Resistance
Max. 10 z
Open circuit in wiring harness
Ground fault in wiring harness
40-248
Starting switch ACC signal 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Insert T-adapter into connectors TM41, L80B, FP1, and EC2. 4. Connect negative (-) battery terminal. 5. Turn starting switch to ON position. Between TM41 (14) or (24) and (31)
Voltage
20 to 30 V
Between L80B (3) and (1)
Voltage
20 to 30 V
Between FP1 (3) and (2)
Voltage
20 to 30 V
Between EC2 (39) and ground
Voltage
20 to 30 V
Starting switch ACC signal 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41, L80B, and FP1, and connect T-adapter to either female side. 4. Disconnect connector EC2, and connect T-adapter to female side. Between any of TM41 (female) (14), (24) L80B (female) (3) and FP1 (female) (3) and the ground
Resistance
Min. 100 kz
Between EC2 (female) (39) and ground
Resistance
Min. 100 kz
GD535-5 (03)
40 Troubleshooting
No.
Failure code [CA1633] KOMNET (CAN communication) error
Cause
Procedure, measuring location, criteria, and remarks
10
Defective engine controller
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
11
Failure of transmission controller
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to CAN
GD535-5 (03)
40-249
Failure code [CA2185] Throttle sensor power supply high error
40 Troubleshooting
Failure code [CA2185] Throttle sensor power supply high error Action code
Failure code
L03
CA2185
Failure
1
Throttle sensor power supply voltage high error (Engine controller system)
Detail of failure High voltage (Min. 5.25 V) appears in throttle sensor power supply circuit. Action of controller Problem on machine Related information
Turn the accelerator pedal OFF, and set the throttle opening to 0%. Then, turn the accelerator pedal ON, set the throttle opening to 50%, and run the engine. q q
Full throttle position cannot be set. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting).
After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it.
Defective throttle sensor (accelerator pedal)
1. Turn the starting switch to OFF position. 2. Disconnect connector T9A, and turn starting switch to ON position. a Other (many) failure codes are output simultaneously. This is because connector is unplugged. Ignore failure codes other than this [CA2185].
2
If this failure code disappears, throttle sensor is defective.
3
4
Short circuit in wiring harness
Hot short circuit in wiring harness
1. Turn the starting switch to OFF position. 2. Disconnect connectors EC2, EC3 and T9A, and connect T-adapter to female side of EC2 and EC3. Between EC2 (female) (22) and each pin other than EC2 (female) (22) pin.
Resistance
Min. 100 kz
Between EC2 (female) (22) and EC3 (female) (3)
Resistance
Min. 100 kz
1. Turn the starting switch to OFF position. 2. Disconnect connector T9A, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between T9A (female) (1) and ground
5
Defective engine controller
4.75 to 5.25 V
1. Turn the starting switch to OFF position. 2. Disconnect connector EC2, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between EC2 (female) (22) and (23)
40-250
Voltage
Voltage
4.75 to 5.25 V
GD535-5 (03)
40 Troubleshooting
Failure code [CA2185] Throttle sensor power supply high error
Circuit diagram related to throttle sensor
GD535-5 (03)
40-251
Failure code [CA2186] Throttle sensor power supply low error
40 Troubleshooting
Failure code [CA2186] Throttle sensor power supply low error Action code
Failure code
L03
CA2186
Failure
1
Throttle sensor power supply voltage low error (Engine controller system)
Detail of failure Low voltage appears in throttle sensor power supply circuit. Action of controller Problem on machine Related information
Turn the accelerator pedal OFF, and set the throttle opening to 0%. Then, turn the accelerator pedal ON, set the throttle opening to 50%, and run the engine. q q
Full throttle position cannot be set. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting).
After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it.
Defective throttle sensor (accelerator pedal)
1. Turn the starting switch to OFF position. 2. Disconnect connector T9A, and turn starting switch to ON position. a Other (many) failure codes are output simultaneously. This is because connector is disconnected. Ignore failure codes other than this [CA2186].
2
If this failure code disappears, throttle sensor is defective. 3
4
5
Ground fault in wiring harness
Short circuit in wiring harness
Defective engine controller
1. Turn the starting switch to OFF position. 2. Disconnect connectors EC2 and T9A, and connect T-adapter to either female side. Between EC2 (female) (22) or T9A (female) (1) and ground
Min. 100 kz
1. Turn the starting switch to OFF position. 2. Disconnect connectors EC2 and T9A, and connect T-adapter to female side of EC2. Between EC2 (female) (22) and each pin other than EC2 (female) (22) pin.
Resistance
Min. 100 kz
1. Turn the starting switch to OFF position. 2. Disconnect connector EC2 and connect T-adapter to male side. 3. Turn starting switch ON with engine wiring harness disconnected. Between EC2 (female) (22) and (23)
40-252
Resistance
Voltage
4.75 to 5.25 V
GD535-5 (03)
40 Troubleshooting
Failure code [CA2186] Throttle sensor power supply low error
Circuit diagram related to throttle sensor
GD535-5 (03)
40-253
Failure code [CA2249] Supply pump pressure low error 2
Failure code [CA2249] Supply pump pressure low error 2 Action code
Failure code
L03
CA2249
Failure
40 Troubleshooting
1
Supply pump pressure low error 2 (Engine controller system)
Detail of failure A low voltage error (2) occurred in the common rail injection circuit. Action of controller
Limits engine output and runs engine. q
Problem on machine
q q q
q
Related information
No. 1
q q
Engine startability is poor. Exhaust smoke is black. Engine output lowers. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting). Signal voltage from common rail pressure sensor can be checked with monitoring function. (Code: 36401) The common rail injection pressure detected by the common rail pressure sensor can be checked with monitoring function. (Code: 36400) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine.
Cause Supply pump pressure low error
40-254
Procedure, measuring location, criteria, and remarks Perform troubleshooting for failure code [CA559].
GD535-5 (03)
40 Troubleshooting
Failure code [CA2311] Abnormality in IMV (IMA) solenoid
Failure code [CA2311] Abnormality in IMV (IMA) solenoid Action code
Failure code
L03
CA2311
Failure
1
IMV solenoid failure (Engine controller system)
Detail of failure Resistance of supply pump actuator circuit is unusually high or low. Action of controller Problem on machine Related information
No. 1
None in particular q q
Engine output lowers. Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor setting).
After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine.
Cause IMV solenoid failure
GD535-5 (03)
Procedure, measuring location, criteria, and remarks Perform troubleshooting for failure codes [CA271] and [CA272].
40-255
Failure code [CA2555] Intake heater relay open circuit
40 Troubleshooting
Failure code [CA2555] Intake heater relay open circuit Action code
Failure code
L01
CA2555
Failure
1
Intake heater relay open circuit (Engine controller system)
Detail of failure Short circuit is in preheat relay drive circuit (primary circuit). Action of controller Problem on machine
None in particular Intake air heater does not work in auto preheating mode (resulting in degraded startability and emission of white smoke at low temperature). q q
Related information
q q
Temperature sensed by charge temperature sensor (boost temperature sensor) can be checked with monitoring function. (Code: 18500) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position (charge temperature: Max. -4°C). Troubleshooting of this failure code covers circuits from engine controller to primary circuit (coil) of preheat relay SP40. For troubleshooting of heater relay and secondary circuit of heater relay and preheat relay SP40, see following E-mode troubleshooting (E-2).
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it. 1. Turn the starting switch to OFF position. 2. Disconnect relay SP40, and connect T-adapter to male side.
2
Defective preheating relay
Between SP40 (male) (1) and (2)
Resistance
200 to 400 z
1. Turn the starting switch to OFF position. 2. Replace relay SP40 with another one. 3. Turn starting switch to ON position. If this failure code disappears, original preheat relay SP40 is defective.
3
Open or short circuit in wiring harness
1. Turn the starting switch to OFF position. 2. Disconnect connector EC2, and connect T-adapter to female side. a Resistance of preheat relay coil Between EC2 (female) (40) and ground
4
5
Open circuit in wiring harness
Short circuit in wiring harness
Defective engine controller
40-256
200 to 400 z
If no failure is found by check on cause 3, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connector EC2 and relay SP40, and connect T-adapter to female side. Between EC2 (female) (40) and SP40 (female) (1)
Resistance
Max. 10 z
Between SP40 (female) (2) and ground
Resistance
Max. 10 z
1. Turn the starting switch to OFF position. 2. Disconnect connector EC2 and relay SP40, and connect T-adapter to female side of EC2. Check by using multimeter in continuity mode. Between EC2 (female) (40) and each pin other than pin (40)
6
Resistance
No continuity (No sound is heard.)
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [CA2555] Intake heater relay open circuit
Circuit diagram related to preheat relay
GD535-5 (03)
40-257
Failure code [CA2556] Intake heater relay short circuit
40 Troubleshooting
Failure code [CA2556] Intake heater relay short circuit Action code
Failure code
L01
CA2556
Failure
1
Intake heater relay short circuit (Engine controller system)
Detail of failure Short circuit is in preheat relay drive circuit (primary circuit). Action of controller Problem on machine
None in particular Intake air heater does not work in auto preheating mode (resulting in degraded startability and emission of white smoke at low temperature). q q
Related information
q q
Temperature sensed by charge temperature sensor (boost temperature sensor) can be checked with monitoring function. (Code: 18500) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position (charge temperature: Max. -4°C). Troubleshooting of this failure code covers circuits from engine controller to primary circuit (coil) of preheat relay SP40. For troubleshooting of heater relay and secondary circuit of heater relay and preheat relay SP40, see following E-mode troubleshooting (E-2).
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it. 1. Turn the starting switch to OFF position. 2. Disconnect relay SP40, and connect T-adapter to male side.
2
Defective preheating relay
Between SP40 (male) (1) and (2)
Resistance
200 to 400 z
1. Turn the starting switch to OFF position. 2. Replace preheat relay SP40 with another one. 3. Turn starting switch to ON position. If this failure code disappears, original preheat relay SP40 is defective.
3
4
Ground fault in wiring harness
Short circuit in wiring harness
1. Turn the starting switch to OFF position. 2. Disconnect connector EC2 and relay SP40, and connect T-adapter to either female side. Between EC2 (female) (40) or SP40 (female) (1) and ground
Defective engine controller
40-258
Min. 100 kz
1. Turn the starting switch to OFF position. 2. Disconnect connector EC2 and relay SP40, and connect T-adapter to female side of EC2. Check by using multimeter in continuity mode. Between EC2 (female) (40) and each pin other than pin (40)
5
Resistance
No continuity (No sound is heard.)
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [CA2556] Intake heater relay short circuit
Circuit diagram related to preheat relay
GD535-5 (03)
40-259
Failure code [D160KA] Disconnection of Backup Light Relay
40 Troubleshooting
Failure code [D160KA] Disconnection of Backup Light Relay Action code
Failure code
L01
D160KA
Detail of failure Action of controller Problem on machine
Open circuit of backup lamp relay output (Transmission controller system)
As the circuit of backup lamp relay primary side (coil side) has opened, the transmission controller cannot turn ON the backup lamp relay. Turns OFF the output to the backup lamp relay. q q q
Related information q
No.
Failure
1
Backup lamp does not light. Backup buzzer does not sound. After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position. + Gear shift lever Output state (ON/OFF) to backup lamp relay can be checked with monitoring function. (Code: 03705)
Cause
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM42, and connect T-adapter to male side. Between TM42 (male) (1) and (2)
1
Defective backup lamp relay
1. 2. 3. 4.
Resistance
200 to 400 z
Turn the starting switch to OFF position. Replace the backup lamp relay TM42 with a relay (5-pin) of the same type. Turn starting switch to ON position. Shift the gear shift lever to "R" position.
If backup lamp becomes normal, original backup lamp relay TM42 is defective. 1. Turn the starting switch to OFF position. 2. Disconnect connector TM40, and connect T-adapter to female side. a Resistance of backup lamp relay coil Between TM40 (female) (18) and ground 2
3
Open circuit in wiring harness
Failure of transmission controller
200 to 400 z
If no failure is found by above checks, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40 and TM42, and connect T-adapters to each female side. 3. Turn starting switch to ON position. Between TM42 (female) (1) and TM40 (female) (18)
Resistance
Max. 1 z
Between TM42 (female) (2) and ground
Resistance
Max. 1 z
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) Reference 1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector TM40. 3. Turn starting switch to ON position. 4. Shift the gear shift lever to perform troubleshooting. Gear shift lever: R (Reverse) Between TM40 (female) (18) Gear shift lever: Other than and (31) above
40-260
Resistance
Voltage
20 to 30 V
Voltage
Max. 1 V
GD535-5 (03)
40 Troubleshooting
Failure code [D160KA] Disconnection of Backup Light Relay
Circuit diagram related to backup lamp relay
GD535-5 (03)
40-261
Failure code [D160KB] Ground Fault of Backup Light Relay
40 Troubleshooting
Failure code [D160KB] Ground Fault of Backup Light Relay Action code
Failure code
L01
D160KB
Failure
1
Grounding of backup lamp relay output (Transmission controller system)
Detail of failure
As the circuit of backup lamp relay primary side (coil side) has grounded, the transmission controller cannot turn ON the backup lamp relay.
Action of controller
Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
Problem on machine
q q q
Related information q
No.
Backup lamp does not light. Backup buzzer does not sound. After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position. + Gear shift lever Output state (ON/OFF) to back lamp relay can be checked with monitoring function. (Code: 03705)
Cause
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM42, and connect T-adapter to male side. Between TM42 (male) (1) and (2)
1
Defective backup lamp relay
1. 2. 3. 4.
Resistance
200 to 400 z
Turn the starting switch to OFF position. Replace the backup lamp relay TM42 with a relay (5-pin) of the same type. Turn starting switch to ON position. Shift the gear shift lever to "R" (Reverse) position.
If backup lamp becomes normal, original backup lamp relay TM42 is defective.
2
3
Ground fault in wiring harness
Failure of transmission controller
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40 and TM42, and connect T-adapter to either female side. Between TM42 (female) (1) or TM40 (female) (18) and ground
Min. 1 Mz
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) Reference 1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector TM40. 3. Turn starting switch to ON position. 4. Shift the gear shift lever to perform troubleshooting. Between TM40 (female) (18) and (31)
40-262
Resistance
Gear shift lever: R (Reverse)
Voltage
20 to 30 V
Gear shift lever: Other than above
Voltage
Max. 1 V
GD535-5 (03)
40 Troubleshooting
Failure code [D160KB] Ground Fault of Backup Light Relay
Circuit diagram related to back lamp relay
GD535-5 (03)
40-263
Failure code [D160KY] Hot Short of Back Lamp Relay Output
40 Troubleshooting
Failure code [D160KY] Hot Short of Back Lamp Relay Output Action code
Failure code
L01
D160KY
Detail of failure Action of controller Problem on machine
Turns OFF the output to the back lamp relay primary circuit (coils). q q
q
No.
1
Hot short of back lamp relay output (Transmission controller system)
As a hot short occurs in back lamp relay output, the current continues to flow even if it is not output to the back lamp relay primary circuit (coils).
q
Related information
Failure
1
q
Backup lamp continues to light. Backup buzzer continues to sound. Output state (ON/OFF) to back lamp relay can be checked with monitoring function. (Code: 03705) This failure code shows a failure of the primary side (coil side) circuit of back lamp relay. The failure of the secondary circuit (contact side) cannot be detected. After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause Hot short circuit in wiring harness
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM42, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between TM42 (female) (1) and ground
Voltage
Max. 4.5 V
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
2
Failure of transmission controller
Reference 1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector TM40. 3. Turn starting switch to ON position. 4. Shift the gear shift lever to perform troubleshooting. Gear shift lever: R (Reverse) Between TM40 (18) and (31) Gear shift lever: Other than above
40-264
20 to 30 V Voltage
Max. 1 V
GD535-5 (03)
40 Troubleshooting
Failure code [D160KY] Hot Short of Back Lamp Relay Output
Circuit diagram related to back lamp relay
GD535-5 (03)
40-265
Failure code [D19JKZ] Personal Code Relay Abnormality
40 Troubleshooting
Failure code [D19JKZ] Personal Code Relay Abnormality Action code
Failure code
L03
D19JKZ q
Detail of failure q
Action of controller Problem on machine
q q
No. 1
Personal Code Relay Abnormality (Machine monitor system)
No current flows or large current flows when the output to primary circuit (coil) of personal code relay is turned ON. Current flows when the output to primary circuit (coil) of personal code relay is turned OFF. Lights the centralized warning lamp and sounds the alarm buzzer. If cause of failure disappears, machine becomes normal by itself.
None in particular q
Related information
Failure
1
q
Output signal (ON/OFF) to personal code relay can be checked with monitoring function. (Code: 04700) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause Blown fuse
Procedure, measuring location, criteria, and remarks If fuse No. 2 has blown in fuse box FB1, the circuit may be shorted to ground. (Go to check on cause 4.) 1. Turn the starting switch to OFF position. 2. Replace the personal code relay SP32 and stop lamp relay SP16. 3. Start engine.
2
Personal code relay abnormality
If this failure code disappears, original personal code relay SP32 is defective. Reference 1. Turn the starting switch to OFF position. 2. Disconnect connector SP32, and connect T-adapter to male side. Between connector SP32 (male) (1) and (2)
3
Open circuit in wiring harness
Ground fault in wiring harness
Between FP1 (female) (4) and SP32 (female) (2)
Between FB1-15 or SP32 (female) (1) and ground Defective machine monitor
40-266
Resistance
Max. 1 z Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors FP1 and SP32, and connect T-adapter to female side of FP1 or SP32. 3. Remove fuse No. 15 of fuse box FB1. Between FP1 (female) (4) or SP32 (female) (2) and ground
5
200 to 400 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors FP1 and SP32, and connect T-adapter to each female side. 3. Remove fuse No.15 of fuse box FB1.
Between FB1-15 and SP32 (female) (1)
4
Resistance
Resistance
Min. 1 Mz Min. 1 Mz
If no failure is found by above checks, the machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [D19JKZ] Personal Code Relay Abnormality
Circuit diagram related to personal code relay
GD535-5 (03)
40-267
Failure code [D19KKZ] Failure of Diff Control Relay
40 Troubleshooting
Failure code [D19KKZ] Failure of Diff Control Relay Action code
Failure code
L01
D19KKZ
Failure
1
Failure of differential gear control relay output circuit (Transmission controller system)
Detail of failure The primary side (coil side) circuit of differential gear lock relay is opened or shorted to ground. q
Action of controller
Problem on machine
q q
The differential gear does not work normally. q
Related information
No.
Turns OFF the output to differential lock relay. If the circuit is opened or shorted to ground, the machine becomes normal by itself when cause of failure disappears. If the circuit is shorted to ground, machine is not recovered to normal status until the starting switch is turned to OFF position.
q
Output state (ON/OFF) to differential lock relay can be checked with monitoring function. (Code: 03705) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position. + Operate the differential gear lock switch (ON).
Cause
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM43, and connect T-adapter to male side. Between TM43 (male) (1) and (2)
1
Resistance
200 to 400 z
Failure of differential gear 1. Turn the starting switch to OFF position. lock relay 2. Replace the differential gear lock relay TM43 with the same type of relay. 3. Turn starting switch to ON position. 4. Turn ON the differential gear lock switch. If it becomes normal, original differential gear lock relay TM43 is defective. 1. Turn the starting switch to OFF position. 2. Disconnect connector TM40, and connect T-adapter to female side. a Resistance of differential gear lock relay coils Between TM40 (female) (8) and ground
2
3
4
Open circuit in wiring harness
Ground fault in wiring harness
Short circuit in wiring harness
200 to 400 z
If no failure is found by above checks, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40 and TM43, and connect T-adapter to each female side. Between TM43 (female) (1) and TM40 (female) (8)
Resistance
Max. 1 z
Between TM43 (female) (2) and ground
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40 and TM43, and connect T-adapter to either female side. Between TM43 (female) (1) or TM40 (female) (8) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40 and TM43, and connect T-adapter to female side of TM43. 3. Turn starting switch to ON position. Between TM43 (female) (1) and (2)
40-268
Resistance
Resistance
Min. 1 Mz
GD535-5 (03)
40 Troubleshooting
No.
5
Cause
Failure of transmission controller
Failure code [D19KKZ] Failure of Diff Control Relay
Procedure, measuring location, criteria, and remarks If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) Reference 1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector TM40. 3. Turn starting switch to ON position. 4. Turn ON the differential gear lock switch. Between TM40 (female) (8) and (31)
Turn OFF the differential gear lock switch.
Voltage
20 to 30 V
Turn ON the differential gear lock switch.
Voltage
Max. 1 V
Circuit diagram related to differential gear lock relay
GD535-5 (03)
40-269
Failure code [D1EHKA] Disconnection of Engine Start Relay
40 Troubleshooting
Failure code [D1EHKA] Disconnection of Engine Start Relay Action code
Failure code
L03
D1EHKA
Failure
1
Open circuit of engine start relay output (Transmission controller system)
Detail of failure No current flows when output to the primary circuit (coil) of engine start relay is turned ON. Action of controller Problem on machine
None in particular The engine cannot start. q
Related information
No.
q
Engine start relay output signal can be checked with monitoring function. (Code: 03706) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Replace engine start relay SP17 with the same type of relay. 3. Turn starting switch to ON position.
1
Failure of engine start relay
If it becomes normal, original engine start relay SP17 is defective. 1. Turn the starting switch to OFF position. 2. Disconnect connector SP17, and connect T-adapter to male side. Between SP17 (male) (1) and (2)
2
Open circuit in wiring harness
Failure of transmission controller
200 to 400 z
Check ground terminal FT11 for loose connection or rusting. 1. Turn the starting switch to OFF position. 2. Disconnect connectors TM41 and SP17, and connect T-adapter to each female side. Between SP17 (female) (1) and TM41 (female) (8) Between SP17 (female) (2) and ground
3
Resistance
Resistance
Max. 1 z Max. 1 z
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to engine start relay
40-270
GD535-5 (03)
40 Troubleshooting
Failure code [D1EHKB] Ground Fault of Engine Start Relay
Failure code [D1EHKB] Ground Fault of Engine Start Relay Action code
Failure code
L03
D1EHKB
Failure
1
Output circuit of engine start relay is shorted to ground. (Transmission controller system)
Detail of failure Large current flows when output to the primary circuit (coil) of engine start relay is turned ON. Action of controller Problem on machine
Turns OFF the output to engine start relay. The engine cannot start. q
Related information
No.
q
Engine start relay output signal can be checked with monitoring function. (Code: 03706) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Replace engine start relay SP17 with the same type of relay. 3. Turn starting switch to ON position.
1
Failure of engine start relay
If it becomes normal, original engine start relay SP17 is defective. 1. Turn the starting switch to OFF position. 2. Disconnect connector SP17, and connect T-adapter to male side. Between SP17 (male) (1) and (2) Between SP17 (male) (1) and ground
2
3
Ground fault in wiring harness Failure of transmission controller
Resistance
200 to 400 z Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM41 and SP17, and connect T-adapter to either female side. Between TM41 (female) (8) or SP17 (female) (1) and ground
Resistance
Max. 1 z
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to engine start relay
GD535-5 (03)
40-271
Failure code [D1EHKY] Hot Short of Engine Start Relay
40 Troubleshooting
Failure code [D1EHKY] Hot Short of Engine Start Relay Action code
Failure code
L03
D1EHKY
Failure
1
Output circuit of engine start relay is hot shorted. (Transmission controller system)
Detail of failure Current flows when the output to primary circuit (coil) of engine start relay is turned OFF. Action of controller Problem on machine
None in particular The engine cannot start. q
Related information
No.
q
Engine start relay output signal can be checked with monitoring function. (Code: 03706) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Replace engine start relay SP17 with the same type of relay. 3. Turn starting switch to ON position.
1
Failure of engine start relay
If it becomes normal, original engine start relay SP17 is defective. 1. Turn the starting switch to OFF position. 2. Disconnect connector SP17, and connect T-adapter to male side. Between SP17 (male) (1) and (2)
2
3
Hot short circuit in wiring harness
Failure of transmission controller
Resistance
200 to 400 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM41 and SP17, and connect T-adapter to either female side. 3. Turn starting switch to ON position. Between TM41 (female) (8) or SP17 (female) (1) and ground
Voltage
Max. 4.5 V
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to engine start relay
40-272
GD535-5 (03)
40 Troubleshooting
Failure code [D1FBKB] Ground Fault of Sol. Self-Holding Relay
Failure code [D1FBKB] Ground Fault of Sol. Self-Holding Relay Action code
Failure code
L03
D1FBKB
Detail of failure Action of controller Problem on machine
No.
Solenoid Self-Holding Relay Output Ground Fault (Transmission controller system)
When controller drives primary circuit (coil) of solenoid self-holding relay, excessive current flows through circuit. Stops driving solenoid self-holding relay circuit. q q q q
Related information
Failure
1
q
Gear speed is held in NEUTRAL and machine cannot travel. Radiator fan rotates at its maximum speed and may be damaged. Fan changes its rotating direction to normal while fan is rotating in reverse. Output signal of transmission controller self-holding relay can be checked with monitoring. (Code: 03706) After completion of repair, check if the failure code is cleared by the following procedure. Procedure: Turn the starting switch to ON position.
Cause
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Replace solenoid self-holding relay (SP43) with another relay of same type. 3. Turn the starting switch to ON position.
1
Defective solenoid power If condition becomes normal, original solenoid self-holding relay is defective. holding relay q Reference (transmission) 1. Turn the starting switch to OFF position. 2. Disconnect connector SP43, and connect T-adapter to male side. Resistance
2
3
4
Ground fault in wiring harness (contact with ground circuit)
Short circuit in wiring harness Defective transmission controller
GD535-5 (03)
Between SP43 (male) (1) and (2)
200 to 400 Ω
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM41 and SP43, and connect T-adapter to either female side. Resistance
Between ground and TM41 (female) (4) or SP43 (female) (1)
Min. 1 MΩ
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM41 and SP43, and connect T-adapter to either female side. Resistance
Between TM41 (female) (4) and (21), or between SP43 (female) (1) and (2)
Min. 1 MΩ
If no failure is found by preceding checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-273
Failure code [D1FBKB] Ground Fault of Sol. Self-Holding Relay
40 Troubleshooting
Circuit diagram related to relay of transmission solenoid power holding relay
40-274
GD535-5 (03)
40 Troubleshooting
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 Action code
Failure code
L03
D8AQK4
Failure
1
CAN2 (KOMTRAX) communication failure 2 (Machine monitor system)
Detail of failure Machine monitor cannot recognize the KOMTRAX terminal on the CAN2 communication line (KOMNET/c). Action of controller Problem on machine
Does not update the communication information. Engine does not start. q
q
Related information
q q
No. 1
4 different failure codes, [D8AQK4], [D8AQKR], [DAQQKR], and [DB2QKR], are used for defective CAN communication by CAN2. When all of these 4 failure codes are displayed simultaneously on screen, ground fault, short circuit, or hot short circuit may occur in wiring harness (CAN communication line). Since each controller and machine monitor are connected directly to battery, they are supplied with power even after starting switch is turned to OFF position. Since signal of active CAN communication line is pulse voltage, it cannot be measured by using multimeter. After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause Failure of CAN2 communication system
GD535-5 (03)
Procedure, measuring location, criteria, and remarks Perform troubleshooting for failure code [D8AQKR].
40-275
Failure code [D8AQKR] CAN2 Discon (KOMTRAX)
40 Troubleshooting
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) Action code
Failure code
-
D8AQKR
Failure
1
CAN2 communication failure (KOMTRAX) (Machine monitor system)
Detail of failure Machine monitor cannot recognize the KOMTRAX terminal on the CAN2 communication line (KOMNET/c). Action of controller
None
Problem on machine
None q
q
Related information
q q
No.
4 different failure codes, [D8AQK4], [D8AQKR], [DAQQKR], and [DB2QKR], are used for defective CAN communication by CAN2. When all of these 4 failure codes are displayed simultaneously on screen, ground fault, short circuit, or hot short circuit may occur in wiring harness (CAN communication line). Since each controller and machine monitor are connected directly to battery, they are supplied with power even after starting switch is turned to OFF position. Since signal of active CAN communication line is pulse voltage, it cannot be measured by using multimeter. After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause
Procedure, measuring location, criteria, and remarks
1
Turn the starting switch to OFF position. Failure of slow-blow fuse Remove slow-blow fuse ET48. If the slow-blow fuse has blown, the circuit may be shorted to ground.
2
Blown fuse
3
Defective CAN Perform checks on causes 4 to 9 in troubleshooting for failure code [DB2QKR]. communication 2 system
4
Defective KOMTRAX terminal
If no failure is found by above checks, the KOMTRAX terminal is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
5
Defective machine monitor
If no failure is found by above checks, the machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-276
If fuse No. 4 of FB2 fuse box is blown, the circuit may be shorted to ground.
GD535-5 (03)
40 Troubleshooting
Failure code [D8AQKR] CAN2 Discon (KOMTRAX)
Circuit diagram related to KOMTRAX
GD535-5 (03)
40-277
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON)
40 Troubleshooting
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) Action code
Failure code
L03
DAF0KT
Failure
1
Failure of non-volatile memory in machine monitor (Machine monitor system)
Detail of failure No data can be written into or read from non-volatile memory of the machine monitor. Action of controller
Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
Problem on machine
The service meter, odometer and other set values change.
Related information
After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
No. 1
Cause Defective machine monitor
40-278
Procedure, measuring location, criteria, and remarks Since this is an internal defect, troubleshooting cannot be performed.
GD535-5 (03)
40 Troubleshooting
Failure code [DAF0MB] Monitor ROM Abnormality
Failure code [DAF0MB] Monitor ROM Abnormality Action code
Failure code
-
DAF0MB
Failure
1
Failure of memory (ROM) in machine monitor (Machine monitor system)
Detail of failure The program of machine monitor was overwritten. (Program error) Action of controller Problem on machine Related information
No. 1
Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. q q
The display on the machine monitor is unreliable. Data cannot be sent or received normally to/from each controller.
After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause Defective machine monitor
GD535-5 (03)
Procedure, measuring location, criteria, and remarks Since this is an internal defect, troubleshooting cannot be performed.
40-279
Failure code [DAF0MC] Monitor Error
40 Troubleshooting
Failure code [DAF0MC] Monitor Error Action code
Failure code
-
DAF0MC
Failure
1
Machine monitor operation failure (Machine monitor system)
Detail of failure Malfunction of machine monitor Action of controller Problem on machine Related information
No. 1
Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. q q
The display on the machine monitor is unreliable. Data cannot be sent or received normally to/from each controller.
After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause Defective machine monitor
40-280
Procedure, measuring location, criteria, and remarks Since this is an internal defect, troubleshooting cannot be performed.
GD535-5 (03)
40 Troubleshooting
Failure code [DAF3KK] Controller Power Source Low (MON)
Failure code [DAF3KK] Controller Power Source Low (MON) Action code
Failure code
-
DAF3KK
Failure
1
Dropped voltage of battery direct power supply (MON) (Machine monitor system)
Detail of failure The constant power voltage of machine monitor has dropped below 18 V. Action of controller
q
Problem on machine
q
q
q q
Related information
No.
q
Disables data writing in memory. If cause of failure disappears, machine becomes normal by itself. The monitor screen may not be displayed. As data writing into non-volatile memory is disabled, the information reliability drops. No failure code is displayed on the machine monitor. After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause
Procedure, measuring location, criteria, and remarks
1
Failure of slow-blow fuse If slow-blow fuse ET48 is blown, the circuit may be shorted to ground.
2
Blown fuse
If fuse No. 1 has blown in fuse box FB1, the circuit may be shorted to ground. (See the Harness grounding.) 1. 2. 3. 4. 5.
Turn the starting switch to OFF position. Disconnect cable from negative (-) battery terminal. Disconnect connector FP1, and connect T-adapter to female side. Connect negative (-) battery terminal. Turn starting switch to ON position.
Between FP1 (female) (1) and (2) 3
Open circuit in wiring harness
Between FP1 (female) (6) and (7)
Voltage
Resistance
1. Turn the starting switch to OFF position. 2. Remove fuse No. 1 of FB1 fuse box, Disconnect connector FP1, and connect T-adapter to female side. Between FB1-1 or FP1 (female) (1) or (6) and ground
5
Defective machine monitor
GD535-5 (03)
Max. 1 z Max. 1 z
Between FP1 (female) (2) or (7) and ground
4
20 to 30 V
If the fuse or slow-blow fuse blows, replace it. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connector FP1, and connect T-adapter to female side. Between battery relay ET46 terminal and FP1 (female) (1) or (6)
Ground fault in wiring harness
20 to 30 V
Resistance
Min. 1 Mz
If no failure is found by above checks, the machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-281
Failure code [DAF3KK] Controller Power Source Low (MON)
40 Troubleshooting
Circuit diagram related to battery relay
40-282
GD535-5 (03)
40 Troubleshooting
Failure code [DAQ0KK] Controller Power Source Low (T/M)
Failure code [DAQ0KK] Controller Power Source Low (T/M) Action code
Failure code
L03
DAQ0KK
Failure
1
Dropped voltage of controller power supply (T/M) (Transmission controller system)
Detail of failure When engine is running, the voltage of controller power circuit has dropped below 18 V. q
Action of controller
q q
Flashes the centralized warning lamp and sounds the alarm buzzer. Holds the gear in neutral position. If cause of failure disappears, machine becomes normal by itself. (However, the gear is held to the neutral position until the lever is shifted to the N position.)
Problem on machine
The machine stops.
Related information
After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Failure of slow-blow fuse
If the 30A slow-blow fuse has blown, the circuit may be shorted to ground. In this case, perform check on cause 4 first.
2
Blown fuse
If fuse No. 3 of FB1 fuse box is blown, the circuit may be shorted to ground. In this case, perform check on cause 4 first. Ground cable 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connector TM41, and connect T-adapter to female side. Between each of terminals TM41 (female) (21), (31) to (33) and ground
3
4
Open circuit in wiring harness
Ground fault in wiring harness
1. 2. 3. 4. 5.
6
Defective alternator
Failure of transmission controller
GD535-5 (03)
Max. 1 z
Turn the starting switch to OFF position. Disconnect cable from negative (-) battery terminal. Disconnect connector TM41, and connect T-adapter to female side. Connect negative (-) battery terminal. Turn starting switch to ON position.
Between TM41 (female) (1) and (21)
Voltage
20 to 30 V
Between TM41 (female) (11) and (32)
Voltage
20 to 30 V
If the slow-blow fuse or fuse is not burnt out, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connector TM41, and connect T-adapter to female side. Between TM41 (female) (1) and ground
5
Resistance
Resistance
Min. 1 Mz
Perform troubleshooting for failure code [AB00MA]. If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) Reference 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Insert T-adapter into connector TM41. 4. Connect negative (-) battery terminal. 5. Turn starting switch to ON position. Between TM41 (1) and (21) or (31)
Voltage
20 to 30 V
Between TM41 (11) and (32) or (33)
Voltage
20 to 30 V
40-283
Failure code [DAQ0KK] Controller Power Source Low (T/M)
40 Troubleshooting
Circuit diagram related to transmission controller power supply
40-284
GD535-5 (03)
40 Troubleshooting
Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M)
Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) Action code
Failure code
L01
DAQ0KT
Failure
1
Abnormality of non-volatile memory (T/M) (Transmission controller system)
Detail of failure Information in the ROM (non-volatile memory) of transmission controller is abnormal. Action of controller Problem on machine Related information
No. 1
q q
q q
Sets entire data of ROM (non-volatile memory) to default values. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. The transmission shift feeling may become poor. The inching feeling may become poor.
After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause Failure of transmission controller
GD535-5 (03)
Procedure, measuring location, criteria, and remarks Since this is an internal defect, troubleshooting cannot be performed. (If there is no visible failure on the machine after performing all initial settings of work equipment controller, controller may be used as it is.)
40-285
Failure code [DAQ0MC] T/M Con Error
40 Troubleshooting
Failure code [DAQ0MC] T/M Con Error Action code
Failure code
-
DAQ0MC
Failure
1
Controller operation error (T/M) (Transmission controller system)
Detail of failure The controller malfunctions (unexpected control). Action of controller
Resets the controller CPU and restarts the machine.
Problem on machine
Returns to the initial state that was selected when starting switch is set to ON position.
Related information
After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
No. 1
Cause Failure of transmission controller
40-286
Procedure, measuring location, criteria, and remarks Since this is an internal defect, troubleshooting cannot be performed.
GD535-5 (03)
40 Troubleshooting
Failure code [DAQ1KA] Disconnection of Key SW ACC
Failure code [DAQ1KA] Disconnection of Key SW ACC Action code
Failure code
L03
DAQ1KA
Failure
1
Disconnection of KEY_SIG (ACC) signal line (Transmission controller system)
Detail of failure Although engine is running, the ACC signal of key switch is not entered in the transmission controller. Action of controller Problem on machine Related information
No.
q q q q
Erroneously recognizes the key OFF processing, and tries to hold the speed gear when the machine is traveling. If the gear is shifted to Neutral position, the machine cannot travel. The machine can continue to travel when traveling. If the gear is shifted to Neutral, the machine cannot travel.
After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine.
Cause
Procedure, measuring location, criteria, and remarks 1. 2. 3. 4. 5.
Turn the starting switch to OFF position. Disconnect cable from negative (-) battery terminal. Disconnect connector TM41, and connect T-adapter to female side. Connect negative (-) battery terminal. Turn starting switch to ON position.
Between TM41 (female) (14) and (21) 1
Open circuit in wiring harness
Between TM41 (female) (24) and (31)
Between TM41 (female) (24) and ACC terminal Failure of transmission controller
GD535-5 (03)
20 to 30 V 20 to 30 V
If no failure is found by above checks, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connector TM41, and connect T-adapter to female side. Between TM41 (female) (14) and ACC terminal
2
Voltage
Resistance
Max. 1 z Max. 1 z
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-287
Failure code [DAQ1KA] Disconnection of Key SW ACC
40 Troubleshooting
Circuit diagram related to transmission controller key switch ACC signal circuit
40-288
GD535-5 (03)
40 Troubleshooting
Failure code [DAQ2KK] Solenoid Power Source Low (T/M)
Failure code [DAQ2KK] Solenoid Power Source Low (T/M) Action code
Failure code
L03
DAQ2KK
Detail of failure
Dropped solenoid power source voltage (T/M) (Transmission controller system)
When starting switch is set to ON position (with engine stopped or running), the voltage of controller power supply circuit is normal but the voltage of solenoid power circuit has dropped below 18 V. q
Action of controller
Failure
1
q q
Flashes the centralized warning lamp and sounds the alarm buzzer. Holds the gear in neutral position. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
Problem on machine
The machine stops.
Related information
After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Failure of slow-blow fuse
If the 60A slow-blow fuse of holder 1 has blown, the circuit may be shorted to ground. In this case, perform check on cause 4 first.
2
Blown fuse
If fuse No. 11 of FB1 fuse box is blown, the circuit may be shorted to ground. In this case, perform check on cause 4 first. Ground cable 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connector TM41, and connect T-adapter to female side. Between each of terminals TM41 (female) (21), (31) to (33) and ground
3
4
Open circuit in wiring harness
Ground fault in wiring harness
1. 2. 3. 4. 5.
Defective alternator
GD535-5 (03)
Max. 1 z
Turn the starting switch to OFF position. Disconnect cable from negative (-) battery terminal. Disconnect connector TM41, and connect T-adapter to female side. Connect negative (-) battery terminal. Turn starting switch to ON position.
Between TM41 (female) (2) and (31)
Voltage
20 to 30 V
Between TM41 (female) (12) or (22) and (33)
Voltage
20 to 30 V
If the slow-blow fuse or fuse is not burnt out, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connector TM41, and connect T-adapter to female side. Between TM41 (female) (2) and ground
5
Resistance
Resistance
Min. 1 Mz
Perform troubleshooting for failure code [AB00MA].
40-289
Failure code [DAQ2KK] Solenoid Power Source Low (T/M)
No.
6
Cause
Failure of transmission controller
40 Troubleshooting
Procedure, measuring location, criteria, and remarks If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) Reference 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Insert T-adapter into connector TM41. 4. Connect negative (-) battery terminal. 5. Turn starting switch to ON position. Between TM41 (2) to (21) and (31)
Voltage
20 to 30 V
Between TM41 (12) and (32)
Voltage
20 to 30 V
Between TM41 (22) and (33)
Voltage
20 to 30 V
Circuit diagram related to transmission controller power supply
40-290
GD535-5 (03)
40 Troubleshooting
Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M)
Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) Action code
Failure code
L03
DAQ9KQ q
Detail of failure
q q
Action of controller
q q
Failure
1
Inconsistency of model selection signal (T/M) (Transmission controller system)
The model setting ID of the controller is incorrect. The model information obtained from machine monitor does not match the model information being stored in the controller. The model information stored in the controller is other than the available model information. Lights the centralized warning lamp and sounds the alarm buzzer. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
Problem on machine
If the machine is traveled, the transmission system may be damaged.
Related information
After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
No.
Cause
1
Incorrect machine model setting by machine monitor
The machine model setting of machine monitor is probably incorrect. After replacing the machine monitor or transmission controller, set the options correctly. For details, see Testing and Adjusting.
2
Incorrect installation of transmission controller
Incorrect transmission controller may be installed. Check the part number, and install the correct transmission controller.
3
Failure of machine monitor or transmission controller
If no failure is found by above checks, the machine monitor or transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
Procedure, measuring location, criteria, and remarks
40-291
Failure code [DAQQKR] CAN2 Discon (Transmission Con)
40 Troubleshooting
Failure code [DAQQKR] CAN2 Discon (Transmission Con) Action code
Failure code
L03
DAQQKR
Detail of failure Action of controller Problem on machine
Flashes the centralized warning lamp and sounds the alarm buzzer. Machine monitor system may not operate normally, or the machine monitor may not display normally.
q q q
No.
CAN2 communication failure (T/M) (Machine monitor system)
Machine monitor system cannot recognize the transmission controller on the CAN2 communication line (KOMNET/r).
q
Related information
Failure
1
The start of CAN communication is specified to each controller by sending an ACC signal of starting switch. Since each controller and machine monitor are connected directly to battery, they are supplied with power even after starting switch is turned to OFF position. Since signal of active CAN communication line is pulse voltage, it cannot be measured by using multimeter. After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause
Procedure, measuring location, criteria, and remarks
1
Failure of power supply to the transmission controller
Perform troubleshooting for failure code [DAQ0KK].
2
Failure of CAN2 communication system
Perform checks on causes 4 to 9 in troubleshooting for failure code [DB2QKR].
3
Failure of transmission controller
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
4
Defective machine monitor
If no failure is found by above checks, the machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-292
GD535-5 (03)
40 Troubleshooting
Failure code [DAQRMA] Inconsistency of Option Selection (T/M)
Failure code [DAQRMA] Inconsistency of Option Selection (T/M) Action code
Failure code
L03
DAQRMA q
Detail of failure
Action of controller
q
q q
Failure
1
Inconsistency of option settings (T/M) (Transmission controller system)
The option setting ID of the controller is incorrect. The differential gear setting information obtained from machine monitor does not match the option information being stored in the controller. Flashes the centralized warning lamp and sounds the alarm buzzer. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
Problem on machine Related information
No. 1
After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause Failure of transmission controller
GD535-5 (03)
Procedure, measuring location, criteria, and remarks Since this is an internal defect, troubleshooting cannot be performed.
40-293
Failure code [DB2QKR] CAN2 Discon (Engine Con)
40 Troubleshooting
Failure code [DB2QKR] CAN2 Discon (Engine Con) Action code
Failure code
L03
DB2QKR
Failure
1
CAN2 communication failure (Engine controller) (Machine monitor system)
Detail of failure Machine monitor cannot recognize the engine controller over CAN2 communication line (KOMNET/r). Action of controller Problem on machine
Lights the centralized warning lamp and sounds the alarm buzzer. Machine monitor system may not operate normally, or the machine monitor may not display normally. q q
Related information
q q
No. 1
2
Start of CAN communication is recognized by each controller when ACC signal of starting switch is received. Since each controller and machine monitor are connected directly to battery, they are supplied with power even after starting switch is turned to OFF position. Since signal of active CAN communication line is pulse voltage, it cannot be measured by using multimeter. After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause Blown fuse
Defective engine controller
Procedure, measuring location, criteria, and remarks If fuse No.4 of FB2 fuse box is blown, the engine controller may have shorted. If fuse is not burnt out, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connector EC3 and connect T-adapter to male side. Between EC3 (male) (3) and (1) Between EC3 (male) (4) and (2)
3
Defective power supply to engine controller
Between EC3 (female) (4) and (2)
Defective CAN terminating resistor
Min. 10 z
Voltage
20 to 30 V 20 to 30 V
1. Turn the starting switch to OFF position. 2. Disconnect connectors FP1 and CAN1, and connect T-adapters to each male side. Between CAN1 (male) (A) and (B) Between FP1 (male) (11) and (12)
40-294
Min. 10 z
Check ground terminal 103 for looseness and rusting. 1. Turn the starting switch to OFF position. 2. Disconnect connector EC3, and connect T-adapter to female side. 3. Turn starting switch to ON position. a Perform troubleshooting for failure code [CA441]. Between EC3 (female) (3) and (1)
4
Resistance
Resistance
120 ± 12 z 120 ± 12 z
GD535-5 (03)
40 Troubleshooting
No.
5
Cause
Open or short circuit in wiring harness
Failure code [DB2QKR] CAN2 Discon (Engine Con)
Procedure, measuring location, criteria, and remarks CAN communication line 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect related connectors, and connect T-adapter to female side of the connector to be measured. q The 120 z CAN terminating resistor is also located in machine monitor. That is, 2 CAN terminating resistors of 120 z are connected in parallel. When circuit resistance is measured at connector of controller other than machine monitor, if combined resistance is 60 z, wiring harness does not have open circuit. q If open circuit is found (resistance between 2 terminals is 1 z or below), disconnect all CAN communication connectors of every controller and check whether short circuit occurs in wiring harness or inside controller. Between EC2 (female) (46) and (47)
Approx. 60 z
Between FP1 (female) (11) and (12)
Approx. 120 z
Between TM40 (female) (32) and (22)
Resistance
Approx. 60 z
Between L80A (female) (10) and (11)
Approx. 60 z
Between CAN1 (female) (A) and (B)
Approx. 120 z
ACC signal of starting switch (The start of CAN communication is not recognized.) 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors to be measured and insert T-adapters. 4. Connect negative (-) battery terminal. 5. Turn starting switch to ON position. Between EC2 (39) and EC3 (1) Between FP1 (3) and (2) Between TM41 (14) or (24) and (21)
20 to 30 V Voltage
Between CAN (2) and (12)
6
Open circuit in wiring harness
20 to 30 V 20 to 30 V
If the wiring harness is normal (not opened or shorted), this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect related connectors, and connect T-adapter to female side of the connector to be measured. Between FP1 (female) (11) and EC2 (female) (46)
Max. 1 z
Between FP1 (female) (12) and EC2 (female) (47)
Max. 1 z
Between FP1 (female) (11) and TM40 (female) (32)
Max. 1 z
Between FP1 (female) (12) and TM40 (female) (22) Between FP1 (female) (11) and L80A (female) (10)
GD535-5 (03)
20 to 30 V
Resistance
Max. 1 z Max. 1 z
Between FP1 (female) (12) and L80A (female) (11)
Max. 1 z
Between EC2 (female) (46) and CAN1 (female) (A)
Max. 1 z
Between EC2 (female) (47) and CAN1 (female) (B)
Max. 1 z
40-295
Failure code [DB2QKR] CAN2 Discon (Engine Con)
No.
7
Cause
Ground fault in wiring harness
40 Troubleshooting
Procedure, measuring location, criteria, and remarks If the wiring harness is normal (not opened or shorted), measure resistance at any one place in each case. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect all related connectors, and connect T-adapter to female side of the connector to be measured. Between L80A (female) (1) EC2 (female) (46) or TM40 (female) (32) and ground Between L80A (female) (11), EC2 (female) (47) or TM40 (female) (22) and ground
8
Open circuit or hot short circuit in wiring harness
Between L80A (female) (11), EC2 (female) (47) or TM40 (female) (22) and ground
9
Min. 1 Mz
If the wiring harness is normal (not opened or shorted), measure resistance at any one place in each case. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors to be measured and insert T-adapters. 4. Connect negative (-) battery terminal. 5. Turn starting switch to ON position. a Voltage of CAN H and CAN L is 2.5 ± 1 V including during communication, so regard wiring harness as normal if measured voltage is 1 to 4 V. Between L80A (female) (10), EC2 (female) (46) or TM40 (female) (32) and ground
Failure of engine controller, transmission controller, machine monitor, or KOMTRAX terminal
Min. 1 Mz Resistance
1 to 4 V Voltage 1 to 4 V
If all 3 failure codes [D8AQKR], [DAQQKR], [DB2QKR] are displayed: Identify which controller is defective by disconnecting them one by one from CAN communication line by repeating the following steps 1 to 5. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect each CAN communication connector of engine controller (connector EC2), transmission controller (connector TM40), KOMTRAX terminal (connector L80A), and machine monitor (connector FP1) one by one in turn. 4. Connect negative (-) battery terminal. 5. Turn starting switch to ON position. Has the number of displayed failure codes decreased from 3?
If YES, the disconnected controller is defective.
10
Defective engine controller
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
11
Defective machine monitor
If no failure is found by above checks, the machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-296
GD535-5 (03)
40 Troubleshooting
Failure code [DB2QKR] CAN2 Discon (Engine Con)
Circuit diagram related to CAN2 communication
GD535-5 (03)
40-297
Failure code [DD1PKB] Abnormality of RPM Switch
40 Troubleshooting
Failure code [DD1PKB] Abnormality of RPM Switch Action code
Failure code
L03
DD1PKB
Detail of failure Action of controller Problem on machine
q q q q
Failure
1
Failure of RPMset switch (Transmission controller system)
The SET and RESUME lamps of the set switch turn ON simultaneously. When the set switch is operated, the SET or RESUME lamp is kept ON. Flashes the centralized warning lamp and sounds the alarm buzzer. Sets the RPMset set function to the OFF mode.
The RPMset set switch is turned OFF, and it cannot be used any more.
Related information
No.
Cause
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connectors TM38 and TM41, and connect T-adapter to female side of TM41.
1
2
3
Short circuit in wiring harness
Hot short circuit in wiring harness
Failure of transmission controller
40-298
Between TM41 (female) (2) and (20)
Resistance
Min. 1 Mz
Between TM41 (female) (2) and (30)
Resistance
Min. 1 Mz
Between TM41 (female) (20) and (30)
Resistance
Min. 1 Mz
Between TM41 (female) (20) and (21)
Voltage
Max. 1 V
Between TM41 (female) (30) and (31)
Voltage
Max. 1 V
1. 2. 3. 4.
Turn the starting switch to OFF position. Disconnect connector TM38. Insert T-adapter into connector TM41. Turn starting switch to ON position.
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [DD1PKB] Abnormality of RPM Switch
Circuit diagram related to RPM set switch and RPM set mode switch
GD535-5 (03)
40-299
Failure code [DD1QKB] Abnormality of RPM Set Mode Switch
40 Troubleshooting
Failure code [DD1QKB] Abnormality of RPM Set Mode Switch Action code
Failure code
L03
DD1QKB
Detail of failure Action of controller Problem on machine
q q q q
Failure
1
Failure of RPMset set mode switch (Transmission controller system)
The AUTO and MANUAL lamps of the set switch turn ON simultaneously. When the set switch is operated, the AUTO or MANUAL lamp is kept ON. Flashes the centralized warning lamp and sounds the alarm buzzer. Sets the RPM set function to the OFF mode.
The RPM set function is turned OFF, and it cannot be used any more.
Related information
No.
Cause
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connectors TM37 and TM39, and connect T-adapter to female side of TM37.
1
2
3
Short circuit in wiring harness
Hot short circuit in wiring harness
Failure of transmission controller
40-300
Between TM37 (female) (4) and (5)
Resistance
Min. 1 Mz
Between TM37 (female) (4) and (6)
Resistance
Min. 1 Mz
Between TM37 (female) (5) and (6)
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector TM37, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between TM37 (female) (4) and (2)
Voltage
Max. 1 V
Between TM37 (female) (6) and (2)
Voltage
Max. 1 V
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [DD1QKB] Abnormality of RPM Set Mode Switch
Circuit diagram related to RPM switch and RPM mode switch
GD535-5 (03)
40-301
Failure code [DDB6L4] Parking brake signal error
40 Troubleshooting
Failure code [DDB6L4] Parking brake signal error Action code
Failure code
L03
DDB6L4
Failure
1
Parking brake signal combination error (Transmission controller system)
Detail of failure Both the parking signal and no-parking signal turned ON or OFF. Action of controller Problem on machine
q q q q q
Related information
No. 1
q
Flashes the centralized warning lamp and sounds the alarm buzzer. This error is recovered when the normal shift lever "P" combination signals are entered. The parking brake operates when the gear shift lever is shifted to N or P position and when the speed is 1.0 km/h or less. The parking brake does not operate if the gear shift lever is any position other than N or P. Input condition (ON/OFF or shift lever position) from the shift lever can be checked with monitoring function. (Code: 02213) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position. + Operate gear shift lever.
Cause Blown fuse
Procedure, measuring location, criteria, and remarks If fuse No. 11 of FB1 fuse box blows, the circuit may be shorted to ground. (Go to check on cause 3.) 1. Turn the starting switch to OFF position. 2. Remove fuse No. 11 of the FB1 fuse box. 3. Disconnect connectors TM36 and TM41, and connect T-adapters to each female side.
2
Open circuit in wiring harness
Between FB1-11 and TM36 (female) (1)
Resistance
Max. 1 z
Between TM36 (female) (2) and ground
Resistance
Max. 1 z
Between TM36 (female) (5) and TM41 (female) (40)
Resistance
Max. 1 z
Between TM36 (female) (6) and TM41 (female) (39)
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. 2. Remove fuse No. 11 of the FB1 fuse box. 3. Disconnect connectors TM36 and TM41, and connect T-adapter to each female side. 3
4
5
Ground fault in wiring harness
Short circuit in wiring harness
Hot short circuit in wiring harness
40-302
Between FB1-11 or TM36 (female) (1) and ground
Resistance
Min. 1 Mz
Between TM36 (female) (5) or TM41 (female) (40) and ground
Resistance
Min. 1 Mz
Between TM36 (female) (6) or TM41 (female) (39) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM36, TM40 and TM41, and connect T-adapter to female side of TM36. Between TM36 (female) (5) and each pin other than pin (5)
Resistance
Min. 1 Mz
Between TM36 (female) (6) and each pin other than pin (6)
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connector TM36, and connect T-adapter to female side (with the gear shift lever removed). 4. Connect negative (-) battery terminal. 5. Turn starting switch to ON position. Between TM36 (female) (5) and (2)
Voltage
Max. 1 V
Between TM36 (female) (6) and (2)
Voltage
Max. 1 V
GD535-5 (03)
40 Troubleshooting
No.
Cause
Failure code [DDB6L4] Parking brake signal error
Procedure, measuring location, criteria, and remarks
6
Failure of gear shift lever Perform troubleshooting for failure code [DF10KA].
7
Failure of transmission controller
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) Reference When you check the voltage, see failure code [DF10KA].
Circuit diagram related to gear shift lever
GD535-5 (03)
40-303
Failure code [DDTHKA] Disconnection of Fill Switch (FH)
40 Troubleshooting
Failure code [DDTHKA] Disconnection of Fill Switch (FH) Action code
Failure code
L01
DDTHKA
Detail of failure Action of controller Problem on machine
No. 1
q q
None in particular Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
Large shock occurs during gear shift.
q
Input condition (ON/OFF) from ECMV fill switch of FH-clutch can be checked with monitoring function. (Code: 02216) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of F2, F4, F6 or F8 position).
Cause Failure of FH-clutch fill switch
40-304
Disconnection of FH-clutch fill switch (Transmission controller system)
When signal is output to the FH-clutch ECMV solenoid, the clutch is engaged but signal from fill switch is not turned ON.
q
Related information
Failure
1
Procedure, measuring location, criteria, and remarks Perform troubleshooting for failure code [15SCMA].
GD535-5 (03)
40 Troubleshooting
Failure code [DDTJKA] Disconnection of Fill Switch (FL)
Failure code [DDTJKA] Disconnection of Fill Switch (FL) Action code
Failure code
L01
DDTJKA
Detail of failure Action of controller Problem on machine
No. 1
q q
None in particular Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
Large shock occurs during gear shift.
q
Input condition (ON/OFF) from ECMV fill switch of FL-clutch can be checked with monitoring function. (Code: 02216) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of F1, F3, F5 or F7 position).
Cause Failure of FL-clutch fill switch
GD535-5 (03)
Disconnection of FL-clutch fill Switch (Transmission controller system)
When signal is output to the FL-clutch ECMV solenoid, the clutch is engaged but signal from fill switch is not turned ON.
q
Related information
Failure
1
Procedure, measuring location, criteria, and remarks Perform troubleshooting for failure code [15SDMA].
40-305
Failure code [DDTKKA] Disconnection of Fill Switch (1st)
40 Troubleshooting
Failure code [DDTKKA] Disconnection of Fill Switch (1st) Action code
Failure code
L01
DDTKKA
Detail of failure Action of controller Problem on machine
No. 1
q q
None in particular Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
Large shock occurs during gear shift.
q
Input condition (ON/OFF) from ECMV fill switch of 1st clutch can be checked with monitoring function. (Code: 02217) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of F1, F2 or R1 position).
Cause Failure of 1st-clutch fill switch
40-306
Disconnection of 1st-clutch fill switch (Transmission controller system)
When signal is output to the 1st-clutch ECMV solenoid, the clutch is engaged but signal from fill switch is not turned ON.
q
Related information
Failure
1
Procedure, measuring location, criteria, and remarks Perform troubleshooting for failure code [15SEMA].
GD535-5 (03)
40 Troubleshooting
Failure code [DDTLKA] Disconnection of Fill Switch (2nd)
Failure code [DDTLKA] Disconnection of Fill Switch (2nd) Action code
Failure code
L01
DDTLKA
Detail of failure Action of controller Problem on machine
No. 1
q q
None in particular Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
Large shock occurs during gear shift.
q
Input condition (ON/OFF) from ECMV fill switch of 2nd clutch can be checked with monitoring function. (Code: 02217) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of F3, F4 or R2 position).
Cause Failure of 2nd clutch fill switch
GD535-5 (03)
Disconnection of 2nd clutch fill switch (Transmission controller system)
When signal is output to the 2nd clutch ECMV solenoid, the clutch is engaged but signal is not output from the fill switch.
q
Related information
Failure
1
Procedure, measuring location, criteria, and remarks Perform troubleshooting for failure code [15SFMA].
40-307
Failure code [DDTMKA] Disconnection of Fill Switch (3rd)
40 Troubleshooting
Failure code [DDTMKA] Disconnection of Fill Switch (3rd) Action code
Failure code
L01
DDTMKA
Detail of failure Action of controller Problem on machine
No. 1
q q
None in particular Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
Large shock occurs during gear shift.
q
Input condition (connection/disconnection) from ECMV fill switch of 3rd clutch can be checked with monitoring function. (Code: 02217) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of F5, F6 or R3 position).
Cause Failure of 3rd-clutch fill switch
40-308
Disconnection of 3rd-clutch fill switch (Transmission controller system)
When signal is output to the 3rd-clutch ECMV solenoid, the clutch is engaged but signal is not sent from the fill switch.
q
Related information
Failure
1
Procedure, measuring location, criteria, and remarks Perform troubleshooting for failure code [15SGMA].
GD535-5 (03)
40 Troubleshooting
Failure code [DDTNKA] Disconnection of Fill Switch (R)
Failure code [DDTNKA] Disconnection of Fill Switch (R) Action code
Failure code
L01
DDTNKA
Detail of failure Action of controller Problem on machine
No. 1
q q
None in particular Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
Large shock occurs during gear shift.
q
Input condition (ON/OFF) from ECMV fill switch of R-clutch can be checked with monitoring function. (Code: 02216) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of R1 to R4 positions).
Cause Failure of R-clutch fill switch
GD535-5 (03)
Disconnection of R-clutch fill switch (Transmission controller system)
When signal is output to the R-clutch ECMV solenoid, the clutch is engaged but signal from fill switch is not turned ON.
q
Related information
Failure
1
Procedure, measuring location, criteria, and remarks Perform troubleshooting for failure code [15SBMA].
40-309
Failure code [DDTPKA] Disconnection of Fill Switch (4th)
40 Troubleshooting
Failure code [DDTPKA] Disconnection of Fill Switch (4th) Action code
Failure code
L01
DDTPKA
Detail of failure Action of controller Problem on machine
No. 1
q q
None in particular Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
Large shock occurs during gear shift.
q
Input condition (ON/OFF) from ECMV fill switch of 4th clutch can be checked with monitoring function. (Code: 02217) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of F7, F8 or R4 position).
Cause Failure of 4th-clutch ECMV solenoid system
40-310
Disconnection of 4th-clutch fill switch (Transmission controller system)
When signal is output to the 4th-clutch ECMV solenoid, the clutch is engaged but signal from fill switch is not turned ON.
q
Related information
Failure
1
Procedure, measuring location, criteria, and remarks Perform troubleshooting for failure code [15SHMA].
GD535-5 (03)
40 Troubleshooting
Failure code [DF10KA] Disconnection of Shift Lever Input
Failure code [DF10KA] Disconnection of Shift Lever Input Action code
Failure code
L03
DF10KA q
Detail of failure
q
q q
Action of controller
q q q
Problem on machine
No. 1
Gear shift lever signal is not entered. (Transmission controller system)
The gear shift lever was in intermediate position and an illegal voltage combination was entered in the transmission controller. The gear shift lever signal is not entered in the transmission controller due to short to ground or due to open circuit. (Although the "NOTP" signal voltage is supplied to the controller, but no voltage is supplied to any gear shift signal.) Flashes the centralized warning lamp and sounds the alarm buzzer. If machine is braked and if a speed less than 1.0 km/h continues 0.5 second, the lever is held in N position. The recently entered normal speed gear or direction is kept. If cause of failure disappears, machine becomes normal by itself. However, if failure code [DF10L4] is detected simultaneously, machine does not become normal until starting switch is turned to OFF position.
The gear cannot be shifted. q
Related information
Failure
1
q
Input condition (ON/OFF or shift lever position) from the gear shift lever can be checked with monitoring function. (Code: 02211, 02212, 02213) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position. + Operate gear shift lever.
Cause Incorrect operation
Procedure, measuring location, criteria, and remarks The gear shift lever is pressed by external force when the lever is not operated. Shift lever is stopped in an intermediate position. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM36, TM40 and TM41, and connect T-adapter to each female side.
2
Open circuit in wiring harness
GD535-5 (03)
Between TM36 (female) (3) and TM40 (25)
Resistance
Max. 1 z
Between TM36 (female) (4) and TM40 (15)
Resistance
Max. 1 z
Between TM36 (female) (7) and TM40 (35)
Resistance
Max. 1 z
Between TM36 (female) (8) and TM40 (5)
Resistance
Max. 1 z
Between TM36 (female) (9) and TM40 (36)
Resistance
Max. 1 z
Between TM36 (female) (10) and TM40 (26)
Resistance
Max. 1 z
Between TM36 (female) (11) and TM40 (16)
Resistance
Max. 1 z
Between TM36 (female) (12) and TM40 (6)
Resistance
Max. 1 z
Between TM36 (female) (13) and TM41 (9)
Resistance
Max. 1 z
Between TM36 (female) (14) and TM41 (19)
Resistance
Max. 1 z
Between TM36 (female) (15) and TM41 (29)
Resistance
Max. 1 z
40-311
Failure code [DF10KA] Disconnection of Shift Lever Input
No.
Cause
40 Troubleshooting
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM36, TM40 and TM41, and connect T-adapters to female side of TM40 and TM41.
3
4
Ground fault in wiring harness
Between TM40 (female) (5) and ground
Resistance
Min. 1 Mz
Between TM40 (female) (6) and ground
Resistance
Min. 1 Mz
Between TM40 (female) (15) and ground
Resistance
Min. 1 Mz
Between TM40 (female) (16) and ground
Resistance
Min. 1 Mz
Between TM40 (female) (25) and ground
Resistance
Min. 1 Mz
Between TM40 (female) (26) and ground
Resistance
Min. 1 Mz
Between TM40 (female) (35) and ground
Resistance
Min. 1 Mz
Between TM40 (female) (36) and ground
Resistance
Min. 1 Mz
Between TM41 (female) (9) and ground
Resistance
Min. 1 Mz
Between TM41 (female) (19) and ground
Resistance
Min. 1 Mz
Between TM41 (female) (29) and ground
Resistance
Min. 1 Mz
Lever position indicated by q
Voltage
20 to 30 V
Lever position indicated by Q
Voltage
Max. 1 V
1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector TM36. 3. Turn starting switch to ON position. 4. Shift the gear shift lever to perform troubleshooting. Failure of gear shift lever See the Gear Shift Lever Output Table. Between each pin of TM36 and ground
5
Failure of transmission controller
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) Reference: Input voltage of transmission controller 1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector TM41. 3. Turn starting switch to ON position. 4. Shift the gear lever to perform troubleshooting. See the Gear Shift Lever Output Table. Between each pin of TM41 and ground
40-312
Lever position indicated by q
Voltage
20 to 30 V
Lever position indicated by Q
Voltage
Max. 1 V
GD535-5 (03)
40 Troubleshooting
Failure code [DF10KA] Disconnection of Shift Lever Input
Circuit diagram related to gear shift lever
GD535-5 (03)
40-313
Failure code [DF10KA] Disconnection of Shift Lever Input
40 Troubleshooting
Gear Shift Lever Output Table Gear shift lever signal R
Not P
P
N
1st
2nd
3rd
4th
5th
6th
7th
8th
F8
q
Q
q
Q
Q
Q
Q
Q
Q
Q
Q
Q
q
F7
q
Q
q
Q
Q
Q
Q
Q
Q
Q
Q
q
Q
F6
q
Q
q
Q
Q
Q
Q
Q
Q
Q
q
Q
Q
F5
q
Q
q
Q
Q
Q
Q
Q
Q
q
Q
Q
Q
F4
q
Q
q
Q
Q
Q
Q
Q
q
Q
Q
Q
Q
F3
q
Q
q
Q
Q
Q
Q
q
Q
Q
Q
Q
Q
F2
q
Q
q
Q
Q
Q
q
Q
Q
Q
Q
Q
Q
F1
q
Q
q
Q
Q
q
Q
Q
Q
Q
Q
Q
Q
N
Q
Q
q
Q
q
Q
Q
Q
Q
Q
Q
Q
Q
P
Q
Q
Q
q
q
Q
Q
Q
Q
Q
Q
Q
Q
R1
Q
q
q
Q
Q
q
Q
Q
Q
Q
Q
Q
Q
R2
Q
q
q
Q
Q
Q
q
Q
Q
Q
Q
Q
Q
R3
Q
q
q
Q
Q
Q
Q
q
Q
Q
Q
Q
Q
R4
Q
q
q
Q
Q
Q
Q
Q
q
Q
Q
Q
Q
TM36 (Gear shift lever)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
TM40 (Controller)
(25)
(15)
-
-
(35)
(5)
(36)
(26)
(16)
(6)
-
-
-
TM41 (Controller)
-
-
(40)
(39)
-
-
-
-
-
-
(9)
(19)
(29)
Pin number
Gear speed of shift lever
F
Notes: Voltage indicated by q: 20 to 30V, Voltage indicated by Q: 1V or less
40-314
GD535-5 (03)
40 Troubleshooting
Failure code [DF10L4] Gear Speed/Travel Direction Signal Error
Failure code [DF10L4] Gear Speed/Travel Direction Signal Error Action code
Failure code
L03
DF10L4
Failure
1
Gear speed/travel direction signal error (Transmission controller system)
Detail of failure An illegal voltage combination of N, F, R and 1 to 8 gear shift lever signals was entered. q q
Action of controller
q q
Problem on machine
The gear cannot be shifted. q
Related information
No.
Flashes the centralized warning lamp and sounds the alarm buzzer. If machine is braked and if the speed less than 1.0 km/h continues 0.5 second, the gear shift lever is held in N position. The recently entered normal speed gear or direction is kept. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
Input condition (ON/OFF or shift lever position) from the shift lever can be checked with monitoring function. (Code: 02211, 02212, 02213) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position. + Operate gear shift lever.
Cause
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM36, TM40 and TM41, and connect T-adapter to female side of TM36.
1
Short circuit in wiring harness
GD535-5 (03)
Between TM36 (female) (3) and each pin other than pin (3)
Resistance
Min. 1 Mz
Between TM36 (female) (4) and each pin other than pin (4)
Resistance
Min. 1 Mz
Between TM36 (female) (7) and each pin other than pin (7)
Resistance
Min. 1 Mz
Between TM36 (female) (8) and each pin other than pin (8)
Resistance
Min. 1 Mz
Between TM36 (female) (9) and each pin other than pin (9)
Resistance
Min. 1 Mz
Between TM36 (female) (10) and each pin other than pin (10)
Resistance
Min. 1 Mz
Between TM36 (female) (11) and each pin other than pin (11)
Resistance
Min. 1 Mz
Between TM36 (female) (12) and each pin other than pin (12)
Resistance
Min. 1 Mz
Between TM36 (female) (13) and each pin other than pin (13)
Resistance
Min. 1 Mz
Between TM36 (female) (14) and each pin other than pin (14)
Resistance
Min. 1 Mz
Between TM36 (female) (15) and each pin other than pin (15)
Resistance
Min. 1 Mz
40-315
Failure code [DF10L4] Gear Speed/Travel Direction Signal Error
No.
Cause
40 Troubleshooting
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connector TM36, and connect T-adapter to female side (with the gear shift lever removed). 4. Connect negative (-) battery terminal. 5. Turn starting switch to ON position.
2
Hot short circuit in wiring harness
Between TM36 (female) (3) and (2)
Voltage
Max. 1 V
Between TM36 (female) (4) and (2)
Voltage
Max. 1 V
Between TM36 (female) (7) and (2)
Voltage
Max. 1 V
Between TM36 (female) (8) and (2)
Voltage
Max. 1 V
Between TM36 (female) (9) and (2)
Voltage
Max. 1 V
Between TM36 (female) (10) and (2)
Voltage
Max. 1 V
Between TM36 (female) (11) and (2)
Voltage
Max. 1 V
Between TM36 (female) (12) and (2)
Voltage
Max. 1 V
Between TM36 (female) (13) and (2)
Voltage
Max. 1 V
Between TM36 (female) (14) and (2)
Voltage
Max. 1 V
Between TM36 (female) (15) and (2)
Voltage
Max. 1 V
3
Failure of gear shift lever Perform troubleshooting for failure code [DF10KA].
4
Failure of transmission controller
40-316
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) Reference When you check the voltage, see failure code [DF10KA].
GD535-5 (03)
40 Troubleshooting
Failure code [DF10L4] Gear Speed/Travel Direction Signal Error
Circuit diagram related to gear shift lever
GD535-5 (03)
40-317
Failure code [DGF1KX] Out of Range of T/M Oil Temp. Sensor
40 Troubleshooting
Failure code [DGF1KX] Out of Range of T/M Oil Temp. Sensor Action code
Failure code
L03
DGF1KX
Failure
1
Out of range of transmission oil temperature sensor (Transmission controller system)
Detail of failure The signal of transmission oil temperature sensor is outside of normal range (0.9 to 4.5 V). Action of controller Problem on machine
q q
Large shock occurs during gear shift. q
Related information
No.
Flashes the centralized warning lamp and sounds the alarm buzzer. If cause of failure disappears, machine becomes normal by itself.
q
The input voltage and temperature sent from transmission oil temperature sensor can be checked by the monitoring function. (Code: 32501, 32500) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM19, and connect T-adapter to male side.
1
Between TM19 (male) (1) and (2) Failure of transmission oil (Temperature characteristics of oil temperature sensor temperature sensor) Between TM19 (male) (1) and ground, and between TM19 (male) (2) and ground
2
Open or short circuit in wiring harness
25°C
Resistance
38 to 49 kz
100°C
Resistance
3.7 to 4.0 kz
All ranges
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector TM39, and connect T-adapter to female side. a The resistance is the same as for the temperature characteristics table of oil temperature sensor in cause 1 (25°C to 100°C). Between TM39 (female) (3) and (21)
3
4
5
Open circuit in wiring harness
Ground fault in wiring harness
Hot short or short circuit of wiring harness Failure of transmission controller
40-318
3.7 to 49 kz
If no failure is found by check on cause 2, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors TM39 and TM19, and connect T-adapter to each female side. Between TM39 (female) (3) and TM19 (female) (2)
Resistance
Max. 1 z
Between TM39 (female) (21) and TM19 (female) (1)
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM19 and TM39, and connect T-adapter to either female side. Between TM19 (female) (2) or TM39 (female) (3) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector TM19, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between TM19 (female) (1) and (2)
6
Resistance
Voltage
Approx. 5 V
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [DGF1KX] Out of Range of T/M Oil Temp. Sensor
Circuit diagram related to transmission oil temperature sensor
GD535-5 (03)
40-319
Failure code [DGH2KB] Ground Fault of Hydraulic Oil Temp. S
40 Troubleshooting
Failure code [DGH2KB] Ground Fault of Hydraulic Oil Temp. S Action code
Failure code
L01
DGH2KB
Detail of failure Action of controller
Failure
1
Ground fault of hydraulic temperature sensor (Transmission system)
Hydraulic temperature Min. 150°C (Max. 0.97 V) was detected. (Hydraulic temperature signal circuit is shorted to ground.) If cause of failure disappears, machine becomes normal by itself.
Problem on machine Related information
No.
The input voltage and temperature sent from hydraulic oil temperature sensor can be checked by the monitoring function. (Code: 04404, 04401)
Cause
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector R17, and connect T-adapter to male side.
1
Failure of hydraulic oil temperature sensor
Between R17 (male) (1) and (2) (Temperature characteristics of oil temperature sensor) Between R17 (male) (1) and ground, and between R17 (male) (2) and ground
2
Ground fault in wiring harness
25°C
Resistance
38 to 49 kz
100°C
Resistance
3.7 to 4.0 kz
- (Always)
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM39 and R17, and connect T-adapter to either female side. Between TM39 (female) (20) or R17 (female) (1) and ground
Resistance
Min. 1 Mz
Hydraulic oil temperature: 25°C
Voltage
4.4 to 4.6 V
Hydraulic oil temperature: 100°C
Voltage
2.1 to 2.3 V
1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector TM39. 3. Turn starting switch to ON position. 3
Failure of transmission controller Between TM39 (20) and (21)
40-320
GD535-5 (03)
40 Troubleshooting
Failure code [DGH2KB] Ground Fault of Hydraulic Oil Temp. S
Circuit diagram related to hydraulic oil temperature sensor
GD535-5 (03)
40-321
Failure code [DGT1KX] Out of Range of T/C Oil Temp. Sensor
40 Troubleshooting
Failure code [DGT1KX] Out of Range of T/C Oil Temp. Sensor Action code
Failure code
L01
DGT1KX
Failure
1
Out of range of torque converter oil temperature sensor input signal (Transmission controller system)
Detail of failure The signal of torque converter oil temperature sensor is outside of normal range (0.9 to 4.5 V). Action of controller
q
Problem on machine
q
q
q q
Related information
No.
q
Sends the torque converter oil temperature as the abnormal value to the machine monitor. If cause of failure disappears, machine becomes normal by itself. An overheated torque converter cannot be sensed. Large shock occurs during gear shift. The input voltage and temperature sent from the torque converter oil temperature sensor can be checked by the monitoring function. (Code: 30101, 30100) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM17, and connect T-adapter to male side.
1
Failure of torque converter oil temperature Between TM17 (male) (1) and (2) sensor
Between TM17 (male) (1) or (2) and ground
2
Open or short circuit in wiring harness
25°C
Resistance
38 to 49 kz
100°C
Resistance
3.7 to 4.0 kz
All ranges
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector TM39, and connect T-adapter to female side. a The resistance is the same as for the temperature characteristics table of oil temperature sensor in cause 1 (25°C to 100°C). Between TM39 (female) (9) and (21)
3
4
5
Open circuit in wiring harness
Ground fault in wiring harness
Hot short or short circuit of wiring harness Failure of transmission controller
40-322
3.7 to 49 kz
If no failure is found by check on cause 2, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors TM39 and TM17, and connect T-adapters to each female side. Between TM39 (female) (9) and TM17 (female) (1)
Resistance
Max. 1 z
Between TM39 (female) (21) and TM17 (female) (2)
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM17 and TM39, and connect T-adapter to either female side. Between TM17 (female) (1) or TM39 (female) (9) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector TM17, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between TM17 (female) (1) and (2)
6
Resistance
Voltage
Approx. 5 V
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [DGT1KX] Out of Range of T/C Oil Temp. Sensor
Circuit diagram related to torque converter oil temperature sensor
GD535-5 (03)
40-323
Failure code [DGT7KB] Ground Fault of Diff Oil Temp. S.(C)
40 Troubleshooting
Failure code [DGT7KB] Ground Fault of Diff Oil Temp. S.(C) Action code
Failure code
L01
DGT7KB
Detail of failure Action of controller
Failure
1
Ground fault of differential gear oil temperature sensor (Transmission system)
Differential gear oil temperature Min. 150°C (Max. 0.97 V) was detected. (Differential lock oil temperature signal circuit is shorted to ground.) q q
Overheat of differential gear oil temperature is not detected. Turns ON the output to differential lock relay.
Problem on machine
The differential gear lock is turned OFF independent from switching.
Related information
The input voltage and temperature sent from differential gear oil temperature sensor can be checked by the monitoring function. (Code: 31910, 31909)
No.
Cause
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector R8, and connect T-adapter to male side.
1
Failure of differential gear Between R8 (male) (1) and (2) oil temperature sensor (Temperature characteristics of oil temperature sensor) Between R8 (male) (1) or (2) and ground
2
Ground fault in wiring harness
25°C
Resistance
38 to 49 kz
100°C
Resistance
3.7 to 4.0 kz
- (Always)
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM39 and R8, and connect T-adapter to either female side. Between TM39 (female) (14) or R8 (female) (1) and ground
Resistance
Min. 1 Mz
Hydraulic oil temperature: 25°C
Voltage
4.4 to 4.6 V
Hydraulic oil temperature: 100°C
Voltage
2.1 to 2.3 V
1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector TM39. 3. Turn starting switch to ON position. 3
Failure of transmission controller
Between TM39 (14) and ground
Circuit diagram related to differential gear oil temperature sensor
40-324
GD535-5 (03)
40 Troubleshooting
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor Action code
Failure code
L01
DHT5KX
Failure
1
Out of Range of torque converter input pressure sensor (Transmission controller system)
Detail of failure The voltage of torque converter oil pressure sensor has dropped below 0.3V or exceeded above 4.7V. Action of controller Problem on machine
Sets the torque converter oil pressure to the specified oil pressure inside of controller, and controls it. Large shock occurs during lock up. q
Related information
No.
q
The input voltage and temperature sent from torque converter oil temperature sensor can be checked by the monitoring function. (Code: 30101, 30100) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine.
Cause
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM39, and connect T-adapter to female side. 3. Disconnect connector TM18, and connect T-adapter to female side.
1
Ground fault in wiring harness
Between TM39 (female) (22) or TM18 (female) (3) and ground Between TM39 (female) (2) or TM18 (female) (2) and ground
2
Hot short circuit in wiring harness
Failure of sensor power supply system
Failure of torque converter oil pressure sensor
Min. 1 Mz
Voltage
Max. 1 V
1. Turn the starting switch to OFF position. 2. Disconnect connector TM18, and connect T-adapter to female side. 3. Turn starting switch to ON position. If power supply voltage is abnormal, go to check on cause 5. Between TM18 (1) and (3) (female)
4
Resistance
1. Turn the starting switch to OFF position. 2. Disconnect connector TM18, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between TM18 (female) (2) and ground
3
Min. 1 Mz
Power supply voltage
4 to 6 V
Sensor output voltage
0.3 to 1.5 V
1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector TM18. 3. Turn starting switch to ON position. Between TM18 (2) and (1)
1. Turn the starting switch to OFF position. 2. Disconnect connector TM39, and connect T-adapter to female side. 3. Disconnect connector TM18, and connect T-adapter to female side. 5
Open circuit in wiring harness
If the power voltage is normal, this check is not required. Between TM39 (female) (22) and TM18 (female) (3) If the power voltage is normal, this check is not required. Between TM39 (21) (female) and TM18 (female) (1) Between TM39 (2) (female) and TM18 (female) (2)
GD535-5 (03)
Max. 1 z Resistance
Max. 1 z Max. 1 z
40-325
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor
No.
Cause
40 Troubleshooting
Procedure, measuring location, criteria, and remarks If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
6
Failure of transmission controller
Reference 1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector TM39. 3. Turn starting switch to ON position. Between TM39 (21) and (22) Between TM39 (2) and (21)
Voltage
4 to 6 V 0.3 to 1.5 V
Circuit diagram related to torque converter oil temperature sensor
40-326
GD535-5 (03)
40 Troubleshooting
Failure code [DHT5L6] Failure of T/C Oil Press Sensor
Failure code [DHT5L6] Failure of T/C Oil Press Sensor Action code
Failure code
L01
DHT5L6
Failure
1
Failure of torque converter oil pressure sensor (Transmission controller system)
Transmission controller detects oil pressure corresponding to the input voltage from torque converter oil Detail of failure pressure sensor. (Even after engine is stopped, output voltage of torque converter oil pressure sensor does not drop.) (Input voltage: Min. 0.66 V) Action of controller Problem on machine
Sets the torque converter oil pressure to the specified oil pressure inside of controller, and controls it. Large shock occurs during lock up. q
Related information
No.
1
q
The input voltage and temperature sent from torque converter oil temperature sensor can be checked by the monitoring function. (Code: 30101, 30100) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position, and wait for 10 seconds.
Cause
Hot short circuit in wiring harness
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector TM39. 3. Disconnect connector TM18, and connect T-adapter to female side. 4. Turn starting switch to ON position. Ignore the displayed failure codes. Between TM39 (2) or TM18 (female) (2) and ground
2
Failure of torque converter oil pressure sensor
Voltage
Max. 1 V
1. Turn the starting switch to OFF position. 2. Disconnect connector TM18. 3. Turn starting switch to ON position. This is because the connector is unplugged, ignore failure code [DHT5KX]. If failure code [DHT5L6] is no longer displayed, the torque converter oil pressure sensor has failed. If failure code [DHT5L6] is displayed, the wiring harness or transmission controller has failed. If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
3
Failure of transmission controller
Reference 1. Turn the starting switch to OFF position. 2. Disconnect connector TM39. 3. Turn starting switch to ON position. Between TM39 (21) and (22) Between TM39 (2) and (21)
GD535-5 (03)
Voltage
4 to 6 V 0.3 to 1.5 V
40-327
Failure code [DHT5L6] Failure of T/C Oil Press Sensor
40 Troubleshooting
Circuit diagram related to torque converter oil temperature sensor
40-328
GD535-5 (03)
40 Troubleshooting
Failure code [DJF1KA] Disconnection of Fuel Level Sensor
Failure code [DJF1KA] Disconnection of Fuel Level Sensor Action code
Failure code
L01
DJF1KA
Failure
1
Open circuit of fuel level sensor (Machine monitor system)
Detail of failure The fuel level sensor circuit was opened. Action of controller Problem on machine
None in particular Fuel gauge is displayed abnormally. q
Related information
No.
q
The input resistance and voltage from the fuel level sensor can be checked with monitoring function. (Code: 04201, 04200) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector ET39, and connect T-adapter to male side.
1
2
3
4
Failure of fuel level sensor
Open or short circuit in wiring harness
Open circuit in wiring harness
Hot short or short circuit of wiring harness
Between ET39 (male) (1) and (2) (Fuel level characteristics table)
Defective machine monitor
GD535-5 (03)
Resistance
Max. 7 z
3/4
Resistance
(10 z)
1/2
Resistance
32 z
1/4
Resistance
(50 z)
EMPTY
Resistance
Min. 85 z
1. Turn the starting switch to OFF position. 2. Disconnect connector TM39, and connect T-adapter to female side. Between TM39 (female) (19) and ground Resistance accords with the fuel level sensor characteristics table in cause 1.
Resistance
10 to 80 z
If no failure is found by check on cause 2, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors TM39 and ET39, and connect T-adapter to each female side. Between TM39 (female) (19) and ET39 (female) (1)
Resistance
Max. 1 z
Between ET39 (female) (2) and ground
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connector ET39, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between ET39 (female) (1) and (2)
5
FULL
Voltage
Approx. 3 to 5 V
If no failure is found by above checks, the machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-329
Failure code [DJF1KA] Disconnection of Fuel Level Sensor
40 Troubleshooting
Circuit diagram related to fuel level sensor
40-330
GD535-5 (03)
40 Troubleshooting
Failure code [DK70KX] Out of Range of Inching Potentio.
Failure code [DK70KX] Out of Range of Inching Potentio. Action code
Failure code
L03
DK70KX
Failure
1
Out of range of inching potentiometer input signal (Transmission controller system)
Detail of failure The signal of inching angle sensor of the inching pedal is outside of normal range (0.4 to 4.5 V). Action of controller Problem on machine
q q q
Inching function does not work normally. q
Related information
No.
Flashes the centralized warning lamp and sounds the alarm buzzer. Disables inching by shifting the lever to Neutral position. If cause of failure disappears, machine becomes normal by itself when gear shift lever is in N position.
q
Input voltage from inching pedal angle sensor can be checked with monitoring function. (Code: 44105) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position. + Operating of inching pedal
Cause
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector FL6, and connect T-adapter to male side.
1
2
3
4
5
Failure of inching angle sensor
Open circuit in wiring harness
Ground fault in wiring harness
Hot short circuit in wiring harness
Failure of transmission controller
Between FL6 (male) (A) and (C)
Resistance
4.0 to 6.0 kz
Between FL6 (male) (B) and (A)
Resistance
0.25 to 5.0 kz*
Between FL6 (male) (B) and (C)
Resistance
0.25 to 5.0 kz*
1. Turn the starting switch to zOFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM39, TM40 and FL6, and connect T-adapters to each female side. Between TM39 (female) (21) and FL6 (female) (C)
Resistance
Max. 1 z
Between TM39 (female) (7) and FL6 (female) (B)
Resistance
Max. 1 z
Between TM40 (female) (1) and FL6 (female) (A)
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM39, TM40 and FL6, and connect T-adapter to either female side. Between TM40 (female) (1) or FL6 (female) (A) and ground
Resistance
Min. 1 Mz
Between TM39 (female) (7) or FL6 (female) (B) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector FL6, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between FL6 (female) (A) and (C)
Voltage
Approx. 5 V
Between FL6 (female) (B) and (C)
Voltage
Max. 2.5 V
Between TM40 (1) and TM39 (21)
Voltage
4.6 to 5.4 V
Between TM39 (7) and (21)
Voltage
0.4 to 4.5 V
1. 2. 3. 4. 5.
Turn the starting switch to OFF position. Disconnect cable from negative (-) battery terminal. Insert T-adapters into connectors TM39 and TM40. Connect negative (-) battery terminal. Turn starting switch to ON position.
* When you repeat to press the inching pedal, its resistance changes.
GD535-5 (03)
40-331
Failure code [DK70KX] Out of Range of Inching Potentio.
40 Troubleshooting
Circuit diagram related to inching pedal angle sensor
40-332
GD535-5 (03)
40 Troubleshooting
Failure code [DKD0KX] Out of Range of Articulated Angle Sensor
Failure code [DKD0KX] Out of Range of Articulated Angle Sensor Action code
Failure code
L01
DKD0KX
Failure
1
Out of range of articulated angle sensor input (Transmission controller system)
Detail of failure Signal of articulated angle sensor has exceeded the normal range. Action of controller Problem on machine
If cause of failure disappears, machine becomes normal by itself. The articulated angle sensor is not displayed correctly. q
Related information
q
q
No.
1
Input voltage from articulated angle sensor can be checked with monitoring function. (Code: 43900) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Articulated operation See "Articulated meter display is abnormal" for E mode.
Cause
Failure of articulated angle sensor
Procedure, meas(1)uring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector B11, and connect T-adapter to male side. 3. Turn starting switch to OFF and perform troubleshooting. Then, connect the connector into its position. 4. Start engine, change the articulated angle, and return to Step 1. Between B11 (male) (A) and (B)
Center
Resistance
Approx. 2.5 kz
Left end stroke (25°) Right end stroke (25°)
Resistance
Approx. 1 to 3.8 kz
Resistance
Approx. 5 kz
Between B11 (male) (A) and (C)
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM39 and B11, and connect T-adapters to each female side. 2
Open circuit in wiring harness
Between TM39 (female) (8) and B11 (female) (B)
Resistance
Max. 1 z
Between TM39 (female) (21) and B11 (female) (A)
Resistance
Max. 1 z
Between TM39 (female) (22) and B11 (female) (C)
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM39 and B11, and connect T-adapter to either female side. 3
4
Ground fault in wiring harness
Hot short circuit in wiring harness
GD535-5 (03)
Between TM39 (female) (8) or B11 (female) (B) and ground
Resistance
Min. 1 Mz
Between TM39 (female) (22) or B11 (female) (C) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector B11, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between B11 (female) (B) and (A)
Voltage
Max. 3 V
Between B11 (female) (C) and (A)
Voltage
Approx. 5 V
40-333
Failure code [DKD0KX] Out of Range of Articulated Angle Sensor
No.
5
Cause
Failure of transmission controller
40 Troubleshooting
Procedure, meas(1)uring location, criteria, and remarks 1. 2. 3. 4.
Turn the starting switch to OFF position. Insert T-adapter into connector TM39. Turn starting switch to ON position, then perform troubleshooting. Start engine, change the articulated angle, and return to Step 3.
Between TM39 (8) and (21) Between TM39 (22) and (21)
Center
Voltage
Approx. 2.4 V
Left end (25°) Right end (25°)
Voltage
Approx. 1 to 3.8 V
Voltage
Approx. 5 V
Circuit diagram related to articulated angle sensor
40-334
GD535-5 (03)
40 Troubleshooting
Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor
Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor Action code
Failure code
L03
DLF1KA
Failure
1
Disconnection of transmission input shaft speed sensor (Transmission controller system)
Detail of failure As the circuit of transmission input shaft speed sensor was opened, the speed signal is not entered. q
Action of controller
Problem on machine
q q q
q q q
Related information
No.
1
2
3
q
Flashes the centralized warning lamp and sounds the alarm buzzer. Fixes the relative engine speed to 300 rpm, and controls it. Keeps to turn OFF the output to lockup clutch. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. A clutch slip cannot be ascertained. The lockup mechanism does not work. The transmission input shaft speed and the input speed sent from the sensor can be checked by the monitoring function. (Code: 31200) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Travel
Cause Failure of transmission input shaft speed sensor Poor adjustment of transmission input shaft speed sensor
Open or short circuit in wiring harness
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM20, and connect T-adapter to male side. Between TM20 (male) (1) and (2)
5
Open circuit in wiring harness
Failure of transmission controller
GD535-5 (03)
500 to 1,000 z
The transmission input shaft speed sensor may be adjusted incorrectly. Adjust it by referring to Testing and adjusting, "Adjusting the transmission speed sensor". 1. Turn the starting switch to OFF position. 2. Disconnect connector TM40, and connect T-adapter to female side. If resistance is 1 Mz or higher, wiring harness has open circuit. If it is 1 z or below, wiring harness has short circuit. Between TM40 (female) (40) and (39)
4
Resistance
Resistance
500 to 1000 z
If no failure is found by check on cause 2, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40 and TM20, and connect T-adapter to each female side. Between TM40 (female) (40) and TM20 (female) (1)
Resistance
Max. 1 z
Between TM40 (female) (39) and TM20 (female) (2)
Resistance
Max. 1 z
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-335
Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor
40 Troubleshooting
Circuit diagram related to transmission input shaft speed sensor
40-336
GD535-5 (03)
40 Troubleshooting
Failure code [DLF1LC] Failure of T/M Input Speed Sensor
Failure code [DLF1LC] Failure of T/M Input Speed Sensor Action code
Failure code
L03
DLF1LC
Detail of failure
Problem on machine
q q q
q q q
Related information
No.
Hot short or ground fault of transmission input shaft speed sensor (Transmission controller system)
Although each clutch of L/U, FH, FL, R, 1, 2, 3 and 4 operates normally, the speed signal sent from transmission input shaft speed sensor is abnormal. q
Action of controller
Failure
1
q
Flashes the centralized warning lamp and sounds the alarm buzzer. Fixes the relative speed to 300 rpm, and controls it. Keeps to turn OFF the output to lockup clutch. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. A clutch slip cannot be judged. The lockup mechanism does not work. The input shaft speed sent from the transmission input shaft speed sensor can be checked by the monitoring function. (Code: 31200) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Travel
Cause
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM20, and connect T-adapter to male side.
1
2
Failure of transmission input shaft speed sensor
Open or short circuit in wiring harness
Between TM20 (male) (1) and (2)
Resistance
500 to 1000 z
Between TM20 (male) (1) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector TM40, and connect T-adapter to female side. If resistance is 1 Mz or higher, wiring harness has open circuit. If it is 1 z or below, wiring harness has short circuit. Between TM40 (female) (40) and (39)
3
4
Ground fault in wiring harness
Hot short circuit in wiring harness Failure of transmission controller
GD535-5 (03)
500 to 1000 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40 and TM20, and connect T-adapter to either female side. Between TM40 (female) (40) or TM20 (female) (39) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector TM20, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between TM20 (female) (1) and (2)
5
Resistance
Voltage
3 to 4 V
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-337
Failure code [DLF1LC] Failure of T/M Input Speed Sensor
40 Troubleshooting
Circuit diagram related to transmission input shaft speed sensor
40-338
GD535-5 (03)
40 Troubleshooting
Failure code [DLF2KA] Disconnection of T/M Inter. Speed Sensor
Failure code [DLF2KA] Disconnection of T/M Inter. Speed Sensor Action code
Failure code
L03
DLF2KA
Failure
1
Disconnection of transmission intermediate shaft speed sensor (Transmission controller system)
Detail of failure As the circuit of transmission intermediate shaft speed sensor is opened, the speed signal is not entered. q
Action of controller Problem on machine
q q
A clutch slip cannot be judged. q
Related information
Flashes the centralized warning lamp and sounds the alarm buzzer. Fixes the relative speed to 300 rpm, and controls it. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
The input shaft speed sent from the transmission intermediate shaft speed sensor can be checked by the monitoring function. (Code: 31300) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Travel
No.
Cause
1
Failure of transmission intermediate shaft speed sensor
2
3
Poor adjustment of transmission intermediate shaft speed sensor
Open or short circuit in wiring harness
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM21, and connect T-adapter to male side. Between TM21 (male) (1) and (2)
5
Open circuit in wiring harness
Failure of transmission controller
GD535-5 (03)
500 to 1000 z
The transmission intermediate shaft speed sensor may be adjusted incorrectly. Adjust it by referring to Testing and adjusting, "Adjusting the transmission speed sensor". 1. Turn the starting switch to OFF position. 2. Disconnect connector TM40, and connect T-adapter to female side. If resistance is 1 Mz or higher, wiring harness has open circuit. If it is 1 z or below, wiring harness has short circuit. Between TM40 (female) (20) and (29)
4
Resistance
Resistance
500 to 1000 z
If no failure is found by check on cause 3, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40 and TM21, and connect T-adapters to each female side. Between TM40 (female) (20) and TM21 (female) (1)
Resistance
Max. 1 z
Between TM40 (female) (29) and TM21 (female) (2)
Resistance
Max. 1 z
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-339
Failure code [DLF2KA] Disconnection of T/M Inter. Speed Sensor
40 Troubleshooting
Circuit diagram related to transmission intermediate shaft speed sensor
40-340
GD535-5 (03)
40 Troubleshooting
Failure code [DLF2LC] Failure of T/M Intermediate Speed Sensor
Failure code [DLF2LC] Failure of T/M Intermediate Speed Sensor Action code
Failure code
L03
DLF2LC
Detail of failure
Problem on machine
q q
No.
1
2
Flashes the centralized warning lamp and sounds the alarm buzzer. Fixes the relative speed to 300 rpm, and controls it. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
A clutch slip cannot be judged. q
Related information
Hot short or ground fault of transmission intermediate shaft speed sensor (Transmission controller system)
Although each clutch of L/U, FH, FL, R, 1, 2, 3 and 4 operates normally, the speed signal sent from transmission intermediate shaft speed sensor is abnormal. q
Action of controller
Failure
q
The input shaft speed sent from the transmission intermediate shaft speed sensor can be checked by the monitoring function. (Code: 31300) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Travel
Cause
Failure of transmission intermediate shaft speed sensor
Open or short circuit in wiring harness
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM21, and connect T-adapter to male side. Between TM21 (male) (1) and (2)
Resistance
500 to 1000 z
Between TM21 (male) (1) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector TM40, and connect T-adapter to female side. If resistance is 1 Mz or higher, wiring harness has open circuit. If it is 1 z or below, wiring harness has short circuit. Between TM40 (female) (20) and (29)
3
4
Ground fault in wiring harness
Hot short circuit in wiring harness Failure of transmission controller
GD535-5 (03)
Resistance
500 to 1000 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40 and TM21, and connect T-adapter to either female side. Between TM40 (female) (20) or TM21 (female) (1) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector TM21, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between TM21 (female) (1) and (2)
5
1
Voltage
3 to 4 V
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-341
Failure code [DLF2LC] Failure of T/M Intermediate Speed Sensor
40 Troubleshooting
Circuit diagram related to transmission intermediate shaft speed sensor
40-342
GD535-5 (03)
40 Troubleshooting
Failure code [DLM3KA] Rad Fan Spd Sen Opn/Shrt Cir
Failure code [DLM3KA] Rad Fan Spd Sen Opn/Shrt Cir Action code
Failure code
L01
DLM3KA q
Detail of failure
Action of controller Problem on machine Related information
No.
1
2
q
q q
Failure
4
5
Radiator Fan Speed Sensor Open Circuit or Hot Short Circuit (Transmission controller system)
No pulse voltage is input from fan speed sensor due to open circuit in fan speed sensor system. This failure code is displayed when the following conditions are satisfied. 1. Input voltage is 3 to 4 V. 2. There is no record of pulse input. Even if cause of failure is eliminated, machine does not become normal until starting switch is turned to OFF position. Stops radiator fan feedback control.
Target fan speed is not reached, and engine may overheat or fuel consumption may increase. q q
Radiator fan speed can be checked with monitoring. (Code: 10009) After completion of repair, check if the failure code is cleared by the following procedure. Procedure: Start the engine.
Cause
Defective radiator fan speed sensor
Procedure, measuring location, criteria, and remarks 4. Turn the starting switch to OFF position. 5. Disconnect connector RT8, and connect T-adapter to male side. Resistance
Between RT8 (male) (1) and (2)
2 to 3 kΩ
Between RT8 (male) (1) and ground
Min. 1 MΩ
1. Turn the starting switch to OFF position. Open circuit, short circuit, 2. Disconnect connector RT8, and connect T-adapter to female side. 3. Turn the starting switch to ON position. ground fault, hot short circuit in wiring harness, REMARK or defective transmission Shake the wiring harness by hand while measuring the voltage. If the voltage becomes 0 V while shaking, wiring harness has open circuit at around this point. controller Voltage
3
1
Open or short circuit in wiring harness
Open circuit in wiring harness (wire breakage or defective contact) Defective transmission controller
GD535-5 (03)
Between RT8 (female) (1) and (2)
1 to 4.5 V
1. Turn the starting switch to OFF position. 2. Disconnect connector TM40, and connect T-adapter to female side. Resistance
Between TM40 (female) (10) and (39)
2 to 3 kΩ
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40 and RT8, and connect T-adapter to each female side. Resistance
Between TM40 (female) (10) and RT8 (female) (1)
Max. 1 Ω
Between TM40 (female) (39) and RT8 (female) (2)
Max. 1 Ω
If no failure is found by preceding checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-343
Failure code [DLM3KA] Rad Fan Spd Sen Opn/Shrt Cir
40 Troubleshooting
Circuit diagram related to radiator fan speed sensor
40-344
GD535-5 (03)
40 Troubleshooting
Failure code [DLM3LC] Rad Fan Spd Sen Sig Error
Failure code [DLM3LC] Rad Fan Spd Sen Sig Error Action code
Failure code
L03
DLM3LC
Failure
1
Radiator Fan Speed Sensor Signal Abnormality (Transmission controller system)
Detail of failure No pulse voltage is input from fan speed sensor due to ground fault in fan speed sensor system. Action of controller Problem on machine Related information
No.
1
2
3
4
5
q q
Even if cause of failure is eliminated, machine does not become normal until starting switch is turned to OFF position. Stops radiator fan feedback control.
Target fan speed is not reached, and engine may overheat or fuel consumption may increase. q q
Radiator fan speed can be checked with monitoring. (Code: 10009) After completion of repair, check if the failure code is cleared by the following procedure. Procedure: Start the engine, and run it in normal direction at 500 rpm and above.
Cause
Defective radiator fan speed sensor
Open or short circuit in wiring harness
Ground fault in wiring harness (contact with GND circuit)
Hot short circuit in wiring harness (contact with 24V circuit) Defective transmission controller
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector RT8, and connect T-adapter to male side. Resistance
Between RT8 (male) (1) and (2)
2 to 3 kΩ
Between RT8 (male) (1) and ground
Min. 1 MΩ
1. Turn the starting switch to OFF position. 2. Disconnect connector TM40, and connect T-adapter to female side. Resistance
Between TM40 (female) (10) and (39)
2 to 3 kΩ
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40 and RT8, and connect T-adapter to either female side. Resistance
Between ground and TM40 (female) (10) or RT8 (female) (1)
Min. 1 MΩ
1. Turn the starting switch to OFF position. 2. Disconnect connector RT8, and connect T-adapter to female side. 3. Turn the starting switch to ON position. Voltage
Between RT8 (female) (1) and (2)
3 to 4 V
If no failure is found by preceding checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to radiator fan speed sensor
GD535-5 (03)
40-345
Failure code [DLM3MB] Rad Fan Spd Sen Error
40 Troubleshooting
Failure code [DLM3MB] Rad Fan Spd Sen Error Action code
Failure code
L01
DLM3MB
Detail of failure Action of controller Problem on machine
Radiator Fan Speed Sensor Function Deterioration (Transmission controller system)
Difference between actual speed and target speed of radiator fan exceeds certain value while engine is running and radiator fan is rotating in normal direction. Stops radiator fan feedback control. Target fan speed is not reached, and engine may overheat or fuel consumption may increase. q
Related information
Failure
1
q q
Target speed of radiator fan can be checked with monitoring. (Code: 10007) Radiator fan speed can be checked with monitoring. (Code: 10009) After completion of repair, check if the failure code is cleared by the following procedure. Procedure: Start the engine.
No.
Cause
1
Variations in performance due to hydraulic oil temperature
Procedure, measuring location, criteria, and remarks q
q
Increase hydraulic oil temperature to 50 °C and above, and turn the starting switch to OFF position once. Then start engine again and check if this failure code is displayed again. If it is displayed again, perform following checks.
2
Defective fan speed sensor system
Perform troubleshooting for failure code [DLM3KA].
3
Internal defect of fan motor
Perform the troubleshooting for H mode, “Fan speed is abnormal (too high or low, or stationary)”.
4
Defective fan pump (brake pump)
Perform troubleshooting for H mode, “Wheel brakes do not work or are weak”.
40-346
GD535-5 (03)
40 Troubleshooting
Failure code [DLT3KA] Disconnection of T/M output Speed Sensor
Failure code [DLT3KA] Disconnection of T/M output Speed Sensor Action code
Failure code
L03
DLT3KA
Failure
1
Disconnection of transmission output shaft speed sensor (Transmission controller system)
Detail of failure As the circuit of transmission output shaft speed sensor was opened, the speed signal is not entered. q q
Action of controller
q q q
Problem on machine
q q q
Related information
No.
1
2
3
q
Flashes the centralized warning lamp and sounds the alarm buzzer. Fixes the relative speed to 300 rpm, and controls it. Holds the current gear during automatic gear shifting. Keeps to turn OFF the output to lockup clutch. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. A clutch slip cannot be judged. The lockup mechanism does not work. The input shaft speed sent from the transmission output shaft speed sensor can be checked by the monitoring function. (Code: 31400) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Travel
Cause Failure of transmission output shaft speed sensor
Procedure, measuring location, criteria, and remarks Turn the starting switch to OFF position. Disconnect connector TM22, and connect T-adapter to male side. Between TM22 (male) (1) and (2)
5
Approx. 500 to 1000 z
Poor adjustment of The transmission output shaft speed sensor may be adjusted incorrectly. Adjust it by transmission output shaft referring to Testing and adjusting, "Adjusting the transmission speed sensor". speed sensor
Open or short circuit in wiring harness
1. Turn the starting switch to OFF position. 2. Disconnect connector TM40, and connect T-adapter to female side. If resistance is 1 Mz or higher, wiring harness has open circuit. If it is 1 z or below, wiring harness has short circuit. Between TM40 (female) (30) and (29)
4
Resistance
Open circuit in wiring harness
Failure of transmission controller
GD535-5 (03)
Resistance
Approx. 500 to 1000 z
If no failure is found by check on cause 3, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40 and TM22, and connect T-adapters to each female side. Between TM40 (female) (30) and TM22 (female) (1)
Resistance
Max. 1 z
Between TM40 (female) (29) and TM22 (female) (2)
Resistance
Max. 1 z
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-347
Failure code [DLT3KA] Disconnection of T/M output Speed Sensor
40 Troubleshooting
Circuit diagram related to transmission output shaft speed sensor
40-348
GD535-5 (03)
40 Troubleshooting
Failure code [DW4BKA] Disconnection of Parking Brake Valve
Failure code [DW4BKA] Disconnection of Parking Brake Valve Action code
Failure code
L03
DW4BKA
Failure
1
Disconnection of parking brake valve output (Transmission controller system)
The parking brake solenoid circuit has opened, and the parking brake is not released normally. Detail of failure (When the controller tried to flow current through the parking brake solenoid valve, the current does not flow. Otherwise, current flows from any circuit to the parking brake solenoid valve.) Action of controller Problem on machine
Flashes the centralized warning lamp and sounds the alarm buzzer. The parking brake is not released. q
Related information
q q
No. 1
2
After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (to any position other than P position, or to P position). The parking brake is released only when the parking brake solenoid valve can be driven. The output status (ON/OFF) to the parking brake solenoid valve can be checked with monitoring function. (Code: 03705)
Cause Failure of parking brake solenoid valve
Open or short circuit in wiring harness
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector R11, and connect T-adapter to male side. Between R11 (male) (1) and (2)
4
Open circuit in wiring harness
Failure of transmission controller
GD535-5 (03)
2 to 100 z
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connector TM41, and connect T-adapter to female side. If resistance is 1 Mz or higher, wiring harness has open circuit. If it is 1z or below, wiring harness has short circuit. Between TM41 (female) (7) and ground
3
Resistance
Resistance
2 to 100 z
If no failure is found by check on Cause 2, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and R11, and connect T-adapters to each female side. Between TM41 (female) (7) and R11 (female) (1)
Resistance
Max. 1 z
Between R11 (female) (2) and ground
Resistance
Max. 1 z
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-349
Failure code [DW4BKA] Disconnection of Parking Brake Valve
40 Troubleshooting
Circuit diagram related to parking brake solenoid valve
40-350
GD535-5 (03)
40 Troubleshooting
Failure code [DW4BKB] Ground Fault of Parking Brake Valve
Failure code [DW4BKB] Ground Fault of Parking Brake Valve Action code
Failure code
L03
DW4BKB
Detail of failure Action of controller Problem on machine
No.
1
2
Ground fault of parking brake valve output (Transmission controller system)
The parking brake solenoid circuit has shorted, and the parking brake is not released. (When the controller flowed the current through parking brake solenoid valve, abnormal current flowed.) Flashes the centralized warning lamp and sounds the alarm buzzer. The parking brake is not released. q
Related information
Failure
q q
After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (to any position other than P position). The parking brake is released only when the parking brake solenoid valve is operated. The output status (ON/OFF) to the parking brake solenoid can be checked with monitoring function. (Code: 03705)
Cause
Failure of parking brake solenoid
Ground fault in wiring harness
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector R11, and connect T-adapter to male side. Between R11 (male) (1) and (2)
Resistance
2 to 100 z
Between R11 (female) (1) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and R11, and connect T-adapter to either female side. Between TM41 (female) (7) or R11 (female) (1) and ground
3
Short circuit in wiring harness Failure of transmission controller
GD535-5 (03)
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and R11, and connect T-adapter to female side of R11. Between R11 (female) (1) and (2)
4
1
Resistance
Min. 1 Mz
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-351
Failure code [DW4BKB] Ground Fault of Parking Brake Valve
40 Troubleshooting
Circuit diagram related to parking brake solenoid
40-352
GD535-5 (03)
40 Troubleshooting
Failure code [DW4BKY] Hot Short of Parking Brake Solenoid
Failure code [DW4BKY] Hot Short of Parking Brake Solenoid Action code
Failure code
L03
DW4BKY
Failure
1
Hot short of parking brake release solenoid (Transmission controller system)
Detail of failure The parking brake solenoid circuit has hot shorted, and the parking brake does not work. Action of controller
q
Problem on machine
q
q
q q q
Related information
q
Flashes the centralized warning lamp and sounds the alarm buzzer. If cause of failure disappears, machine becomes normal by itself. The parking brake is not released. Auto idle stop does not work. The parking brake is released only when the parking brake solenoid valve is operated. The output status (ON/OFF) to the parking brake solenoid can be checked with monitoring function. (Code: 03705) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (P position).
No.
Cause
1
Hot short circuit in wiring harness
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector R11, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between R11 (female) (1) and ground
Voltage
Max. 4.5 V
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and R11, and connect T-adapter to female side of TM41. Between TM41 (female) (7) and each pin other than pin (7)
2
Short circuit in wiring harness
Between TM41 (female) (7) and each pin of TM40 (female) Failure of transmission controller
GD535-5 (03)
No conductivity
Since T-adapter is not available for connector R1, perform troubleshooting for short circuit at R1 according to the following procedure. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM39, TM40, TM41 and R11, and connect T-adapters to female side of TM39, TM40 and TM41. a Connectors TM39, TM40 and TM41 are used as transmission controller connectors, and they use connector R1 as an intermediate connector. Between TM41 (female) (7) and each pin of TM39 (female)
3
Continuity
Conductive
No continuity No continuity
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-353
Failure code [DW4BKY] Hot Short of Parking Brake Solenoid
40 Troubleshooting
Circuit diagram related to parking brake solenoid
40-354
GD535-5 (03)
40 Troubleshooting
Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup)
Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) Action code
Failure code
L03
DXH1KA
Failure
1
Disconnection of ECMV solenoid output (Lockup clutch) (Transmission controller system)
Detail of failure No current flows during output to lockup clutch ECMV solenoid. q
Action of controller
Problem on machine
q q
q q q
Related information
No. 1
q
Flashes the centralized warning lamp and sounds the alarm buzzer. Keeps to turn OFF the output to lockup clutch ECMV solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. Even if the direct mode is selected by the transmission mode selector switch, the AUTO mode (Torque Converter mode) is always selected. The clutch lockup is released. The output current command value to the lockup clutch ECMV solenoid can be checked with monitoring function. (Code: 31609) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position. + Operate the transmission mode selector switch (DIRECT mode).
Cause
Procedure, measuring location, criteria, and remarks
1. Turn the starting switch to OFF position. Failure of lockup solenoid 2. Disconnect connector TM16, and connect T-adapter to male side. Between TM16 (male) (1) and (2)
2
Open or short circuit in wiring harness
4
Open circuit in wiring harness
Failure of transmission controller
GD535-5 (03)
5 to 15 z
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connector TM41, and connect T-adapter to female side. If resistance is 1 Mz or higher, wiring harness has open circuit. If it is 1 z or below, wiring harness has short circuit. Between TM41 (female) (38) and (13)
3
Resistance
Resistance
5 to 15 z
If no failure is found by check on Cause 2, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and TM16, and connect T-adapters to each female side. Between TM41 (female) (38) and TM16 (female) (1)
Resistance
Max. 1 z
Between TM41 (female) (13) and TM16 (female) (2)
Resistance
Max. 1 z
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-355
Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup)
40 Troubleshooting
Circuit diagram related to lockup solenoid
40-356
GD535-5 (03)
40 Troubleshooting
Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup)
Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) Action code
Failure code
L03
DXH1KB
Failure
1
Ground fault of ECMV solenoid output (Lockup clutch) (Transmission controller system)
Detail of failure Abnormal current flowed during output to lockup clutch ECMV solenoid. q
Action of controller Problem on machine
q q
Even if the DIRECT mode (Mode 1) is selected by the transmission mode selector switch, the Torque Converter mode (Mode 2) is always selected. q
Related information
No.
Flashes the centralized warning lamp and sounds the alarm buzzer. Keeps to turn OFF the output to lockup clutch ECMV solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
The output current command value to the lockup clutch ECMV solenoid can be checked with monitoring function. (Code: 31609) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position. + Operate the transmission mode selector switch (DIRECT mode).
Cause
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM16, and connect T-adapter to male side.
1
2
3
4
Failure of lockup solenoid
Ground fault in wiring harness
Short circuit in wiring harness
Failure of transmission controller
Between TM16 (male) (1) and (2)
Resistance
5 to 15 z
Between TM16 (female) (1) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and TM16, and connect T-adapter to either female side. Between TM41 (female) (38) or TM16 (female) (1) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and TM16, and connect T-adapter to either female side. Between TM41 (female) (38) and (13), or between TM16 (female) (1) and (2)
Resistance
Min. 1 Mz
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to lockup solenoid
GD535-5 (03)
40-357
Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup)
40 Troubleshooting
Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) Action code
Failure code
L03
DXH1KY
Detail of failure Action of controller Problem on machine
No.
Hot short of ECMV solenoid output (Lockup clutch) (Transmission controller system)
As a hot short occurs in the lockup ECMV solenoid system, abnormal voltage is detected when lockup ECMV solenoid output is OFF. q q
q q q q
Related information
Failure
1
q
Lights the centralized warning lamp and sounds the alarm buzzer. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. The lockup clutch is always engaged. The engine may stop. The solenoid may be burnt out. The output current command value to the lockup clutch ECMV solenoid can be checked with monitoring function. (Code: 31609) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM16, and connect T-adapter to male side.
1
2
Failure of lockup solenoid
Hot short circuit in wiring harness
Between TM16 (male) (1) and (2)
Resistance
5 to 15 z
Between TM16 (female) (1) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector TM16, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between TM16 (female) (1) and ground
Voltage
Max. 1 V
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM41 and TM16, and connect T-adapter to female side of TM41. Check by using multimeter in continuity mode. Between TM41 (female) (38) and each pin other than pin (38)
3
4
Short circuit in wiring harness
Failure of transmission controller
40-358
No conductivity (No sound is heard.)
Since T-adapter is not available for connector R1, perform troubleshooting for short circuit at R1 according to the following procedure. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM39 to TM41 and TM16, and connect T-adapters to female side of TM39 to TM41. Check by using multimeter in continuity mode. Between TM41 (female) (38) and each pin of TM39 (female)
No conductivity (No sound is heard.)
Between TM41 (female) (38) and each pin of TM40 (female)
No conductivity (No sound is heard.)
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup)
Circuit diagram related to lockup solenoid
GD535-5 (03)
40-359
Failure code [DXH2KA] Disconnection of ECMV Solenoid (High)
40 Troubleshooting
Failure code [DXH2KA] Disconnection of ECMV Solenoid (High) Action code
Failure code
L03
DXH2KA
Failure
1
Open circuit of ECMV solenoid output (H-clutch) (Transmission controller system)
Detail of failure No current flows during output to FH-clutch ECMV solenoid. q
Action of controller Problem on machine
q q
The FH-clutch is not engaged. q
Related information
No. 1
2
Flashes the centralized warning lamp and sounds the alarm buzzer. Keeps to turn OFF the output to FH-clutch ECMV solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
The output current command value to the FH-clutch ECMV solenoid can be checked with monitoring function. (Code: 31608) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of F2, F4, F6 or F8 position).
Cause Failure of FH-clutch ECMV solenoid
Open or short circuit in wiring harness
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM2, and connect T-adapter to male side. Between TM2 (male) (1) and (2)
4
Open circuit in wiring harness
Failure of transmission controller
40-360
5 to 15 z
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connector TM41, and connect T-adapter to female side. If resistance is 1 Mz or higher, wiring harness has open circuit. If it is 1 zor below, wiring harness has short circuit. Between TM41 (male) (36) and (3)
3
Resistance
Resistance
5 to 15 z
If no failure is found by check on Cause 2, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and TM2, and connect T-adapters to each female side. Between TM41 (female) (36) and TM2 (female) (1)
Resistance
Max. 1 z
Between TM41 (female) (3) and TM2 (female) (2)
Resistance
Max. 1 z
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [DXH2KA] Disconnection of ECMV Solenoid (High)
Circuit diagram related to FH-clutch ECMV solenoid
GD535-5 (03)
40-361
Failure code [DXH2KB] Ground Fault of ECMV Solenoid (High)
40 Troubleshooting
Failure code [DXH2KB] Ground Fault of ECMV Solenoid (High) Action code
Failure code
L03
DXH2KB
Failure
1
Ground fault of ECMV solenoid output (H-clutch) (Transmission controller system)
Detail of failure Abnormal current flows during output to FH-clutch ECMV solenoid. q
Action of controller Problem on machine
q q
The FH-clutch is not engaged. q
Related information
No.
1
2
3
4
Flashes the centralized warning lamp and sounds the alarm buzzer. Keeps to turn OFF the output to FH-clutch ECMV solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
The output current command value to the FH-clutch ECMV solenoid can be checked with monitoring function. (Code: 31608) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of F2, F4, F6 or F8 position).
Cause
Failure of FH-clutch ECMV solenoid
Ground fault in wiring harness
Short circuit in wiring harness
Failure of transmission controller
40-362
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM2, and connect T-adapter to male side. Between TM2 (male) (1) and (2)
Resistance
5 to 15 z
Between TM2 (male) (1) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and TM2, and connect T-adapter to either female side. Between TM41 (female) (36) or TM2 (female) (1) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and TM2, and connect T-adapter to either female side. Between TM41 (female) (36) and (3), or between TM2 (female) (1) and (2)
Resistance
Min. 1 Mz
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [DXH2KB] Ground Fault of ECMV Solenoid (High)
Circuit diagram related to FH-clutch ECMV solenoid
GD535-5 (03)
40-363
Failure code [DXH2KY] Hot Short of ECMV Solenoid (High)
40 Troubleshooting
Failure code [DXH2KY] Hot Short of ECMV Solenoid (High) Action code
Failure code
L03
DXH2KY
Detail of failure Action of controller Problem on machine
No.
1
2
Hot short of ECMV solenoid output (H-clutch) (Transmission controller system)
As a hot short occurs in the FH-clutch ECMV solenoid system, abnormal voltage is detected when FHclutch ECMV solenoid output is OFF. q q
q q q
Related information
Failure
1
q
Lights the centralized warning lamp and sounds the alarm buzzer. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. The FH-clutch is always engaged. If failure code [1500L0] is detected, the gear is shifted to Neutral position. The output current command value to the FH-clutch ECMV solenoid can be checked with monitoring function. (Code: 31608) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause
Failure of FH-clutch solenoid
Hot short circuit in wiring harness
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM2, and connect T-adapter to male side. Between TM2 (male) (1) and (2)
Resistance
5 to 15 z
Between TM2 (female) (1) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector TM2, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between TM2 (female) (1) and ground
Voltage
Max. 1 V
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and TM2, and connect T-adapter to female side of TM41. Check by using multimeter in continuity mode. Between TM41 (female) (36) and each pin other than pin (36)
3
4
Short circuit in wiring harness
Failure of transmission controller
40-364
No conductivity (No sound is heard.)
Since T-adapter is not available for connector R1, perform troubleshooting for short circuit at R1 according to the following procedure. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM39 to TM41 and TM2, and connect T-adapter to female side of TM39 to TM41. Check by using multimeter in continuity mode. Between TM41 (female) (36) and each pin of TM39 (female)
No conductivity (No sound is heard.)
Between TM41 (female) (36) and each pin of TM40 (female)
No conductivity (No sound is heard.)
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [DXH2KY] Hot Short of ECMV Solenoid (High)
Circuit diagram related to FH-clutch solenoid
GD535-5 (03)
40-365
Failure code [DXH3KA] Disconnection of ECMV Solenoid (Low)
40 Troubleshooting
Failure code [DXH3KA] Disconnection of ECMV Solenoid (Low) Action code
Failure code
L03
DXH3KA
Failure
1
Open circuit of ECMV solenoid output (L-clutch) (Transmission controller system)
Detail of failure No current flows during output to FL-clutch ECMV solenoid. q
Action of controller Problem on machine
q q
The FL-clutch is not engaged. q
Related information
No. 1
2
Flashes the centralized warning lamp and sounds the alarm buzzer. Keeps to turn OFF the output to FL-clutch ECMV solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
The output current command value to the FL-clutch ECMV solenoid can be checked with monitoring function. (Code: 31607) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of F1, F3, F5 or F7 position).
Cause Failure of FL-clutch ECMV solenoid
Open or short circuit in wiring harness
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM4, and connect T-adapter to male side. Between TM4 (male) (1) and (2)
4
Open circuit in wiring harness
Failure of transmission controller
40-366
5 to 15 z
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connector TM41, and connect T-adapter to female side. If resistance is 1 Mz or higher, wiring harness has open circuit. If it is 1 z or below, wiring harness has short circuit. Between TM41 (male) (26) and (23)
3
Resistance
Resistance
5 to 15 z
If no failure is found by check on Cause 2, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and TM4, and connect T-adapters to each female side. Between TM41 (female) (26) and TM4 (female) (1)
Resistance
Max. 1 z
Between TM41 (female) (23) and TM4 (female) (2)
Resistance
Max. 1 z
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [DXH3KA] Disconnection of ECMV Solenoid (Low)
Circuit diagram related to FL-clutch ECMV solenoid
GD535-5 (03)
40-367
Failure code [DXH3KB] Ground Fault of ECMV Solenoid (Low)
40 Troubleshooting
Failure code [DXH3KB] Ground Fault of ECMV Solenoid (Low) Action code
Failure code
L03
DXH3KB
Failure
1
Ground fault of ECMV solenoid output (L-clutch) (Transmission controller system)
Detail of failure Abnormal current flows during output to FL-clutch ECMV solenoid. q
Action of controller Problem on machine
q q
The FL-clutch is not engaged. q
Related information
No.
1
2
3
4
Flashes the centralized warning lamp and sounds the alarm buzzer. Keeps to turn OFF the output to FL-clutch ECMV solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
The output current command value to the FL-clutch ECMV solenoid can be checked with monitoring function. (Code: 31607) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of F1, F3, F5, F7 positions).
Cause
Failure of FL-clutch ECMV solenoid
Ground fault in wiring harness
Short circuit in wiring harness
Failure of transmission controller
40-368
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM4, and connect T-adapter to male side. Between TM4 (male) (1) and (2)
Resistance
5 to 15 z
Between TM4 (male) (1) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and TM4, and connect T-adapter to either female side. Between TM41 (female) (26) or TM4 (female) (1) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and TM4, and connect T-adapter to either female side. Between TM41 (female) (26) and (23), or between TM4 (female) (1) and (2)
Resistance
Min. 1 Mz
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [DXH3KB] Ground Fault of ECMV Solenoid (Low)
Circuit diagram related to FL-clutch ECMV solenoid
GD535-5 (03)
40-369
Failure code [DXH3KY] Hot Short of ECMV Solenoid (Low)
40 Troubleshooting
Failure code [DXH3KY] Hot Short of ECMV Solenoid (Low) Action code
Failure code
L03
DXH3KY
Detail of failure Action of controller Problem on machine
No.
1
Hot short of ECMV solenoid output (L-clutch) (Transmission controller system)
As a hot short occurs in the FL-clutch ECMV solenoid system, abnormal voltage is detected when FL-clutch ECMV solenoid output is OFF. q q
q q q
Related information
Failure
1
q
Lights the centralized warning lamp and sounds the alarm buzzer. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. The FL-clutch is always engaged. If failure code [1500L0] is detected, the gear is shifted to Neutral position. The output current command value to the FL-clutch ECMV solenoid can be checked with monitoring function. (Code: 31607) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause
Failure of FL-clutch solenoid
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM4, and connect T-adapter to male side. Between TM4 (male) (1) and (2)
Resistance
5 to 15 z
Between TM4 (female) (1) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector TM4, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between TM4 (female) (1) and ground
Voltage
Max. 1 V
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and TM4, and connect T-adapter to female side of TM41. Check by using multimeter in continuity mode.
2
3
Hot short circuit in wiring harness
Failure of transmission controller
40-370
Between TM41 (female) (26) and each pin other than pin (26)
No conductivity (No sound is heard.)
Since T-adapter is not available for connector R1, perform troubleshooting for short circuit at R1 according to the following procedure. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM39 to TM41 and TM4, and connect T-adapters to female side of TM39 to TM41. Check by using multimeter in continuity mode. Between TM41 (female) (26) and each pin of TM39 (female)
No conductivity (No sound is heard.)
Between TM41 (female) (26) and each pin of TM40 (female)
No conductivity (No sound is heard.)
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [DXH3KY] Hot Short of ECMV Solenoid (Low)
Circuit diagram related to FL-clutch solenoid
GD535-5 (03)
40-371
Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st)
40 Troubleshooting
Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st) Action code
Failure code
L03
DXH4KA
Failure
1
Open circuit of ECMV solenoid output (1st clutch) (Transmission controller system)
Detail of failure No current flows during output to 1st clutch ECMV solenoid. q
Action of controller Problem on machine
q q
The 1st clutch is not engaged. q
Related information
No. 1
2
Flashes the centralized warning lamp and sounds the alarm buzzer. Keeps to turn OFF the output to 1st clutch ECMV solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
The output current command value to the 1st clutch ECMV solenoid can be checked with monitoring function. (Code: 31602) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of F1, F2 or R1 position).
Cause Failure of 1st clutch ECMV solenoid
Open or short circuit in wiring harness
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM11, and connect T-adapter to male side. Between TM11 (male) (1) and (2)
4
Open circuit in wiring harness
Failure of transmission controller
40-372
5 to 15 z
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connector TM41, and connect T-adapter to female side. If resistance is 1 Mz or higher, wiring harness has open circuit. If it is 1 z or below, wiring harness has short circuit. Between TM41 (male) (5) and (13)
3
Resistance
Resistance
5 to 15 z
If no failure is found by check on Cause 2, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and TM11, and connect T-adapter to each female side. Between TM41 (female) (5) and TM11 (female) (1)
Resistance
Max. 1 z
Between TM41 (female) (13) and TM11 (female) (2)
Resistance
Max. 1 z
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st)
Circuit diagram related to clutch ECMV
GD535-5 (03)
40-373
Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st)
40 Troubleshooting
Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) Action code
Failure code
L03
DXH4KB
Failure
1
Ground fault of ECMV solenoid output (1st clutch) (Transmission controller system)
Detail of failure Abnormal current flows during output to the 1st clutch ECMV solenoid. q
Action of controller Problem on machine
q q
The 1st clutch is not engaged. q
Related information
No.
1
2
3
4
Flashes the centralized warning lamp and sounds the alarm buzzer. Keeps to turn OFF the output to 1st clutch ECMV solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
The output current command value to the 1st clutch ECMV solenoid can be checked with monitoring function. (Code: 31602) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of F1, F2 or R1 position).
Cause
Failure of 1st clutch ECMV solenoid
Ground fault in wiring harness
Short circuit in wiring harness
Failure of transmission controller
40-374
Procedure, measuring location, criteria, and remarks Turn the starting switch to OFF position. Disconnect connector TM11, and connect T-adapter to male side. Between TM11 (male) (1) and (2)
Resistance
5 to 15 z
Between TM11 (male) (1) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and TM11, and connect T-adapter to either female side. Between TM41 (female) (5) or TM11 (female) (1) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and TM11, and connect T-adapter to either female side. Between TM41 (female) (5) and (13), or between TM11 (female) (1) and (2)
Resistance
Min. 1 Mz
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st)
Circuit diagram related to 1st clutch ECMV solenoid
GD535-5 (03)
40-375
Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st)
40 Troubleshooting
Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st) Action code
Failure code
L03
DXH4KY
Detail of failure Action of controller Problem on machine
No.
1
2
Hot short of ECMV solenoid output (1st clutch) (Transmission controller system)
As a hot short occurs in the 1st clutch ECMV solenoid system, abnormal voltage is detected when 1st clutch ECMV solenoid output is OFF. q q
q q q
Related information
Failure
1
q
Lights the centralized warning lamp and sounds the alarm buzzer. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. The 1st clutch is always engaged. If failure code [1500L0] is detected, the gear is shifted to Neutral position. The output current command value to the 1st clutch ECMV solenoid can be checked with monitoring function. (Code: 31602) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause
Failure of 1st clutch solenoid
Hot short circuit in wiring harness
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM11, and connect T-adapter to male side. Between TM11 (male) (1) and (2)
Resistance
5 to 15 z
Between TM11 (female) (1) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector TM11, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between TM11 (female) (1) and ground
Voltage
Max. 1 V
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and TM11, and connect T-adapter to female side of TM41. Check by using multimeter in continuity mode. Between TM41 (female) (5) and each pin other than pin (5)
3
4
Short circuit in wiring harness
Failure of transmission controller
40-376
No conductivity (No sound is heard.)
Since T-adapter is not available for connector R1, perform troubleshooting for short circuit at R1 according to the following procedure. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM39 to TM41 and TM11, and connect T-adapters to female side of TM39 to TM41. Check by using multimeter in continuity mode. Between TM41 (female) (5) and each pin of TM39 (female)
No conductivity (No sound is heard.)
Between TM41 (female) (5) and each pin of TM40 (female)
No conductivity (No sound is heard.)
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st)
Circuit diagram related to 1st clutch solenoid
GD535-5 (03)
40-377
Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd)
40 Troubleshooting
Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd) Action code
Failure code
L03
DXH5KA
Failure
1
Open circuit of ECMV solenoid output (2nd clutch) (Transmission controller system)
Detail of failure No current flows during output to 2nd clutch ECMV solenoid. q
Action of controller Problem on machine
q q
The 2nd clutch is not engaged. q
Related information
No. 1
2
Flashes the centralized warning lamp and sounds the alarm buzzer. Keeps to turn OFF the output to 2nd clutch ECMV solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
The output current command value to the 2nd clutch ECMV solenoid can be checked with monitoring function. (Code: 31603) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of F3, F4 or R2 position).
Cause Failure of 2nd clutch ECMV solenoid
Open or short circuit in wiring harness
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM6, and connect T-adapter to male side. Between TM6 (male) (1) and (2)
4
Open circuit in wiring harness
Failure of transmission controller
40-378
5 to 15 z
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connector TM41, and connect T-adapter to female side. If resistance is 1 Mz or higher, wiring harness has open circuit. If it is 1 z or below, wiring harness has short circuit. Between TM41 (male) (15) and (23)
3
Resistance
Resistance
5 to 15 z
If no failure is found by check on Cause 2, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and TM6, and connect T-adapters to each female side. Between TM41 (female) (15) and TM6 (female) (1)
Resistance
Max. 1 z
Between TM41 (female) (23) and TM6 (female) (2)
Resistance
Max. 1 z
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd)
Circuit diagram relating to 2nd clutch ECMV solenoid
GD535-5 (03)
40-379
Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd)
40 Troubleshooting
Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) Action code
Failure code
L03
DXH5KB
Failure
1
Ground fault of ECMV solenoid output (2nd clutch) (Transmission controller system)
Detail of failure Abnormal current flows during output to 2nd clutch ECMV solenoid. q
Action of controller Problem on machine
q q
The 2nd clutch is not engaged. q
Related information
No.
1
2
3
4
Flashes the centralized warning lamp and sounds the alarm buzzer. Keeps to turn OFF the output to 2nd clutch ECMV solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
The output current command value to the 2nd clutch ECMV solenoid can be checked with monitoring function. (Code: 31603) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of F3, F4 or R2 position).
Cause
Failure of 2nd clutch ECMV solenoid
Ground fault in wiring harness
Short circuit in wiring harness
Failure of transmission controller
40-380
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM6, and connect T-adapter to male side. Between TM6 (male) (1) and (2)
Resistance
5 to 15 z
Between TM6 (male) (1) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and TM6, and connect T-adapter to either female side. Between TM41 (female) (15) or TM6 (female) (1) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and TM6, and connect T-adapter to either female side. Between TM41 (female) (15) and (23), or between TM6 (female) (1) and (2)
Resistance
Min. 1 Mz
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd)
Circuit diagram relating to 2nd clutch ECMV solenoid
GD535-5 (03)
40-381
Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd)
40 Troubleshooting
Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd) Action code
Failure code
L03
DXH5KY
Detail of failure Action of controller Problem on machine
No.
1
2
Hot short of ECMV solenoid output (2nd clutch) (Transmission controller system)
As a hot short occurs in the 2nd clutch ECMV solenoid system, abnormal voltage is detected when 2nd clutch ECMV solenoid output is OFF. q q
q q q
Related information
Failure
1
q
Lights the centralized warning lamp and sounds the alarm buzzer. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. The 2nd clutch is always engaged. If failure code [1500L0] is detected, the gear is shifted to Neutral position. The output current command value to the 2nd clutch ECMV solenoid can be checked with monitoring function. (Code: 31603) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause
Failure of 2nd clutch solenoid
Hot short circuit in wiring harness
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM6, and connect T-adapter to male side. Between TM6 (male) (1) and (2)
Resistance
5 to 15 z
Between TM6 (female) (1) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector TM6, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between TM6 (female) (1) and ground
Voltage
Max. 1 V
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and TM6, and connect T-adapter to female side of TM41. Check by using multimeter in continuity mode. Between TM41 (female) (15) and each pin other than pin (15)
3
4
Short circuit in wiring harness
Failure of transmission controller
40-382
No conductivity (No sound is heard.)
Since T-adapter is not available for connector R1, perform troubleshooting for short circuit at R1 according to the following procedure. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM39 to TM41 and TM6, and connect T-adapters to female side of TM39 to TM41. Check by using multimeter in continuity mode. Between TM41 (female) (15) and each pin of TM39 (female)
No conductivity (No sound is heard.)
Between TM41 (female) (15) and each pin of TM40 (female)
No conductivity (No sound is heard.)
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd)
Circuit diagram related to 2nd clutch solenoid
GD535-5 (03)
40-383
Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd)
40 Troubleshooting
Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) Action code
Failure code
L03
DXH6KA
Failure
1
Open circuit of ECMV solenoid output (3rd clutch) (Transmission controller system)
Detail of failure No current flows during output to 3rd clutch ECMV solenoid. q
Action of controller Problem on machine
q q
The 3rd clutch is not engaged. q
Related information
No. 1
2
Flashes the centralized warning lamp and sounds the alarm buzzer. Keeps to turn OFF the output to 3rd clutch ECMV solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
The output current command value to the 3rd clutch ECMV solenoid can be checked with monitoring function. (Code: 31604) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of F5, F6 or R3 position).
Cause Failure of 3rd clutch ECMV solenoid
Open or short circuit in wiring harness
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM8, and connect T-adapter to male side. Between TM8 (male) (1) and (2)
4
Open circuit in wiring harness
Failure of transmission controller
40-384
5 to 15 z
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connector TM41, and connect T-adapter to female side. If resistance is 1 Mz or higher, wiring harness has open circuit. If it is 1 z or below, wiring harness has short circuit. Between TM41 (male) (25) and (3)
3
Resistance
Resistance
5 to 15 z
If no failure is found by check on Cause 2, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and TM8, and connect T-adapters to each female side. Between TM41 (female) (25) and TM8 (female) (1)
Resistance
Max. 1 z
Between TM41 (female) (3) and TM8 (female) (2)
Resistance
Max. 1 z
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd)
Circuit diagram relating to 3rd clutch ECMV solenoid
GD535-5 (03)
40-385
Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd)
40 Troubleshooting
Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) Action code
Failure code
L03
DXH6KB
Failure
1
Ground fault of ECMV solenoid output (3rd clutch) (Transmission controller system)
Detail of failure Abnormal current flows during output to 3rd clutch ECMV solenoid. q
Action of controller Problem on machine
q q
The 3rd clutch is not engaged. q
Related information
No.
1
2
3
4
Flashes the centralized warning lamp and sounds the alarm buzzer. Keeps to turn OFF the output to 3rd clutch ECMV solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
The output current command value to the 3rd clutch ECMV solenoid can be checked with monitoring function. (Code: 31604) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of F5, F6 or R3 position).
Cause
Failure of 3rd clutch ECMV solenoid
Ground fault in wiring harness
Short circuit in wiring harness
Failure of transmission controller
40-386
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM8, and connect T-adapter to male side. Between TM8 (male) (1) and (2)
Resistance
5 to 15 z
Between TM8 (male) (1) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and TM8, and connect T-adapter to either female side. Between TM41 (female) (25) or TM8 (female) (1) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and TM8, and connect T-adapter to either female side. Between TM41 (female) (25) and (3), or between TM8 (female) (1) and (2)
Resistance
Min. 1 Mz
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd)
Circuit diagram relating to 3rd clutch ECMV solenoid
GD535-5 (03)
40-387
Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd)
40 Troubleshooting
Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) Action code
Failure code
L03
DXH6KY
Detail of failure Action of controller Problem on machine
No.
1
2
Hot short of ECMV solenoid output (3rd clutch) (Transmission controller system)
As a hot short occurs in the 3rd clutch ECMV solenoid system, abnormal voltage is detected when 3rd clutch ECMV solenoid output is OFF. q q
q q q
Related information
Failure
1
q
Lights the centralized warning lamp and sounds the alarm buzzer. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. The 3rd clutch is always engaged. If failure code [1500L0] is detected, the gear is shifted to Neutral position. The output current command value to the 3rd clutch ECMV solenoid can be checked with monitoring function. (Code: 31604) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause
Failure of 3rd clutch solenoid
Hot short circuit in wiring harness
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM8, and connect T-adapter to male side. Between TM8 (male) (1) and (2)
Resistance
5 to 15 z
Between TM8 (female) (1) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector TM8, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between TM8 (female) (1) and ground
Voltage
Max. 1 V
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and TM8, and connect T-adapter to female side of TM41. Check by using multimeter in continuity mode. Between TM41 (female) (25) and each pin other than pin (25)
3
4
Short circuit in wiring harness
Failure of transmission controller
40-388
No conductivity (No sound is heard.)
Since T-adapter is not available for connector R1, perform troubleshooting for short circuit at R1 according to the following procedure. 1. Turn starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM39 to TM41 and TM8, and connect T-adapters to female side of TM39 to TM41. Check by using multimeter in continuity mode. Between TM41 (female) (25) and each pin of TM39 (female)
No conductivity (No sound is heard.)
Between TM41 (female) (25) and each pin of TM40 (female)
No conductivity (No sound is heard.)
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd)
Circuit diagram related to 3rd clutch solenoid
GD535-5 (03)
40-389
Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse)
40 Troubleshooting
Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse) Action code
Failure code
L03
DXH7KA
Failure
1
Open circuit of ECMV solenoid output (Reverse clutch) (Transmission controller system)
Detail of failure No current flows during output to clutch ECMV solenoid. q
Action of controller Problem on machine
q q
The R clutch is not engaged. q
Related information
No. 1
2
Flashes the centralized warning lamp and sounds the alarm buzzer. Keeps to turn OFF the output to R-clutch ECMV solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
The output current command value to the R-clutch ECMV solenoid can be checked with monitoring function. (Code: 31606) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of R1 to R4 positions).
Cause
Procedure, measuring location, criteria, and remarks
1. Turn the starting switch to OFF position. Failure of R clutch ECMV 2. Disconnect connector TM13, and connect T-adapter to male side. solenoid Between TM13 (male) (1) and (2) Resistance
Open or short circuit in wiring harness
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connector TM41, and connect T-adapter to female side. If resistance is 1 Mzor higher, wiring harness has open circuit. If it is 1 z or below, wiring harness has short circuit. Between TM41 (male) (16) and (3)
3
4
Open circuit in wiring harness
Failure of transmission controller
40-390
5 to 15 z
Resistance
5 to 15 z
If no failure is found by check on Cause 2, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and TM13, and connect T-adapters to each female side. Between TM41 (female) (16) and TM13 (female) (1)
Resistance
Max. 1 z
Between TM41 (female) (3) and TM13 (female) (2)
Resistance
Max. 1 z
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse)
Circuit diagram related to R clutch ECMV
GD535-5 (03)
40-391
Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse)
40 Troubleshooting
Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) Action code
Failure code
L03
DXH7KB
Failure
1
Ground fault of ECMV solenoid output (Reverse clutch) (Transmission controller system)
Detail of failure Abnormal current flows during output to R clutch ECMV solenoid. q
Action of controller Problem on machine
q q
The R clutch is not engaged. q
Related information
No.
Flashes the centralized warning lamp and sounds the alarm buzzer. Keeps to turn OFF the output to R-clutch ECMV solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
The output current command value to the R-clutch ECMV solenoid can be checked with monitoring function. (Code: 31606) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of R1 to R4 positions).
Cause
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM13, and connect T-adapter to male side.
1
Failure of R clutch ECMV solenoid Between TM13 (male) (1) and (2)
Between TM13 (male) (1) and ground
2
3
4
Ground fault in wiring harness
Short circuit in wiring harness
Failure of transmission controller
40-392
Resistance
5 to 15 z
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and TM13, and connect T-adapter to either female side. Between TM41 (female) (16) or TM13 (female) (1) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and TM13, and connect T-adapter to either female side. Between TM41 (female) (16) and (3), or between TM13 (female) (1) and (2)
Resistance
Min. 1 Mz
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse)
Circuit diagram related to R clutch ECMV
GD535-5 (03)
40-393
Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse)
40 Troubleshooting
Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse) Action code
Failure code
L03
DXH7KY
Detail of failure Action of controller Problem on machine
No.
1
2
Hot short of ECMV solenoid output (Reverse clutch) (Transmission controller system)
As a hot short occurs in the R clutch ECMV solenoid system, abnormal voltage is detected when R clutch ECMV solenoid output is OFF. q q
q q q
Related information
Failure
1
q
Lights the centralized warning lamp and sounds the alarm buzzer. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. The R clutch is always engaged. If failure code [1500L0] is detected, the gear is shifted to Neutral position. The output current command value to the R-clutch ECMV solenoid can be checked with monitoring function. (Code: 31606) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause
Failure of R clutch solenoid
Hot short circuit in wiring harness
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM13, and connect T-adapter to male side. Between TM13 (male) (1) and (2)
Resistance
5 to 15 z
Between TM13 (female) (1) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector TM13, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between TM13 (female) (1) and ground
Voltage
Max. 1 V
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and TM13, and connect T-adapter to female side of TM41. Check by using multimeter in continuity mode. Between TM41 (female) (16) and each pin other than pin (16)
3
4
Short circuit in wiring harness
Failure of transmission controller
40-394
No conductivity (No sound is heard.)
Since T-adapter is not available for connector R1, perform troubleshooting for short circuit at R1 according to the following procedure. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM39 to TM41 and TM13, and connect T-adapters to female side of TM39 to TM41. Check by using multimeter in continuity mode. Between TM41 (female) (16) and each pin of TM39 (female)
No conductivity (No sound is heard.)
Between TM41 (female) (16) and each pin of TM40 (female)
No conductivity (No sound is heard.)
If no failure is found by above checks, the transmission controller has failed. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse)
Circuit diagram related to R clutch solenoid
GD535-5 (03)
40-395
Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th)
40 Troubleshooting
Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th) Action code
Failure code
L03
DXHHKA
Failure
1
Open circuit of ECMV solenoid output (4th clutch) (Transmission controller system)
Detail of failure No current flows during output to 4th clutch ECMV solenoid. q
Action of controller Problem on machine
q q
The 4th clutch is not engaged. q
Related information
No. 1
2
Flashes the centralized warning lamp and sounds the alarm buzzer. Keeps to turn OFF the output to 4th clutch ECMV solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
The output current command value to the 4th clutch ECMV solenoid can be checked with monitoring function. (Code: 31605) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of F7, F8 or R4 position).
Cause Failure of 4th clutch ECMV solenoid system
Open or short circuit in wiring harness
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM15, and connect T-adapter to male side. Between TM15 (male) (1) and (2)
4
Open circuit in wiring harness
Failure of transmission controller
40-396
5 to 15 z
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connector TM41, and connect T-adapter to female side. If resistance is 1 Mz or higher, wiring harness has open circuit. If it is 1 z or below, wiring harness has short circuit. Between TM41 (male) (35) and (23)
3
Resistance
Resistance
5 to 15 z
If no failure is found by check on Cause 2, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and TM15, and connect T-adapters to each female side. Between TM41 (female) (35) and TM15 (female) (1)
Resistance
Max. 1 z
Between TM41 (female) (23) and TM15 (female) (2)
Resistance
Max. 1 z
If no failure is found by above checks, the transmission controller has failed. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th)
Circuit diagram relating to 4th clutch ECMV solenoid
GD535-5 (03)
40-397
Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th)
40 Troubleshooting
Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th) Action code
Failure code
L03
DXHHKB
Failure
1
Ground fault of ECMV solenoid output (4th clutch) (Transmission controller system)
Detail of failure Abnormal current flows during output to 4th clutch ECMV solenoid. q
Action of controller Problem on machine
q q
The 4th clutch is not engaged. q
Related information
No.
1
2
3
4
Flashes the centralized warning lamp and sounds the alarm buzzer. Keeps to turn OFF the output to 4th clutch ECMV solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
The output current command value to the 4th clutch ECMV solenoid can be checked with monitoring function. (Code: 31605) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Start engine. + Shift the lever (any of F7, F8 or R4 position).
Cause
Failure of 4th clutch ECMV solenoid system
Ground fault in wiring harness
Short circuit in wiring harness
Failure of transmission controller
40-398
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connector TM15, and connect T-adapter to male side. Between TM15 (male) (1) and (2)
Resistance
5 to 15 z
Between TM15 (male) (1) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and TM15, and connect T-adapter to either female side. Between TM41 (female) (35) or TM15 (female) (1) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and TM15, and connect T-adapter to either female side. Between TM41 (female) (35) and (23), or between TM15 (female) (1) and (2)
Resistance
Min. 1 Mz
If no failure is found by above checks, the transmission controller has failed. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th)
Circuit diagram relating to 4th clutch ECMV solenoid
GD535-5 (03)
40-399
Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th)
40 Troubleshooting
Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th) Action code
Failure code
L03
DXHHKY
Detail of failure Action of controller Problem on machine
No.
1
2
Ground fault of ECMV solenoid output (4th clutch) (Transmission controller system)
As a hot short occurs in the 4th clutch ECMV solenoid system, abnormal voltage is detected when 4th clutch ECMV solenoid output is OFF. q q
q q q
Related information
Failure
1
q
Lights the centralized warning lamp and sounds the alarm buzzer. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. The 4th clutch is always engaged. If failure code [1500L0] is detected, the gear is shifted to Neutral position. The output current command value to the 4th clutch ECMV solenoid can be checked with monitoring function. (Code: 31605) After the repair has completed, follow the procedure below and check to see that no failure code is displayed. Procedure: Turn starting switch to ON position.
Cause
Failure of 4th clutch solenoid system
Hot short circuit in wiring harness
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM15, and connect T-adapter to male side. Between TM15 (male) (1) and (2)
Resistance
5 to 15 z
Between TM15 (female) (1) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector TM15, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between TM15 (female) (1) and ground
Voltage
Max. 1 V
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM41 and TM15, and connect T-adapter to female side of TM41. Check by using multimeter in continuity mode. Between TM41 (female) (35) and each pin other than pin (35)
3
4
Short circuit in wiring harness
Failure of transmission controller
40-400
No conductivity (No sound is heard.)
Since T-adapter is not available for connector R1, perform troubleshooting for short circuit at R1 according to the following procedure. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connectors TM39 to TM41 and TM15, and connect T-adapters to female side of TM39 to TM41. Check by using multimeter in continuity mode. Between TM41 (female) (35) and each pin of TM39 (female)
No conductivity (No sound is heard.)
Between TM41 (female) (35) and each pin of TM40 (female)
No conductivity (No sound is heard.)
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th)
Circuit diagram related to 4th clutch solenoid
GD535-5 (03)
40-401
E-1 Engine does not start (Starting motor does not rotate).
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
1
E-1 Engine does not start (Starting motor does not rotate).
1
Failure
Starting motor does not rotate, and engine does not start. q q q q
Related information q
q
No.
Since the engine start circuit has the neutral safety function, the engine does not start unless the gear shift lever is in Parking position. Before performing troubleshooting, check that no related failure code is displayed. (If failure code [DDB6L4], [DF10KA] or [DF10L4] is also displayed, perform troubleshooting for it first.) If failure symptom is "Battery relay operation sound is not heard" when starting switch is turned to ON position, perform troubleshooting for E-1 as well. Flow of safety circuit by the shift lever (Parking position detection) Output of shift lever (P) output (Parking position: 24 V; Other than P position: 0 V) ---> Diode SP35 ---> Between safety relay SP17 (15) C input and (3) 24V output: ON (Parking position) / OFF (Other than parking position) Flow of starting switch C signal C signal (ST8 terminal) ---> Safety relay: SP17(5) input, (3) output ---> Engine cut relay SP32 (6) input, (3) output ---> ---> Diode R28 or R29 ---> Safety relay E01 ---> Turn ON input E20 terminal and output E19 terminal. ---> Flow current (from slow-blow fuse E31 terminal) to the starting motor C terminal (E21 terminal). Check the diode before checking the shift lever.
Cause
Procedure, measuring location, criteria, and remarks
1
Blown slow-blow fuse (Holder 2 120A, 120A, Holder 1 30A)
2
Blown fuse FB1 (2) (11) or If fuse No. 2, No. 11 or No. 15 of FB1 fuse box is blown, the circuit may be shorted to (15) ground. In this case, perform check on cause 14 first.
3
Loose terminal or open circuit in terminal
4
Insufficient battery capacity
5
Defective safety relay
If slow-blow fuse has blown, the circuit may be shorted to ground. In this case, perform check on cause 14 first.
1. Turn the starting switch to OFF position. Check the battery relay, alternator, starting motor, each GND (FT11, FT13) terminal and others. Battery voltage
Min. 24 V
Specific gravity of battery
Min. 1.26
1. Turn the starting switch to OFF position. 2. Replace safety relay SP17 with another relay (for example, stop lamp relay SP16) 3. Start engine. If engine starts, original safety relay SP17 is defective.
6
1. Turn the starting switch to OFF position. 2. Replace engine cut relay SP32 with another relay (for example, stop lamp relay SP16) Failure of engine cut relay 3. Start engine. If engine starts, original cut relay SP32 is defective.
7
Defective diode
40-402
1. Turn the starting switch to OFF position. 2. Disconnect connectors R28, R29, R18 and R19, and connect T-adapters to each diode. Measure in the diode range of multimeter. Between each diode (male) (1) (+) and (2) (-)
No continuity
Between each diode (male) (2) (-) and (1) (-)
Conductive
GD535-5 (03)
40 Troubleshooting
No.
E-1 Engine does not start (Starting motor does not rotate).
Cause
Procedure, measuring location, criteria, and remarks 1. Turn starting switch to ON position. 2. Shift the gear shift lever to perform troubleshooting.
8
Failure of gear shift lever
"P" is displayed on machine monitor. 1. 2. 3. 4.
9
Defective starting switch
Lever position: FREE
Other than "P"
P position
"P" display
Turn the starting switch to OFF position. Disconnect cable from negative (-) battery terminal. Disconnect terminals ST6 to 9. (Put an identification mark at the destination point.) Turn starting switch to OFF, ON and START positions, and perform troubleshooting.
Between terminals ST6 and ST7
Between terminals ST6 and ST9
Between terminals ST6 and ST8
10
Defective alternator
OFF
Resistance
Min. 1 Mz
ON
Resistance
Max. 1 z
OFF
Resistance
Min. 1 Mz
ON
Resistance
Max. 1 z
OFF
Resistance
Min. 1 Mz
START
Resistance
Max. 1 z
1. Turn starting switch to ON position. Between terminal R and ground
Voltage
Max. 1 V
1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector E01. 3. Turn starting switch to ON and START positions, and perform troubleshooting.
11
Defective starting motor
Power supply: Between terminal E30 (B) and ground
ON
Voltage
20 to 30 V
Power supply: Between terminal E01 (2) (R) and ground
ON
Voltage
Max. 1 V
START
Voltage
20 to 30 V
Power supply: Between terminal E21 (C) and ground
If voltage of power supply, charging, and starting devices is normal but starting motor does not rotate, the starting motor is defective. Battery relay 1. Turn the starting switch to OFF position. Resistance
Max. 1 z
Between terminal ST7 and ground
Voltage
20 to 30 V
Between terminal ET75 and ground
Voltage
20 to 30 V
Between secondary input terminal of battery relay and ground
Voltage
20 to 30 V
Between secondary output terminal of battery relay and ground
Voltage
20 to 30 V
Between terminal ET76 and ground
12
Open circuit in wiring harness
GD535-5 (03)
Battery relay 1. Turn the starting switch to OFF position. 2. Turn starting switch to ON position. Check the 24V line and locate the open circuit.
40-403
E-1 Engine does not start (Starting motor does not rotate).
No.
Cause
40 Troubleshooting
Procedure, measuring location, criteria, and remarks Alternator, starting motor 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Insert T-adapters into connectors SP17, SP32, E01 and R28. 4. Connect negative (-) battery terminal. 5. Make sure that shift lever is in "P" position. 6. Turn starting switch to START positions, and perform troubleshooting. Check the 24V line and locate the open circuit.
12
Open circuit in wiring harness
Between terminal ST8 and ground
Voltage
20 to 30 V
Between SP17 (1) and ground
Voltage
20 to 30 V
Between SP32 (6) and ground
Voltage
20 to 30 V
Between R28 (2) and ground
Voltage
20 to 30 V
Between E01 (1) and ground
Voltage
20 to 30 V
Between alternator B terminal and ground
Voltage
20 to 30 V
Between terminal E30 and ground
Voltage
20 to 30 V
Resistance
Max. 1 z
Primary circuit of relay SP17 1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector SP17. Check ground terminal FT11 for looseness and rusting. Between SP17 (2) and ground 13
14
15
Defective battery relay
Ground fault in wiring harness
Hot short circuit in wiring harness
When checking the battery relay for cause 12 and if only the voltage is abnormal at secondary output terminal of battery relay, the battery relay is defective. If the slow-blow fuse or fuse is not burnt out, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect the battery ground, battery relay terminal ET75, and battery relay secondary output terminal. Between ST7 and ground
Resistance
Min. 1 Mz
Between ST8 and ground
Resistance
Min. 1 Mz
Between ET75 (wiring harness side) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector E01, and connect T-adapter to female side. 3. Disconnect cable from R terminal of alternator. 4. Turn starting switch to ON position. If a hot short occurs, the charge lamp lights when starting switch is turned to ON position. Between E01 (female) (2) and ground
16
Failure of transmission controller
1. 2. 3. 4. 5.
Voltage
Max. 1 V
Turn the starting switch to OFF position. Disconnect cable from negative (-) battery terminal. Disconnect connector TM41. Connect negative (-) battery terminal. Turn the starting switch to START position.
If the starting motor rotates, the transmission controller is defective.
40-404
GD535-5 (03)
40 Troubleshooting
E-1 Engine does not start (Starting motor does not rotate).
Circuit diagram related to engine starting system
GD535-5 (03)
40-405
E-2 Manual preheating system does not work
40 Troubleshooting
E-2 Manual preheating system does not work Failure
1) Manual preheating system does not work. q q q
Related information
q
q
No.
This troubleshooting describes procedures to be followed when manual preheating does not function to heat the intake air heater mounting section. This machine has "Automatic preheating" and "Manual preheating" functions. When either preheating works, preheating monitor lights up. (When only preheating monitor does not light up, perform troubleshooting for "3) While preheating is working, preheating monitor does not light up"). If failure symptom "Machine monitor displays nothing" or "Battery relay does not make operating sound" appears when starting switch is turned to ON position, main electric power supply system may be defective. In these cases, perform troubleshooting for E-3 and E-1 respectively. Before performing troubleshooting, check that no related failure code is displayed. (If failure code [CA153], [CA154] or [CA2555] or [CA2556] is also displayed, perform troubleshooting for it first.)
Cause
1
Failure of slow-blow fuse
2
Loose terminal or open circuit in terminal
3
4
5
1
Defective diode
Defective intake air heater
Defective starting switch
Procedure, measuring location, criteria, and remarks If the 120A slow-blow fuse of holder 2 has blown, the circuit may be shorted to ground. In this case, perform check on cause 7 first. 1. Turn the starting switch to OFF position. Check terminals of heater relay, battery relay ground ET77, etc. 1. Turn the starting switch to OFF position. 2. Disconnect connectors R31, and connect T-adapter to the diode. Measure in the diode range of multimeter. Between R31 (male) (1) (+) and (2) (-)
No continuity
Between R31 (male) (2) (+) and (1) (-)
Conductive
1. Turn the starting switch to OFF position. 2. Disconnect terminal E07. Between E07 terminal (electrical intake air heater side) and ground
Conductive
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Turn starting switch to OFF and the HEAT positions to perform troubleshooting. Between terminal ST6 and terminal ST10 both at switch side)
OFF
Resistance
Min. 1 Mz
HEAT
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. Between terminal ST10 and ground
Conductive
1. Turn the starting switch to OFF position. 2. Turn starting switch to ON position. 6
Open circuit or ground fault in wiring harness
Between heater relay terminal A and ground
20 to 30 V
1. Turn the starting switch to OFF position. 2. Disconnect terminal ET54. To prevent current from flowing through heater when starting switch is turned to HEAT position 3. Turn starting switch to HEAT position (R1 connection). Between terminal ET82 and ground
40-406
Voltage
Voltage
20 to 30 V
GD535-5 (03)
40 Troubleshooting
No.
7
8
Cause
Ground fault in wiring harness
Defective heater relay
E-2 Manual preheating system does not work
Procedure, measuring location, criteria, and remarks If no failure is found by check on cause 6, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors TM39 and R31 and terminals ET82 and E31. Between heater relay terminal A and ground
Resistance
Min. 1 Mz
Between terminal ET82 (wiring harness side) and ground
Resistance
Min. 1 Mz
If no failure is found by check on cause 6 and if heater relay operation sound is not heard, heater relay is defective.
Circuit diagram related to engine preheat system
GD535-5 (03)
40-407
E-2 Manual preheating system does not work
Failure
2) Automatic preheating system does not work. q
Related information
No. 1
2
40 Troubleshooting
q q q
Automatic preheating starts when charge temperature is below -4°C The charge temperature can be checked by using the monitoring code (Code: 18500). If automatic preheating function does not work, make sure that the manual preheating function works. Engine controller checks primary (coil) side of preheat relay SP40 by reading failure code [CA2555] and [CA2556].
Cause Blown fuse
Defective preheat relay
Procedure, measuring location, criteria, and remarks If fuse No. 4 of FB2 fuse box is blown, the circuit may be shorted to ground. In this case, perform check on cause 5 first. 1. Turn the starting switch to OFF position. 2. Replace preheat relay SP40 with stop lamp relay SP16. 3. Turn starting switch to ON position. If automatic preheating functions when charge temperature is below -4°C, original preheat relay SP40 is defective.
3
Open circuit or ground fault in wiring harness
1. Turn the starting switch to OFF position. 2. Disconnect connector EC2, and connect T-adapter to female side. q If resistance is 1 Mz or higher, wiring harness has open circuit. If it is below 1 z, wiring harness has short circuit. q Resistance of preheat relay coil Between EC2 (female) (40) and ground
4
Open circuit in wiring harness
Between SP40 (female) (3) and FB2 (4)
Ground fault in wiring harness
Continuity Resistance
Max. 1 z
If fuse is not burnt out, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connector SP40, and connect T-adapter to female side. 3. Remove fuse No. 4 of FB2 fuse box. Between SP40 (female) (3) and ground
40-408
200 to 400 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors SP40 and TM39, and connect T-adapter to female side of SP40. 3. Remove fuse No. 4 of FB2 fuse box. Between SP40 (female) (5) and ground
5
Resistance
Resistance
Min. 1 Mz
GD535-5 (03)
40 Troubleshooting
E-2 Manual preheating system does not work
Circuit diagram related to engine preheat system
GD535-5 (03)
40-409
E-2 Manual preheating system does not work
Failure
3) While preheating is working, preheating monitor does not light up. q
Related information
q q
No.
1
2
40 Troubleshooting
This machine has "Automatic preheating" and "Manual preheating" functions. When either preheating works, preheating monitor lights up. The preheating information of transmission controller is transmitted to machine monitor through CAN communication. For the related circuit diagram, see the previous page.
Cause
Open circuit in wiring harness
Ground fault in wiring harness
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connectors SP40 and TM39, and connect T-adapter to each female side. Between SP40 (female) (5) and TM39 (female) (5)
Resistance
Max. 1 z
Between terminal ST10 and TM39 (female) (5)
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connector TM39 and terminal ET82, and connect T-adapter to female side of TM39. Between TM39 (female) (5) and ground
3
Failure of transmission controller
Max. 1 z
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) Reference 1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector TM39. 3. Disconnect terminal ET54. a To prevent current from flowing through heater when starting switch is turned to HEAT position 4. Turn starting switch to HEAT position. Between TM39 (5) and (4)
40-410
Resistance
Voltage
20 to 30 V
GD535-5 (03)
40 Troubleshooting
E-2 Manual preheating system does not work
Circuit diagram related to engine preheat system
GD535-5 (03)
40-411
E-3 When starting switch is turned ON, machine monitor displays nothing.
40 Troubleshooting
E-3 When starting switch is turned ON, machine monitor displays nothing.1 Failure
When starting switch is turned to ON position, machine monitor displays nothing. q
Related information
No.
q
When starting switch is turned to ON position, machine monitor displays KOMATSU logo, screen to input password (if set), and standard screen in that order. When engine is started, the battery voltage may quickly drop according to the temperature and battery conditions. In such case, the display on the machine monitor may disappear temporarily, but this is not a problem.
Cause
Procedure, measuring location, criteria, and remarks
1
Blown slow-blow fuse
If the 30A slow-blow fuse of holder 1 has blown, the circuit may be shorted to ground. In this case, perform check on cause 8 first.
2
Blown fuse
If fuses No. 1 and No. 2 of FB1 fuse box are blown, the circuit may be shorted to ground. In this case, perform check on cause 8 first.
3
Loose terminal or open circuit in terminal
4
Insufficient battery capacity
1. Turn the starting switch to OFF position. Check terminals of battery relay, battery, etc. 1. Turn the starting switch to OFF position.
5
Open circuit or ground fault of wiring harness, or defective starting switch
Battery voltage (2 cells)
Min. 24 V
Specific gravity of battery
Min. 1.26
1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. Disconnect connector FP1, and connect T-adapter to female side. 4. Connect negative (-) battery terminal. If voltage is 0 V, it has open-circuit or ground fault. Between FP1 (female) (6) and (2)
Voltage
20 to 30 V
Voltage
20 to 30 V
Steps 1 to 4 are the same as above. Starting switch ON (ACC connection) Between FP1 (female) (3) and (2)
6
Defective starting switch
1. 2. 3. 4.
Turn the starting switch to OFF position. Disconnect cable from negative (-) battery terminal. Disconnect terminals ST6 and ST9. Turn starting switch to ON and OFF positions, and perform troubleshooting.
Between terminals ST6 and ST9 (Starting switch side)
OFF
Resistance
Min. 1 Mz
ON
Resistance
Max. 1 z
If no failure is found by check on cause 5, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. If fuse is blown, replace it in advance. 4. Disconnect connector FP1, and connect T-adapter to female side. 7
Open circuit in wiring harness
Between FP1 (female) (2) or (7) and ground Check terminal ET89 for looseness and rusting.
Resistance
Max. 1 z
Between FP1 (female) (1) and battery positive (+) terminal
Resistance
Max. 1 z
Steps 1 to 4 are the same as above. 5. Turn starting switch to ON position. (Disconnect cable from negative (-) battery terminal, and connect ACC.) Between FP1 (female) (3) and battery positive (+) terminal
40-412
Resistance
Max. 1 z
GD535-5 (03)
40 Troubleshooting
No.
8
Cause
Ground fault in wiring harness
E-3 When starting switch is turned ON, machine monitor displays nothing.
Procedure, measuring location, criteria, and remarks If no failure is found by check on cause 5, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect cable from negative (-) battery terminal. 3. If fuse is blown, replace it in advance. 4. Disconnect connector FP1, and connect T-adapter to female side. 5. Perform troubleshooting with the starting switch ON and OFF positions (with the negative (-) battery terminal disconnected). Between FP1 (female) (3) and ground
9
Defective machine monitor
GD535-5 (03)
Resistance
Min. 1 Mz
If no failure is found by above checks, the machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-413
E-3 When starting switch is turned ON, machine monitor displays nothing.
40 Troubleshooting
Circuit diagram related to Machine monitor
40-414
GD535-5 (03)
40 Troubleshooting
E-4 LCD panel backlight of machine monitor fails (goes out or flickers).
E-4 LCD panel backlight of machine monitor fails (goes out or flickers). Failure
1
The LCD panel backlight of machine monitor fails (goes out or flickers).
Related information
No.
Cause
1
Defective machine monitor
GD535-5 (03)
Procedure, measuring location, criteria, and remarks Machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-415
E-5 LCD display failure of machine monitor
40 Troubleshooting
E-5 LCD display failure of machine monitor Failure
1
LCD display failure of machine monitor
Related information
No.
Cause
1
Defective machine monitor
40-416
Procedure, measuring location, criteria, and remarks Machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
E-6 The switch of machine monitor switch panel does not work.
E-6 The switch of machine monitor switch panel does not work. Failure
1
The switch of machine monitor switch panel does not work.
Related information
No.
Cause
1
Defective machine monitor
GD535-5 (03)
Procedure, measuring location, criteria, and remarks Machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-417
E-7 Two-switch operation of switch panel on machine monitor does not function.
40 Troubleshooting
E-7 Two-switch operation of switch panel on machine monitor does not function. Failure
1
2 switches operation of switch panel on machine monitor does not function
Related information
No.
Cause
1
Defective machine monitor
40-418
Procedure, measuring location, criteria, and remarks Machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
E-8 Machine monitor buzzer does not sound.
E-8 Machine monitor buzzer does not sound. Failure
1
The machine monitor buzzer does not sound, or it continues to sound.
Related information
No.
Cause
1
Defective machine monitor
GD535-5 (03)
Procedure, measuring location, criteria, and remarks Machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-419
E-9 Some gauges or caution lamps of machine monitor do not work normally.
40 Troubleshooting
E-9 Some gauges or caution lamps of machine monitor do not work normally. Failure Related information
No.
1
Some gauges or lamps do not work normally. Check to see that failure code relating to the machine is not displayed.
Cause
Procedure, measuring location, criteria, and remarks
1
Some sensors or switches Troubleshoot sensors or switches by referring to the failure code. have failed.
2
Failure of CAN communication circuit
Perform troubleshooting by referring to the CAN communication failure code.
3
Defective machine monitor
If no failure is found by above checks, the machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-420
GD535-5 (03)
40 Troubleshooting
E-10 Speedometer or engine speed display is abnormal.
E-10 Speedometer or engine speed display is abnormal. Failure Related information
No.
1
1) Speedometer display is abnormal. The source information of the speedometer (the signal of transmission output shaft speed sensor) is received from transmission controller through CAN communication.
Cause
Procedure, measuring location, criteria, and remarks
1
An error occurred in the transmission output shaft speed sensor system.
If failure code [DLT3KA] is displayed, perform troubleshooting for it first.
2
Clutch slipping
If failure code [15K0MW], [15L0MW], [15M0MW] or [15N0MW] is displayed, perform troubleshooting for it first.
3
Defective machine monitor
If no failure is found by check on cause 1, machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
4
Failure of transmission controller
If no failure is found by checks on cause 1, transmission controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Failure Related information
2) Speedometer display pilot lamp does not work normally. q q
The signal of speedometer display pilot lamp is processed in the machine monitor. The speedometer display pilot lamp lights during "km/h" display mode, and the speed step is displayed during "MPH" display mode.
No.
Cause
1
Defective machine monitor
Failure
No.
Machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
3) Engine speed display is abnormal. q
Related information
Procedure, measuring location, criteria, and remarks
q
The engine speed information (the signal of engine Ne speed sensor) is received by machine monitor through CAN communication from engine controller. Engine speed can be checked with monitoring function. (Code: 01002)
Cause
Procedure, measuring location, criteria, and remarks
1
An error occurred in engine Ne speed sensor system
If failure code [CA238] is displayed, perform troubleshooting for it first.
2
Defective machine monitor
If no failure is found by check on cause 1, machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
3
Defective engine controller
If no failure is found by checks on cause 1, engine controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40-421
E-11 Engine coolant temperature is displayed abnormally.
40 Troubleshooting
E-11 Engine coolant temperature is displayed abnormally. Failure
1) While coolant temperature is rising normally, it does not rise from white range (C). 2) While coolant temperature is stabilized normally, it rises to red range (H). q
Related information
No.
1
q
Signal voltage of coolant temperature sensor is input to engine controller, and then it is transmitted to machine monitor through CAN communication system. Coolant temperature can be checked with monitoring function. (Code: 04107)
Cause
Procedure, measuring location, criteria, and remarks
1
Defective engine coolant temperature sensor system
Coolant temperature sensor system may be defective. Perform troubleshooting for failure codes [CA144] and [CA145].
2
Defective machine monitor
If no failure is found by check on Cause 1, machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Failure
3) Coolant temperature is different from indication of engine coolant temperature gauge. 4) Indication of engine coolant temperature gauge is different from indication of coolant temperature monitor. q
Related information
No.
q
Signal voltage of coolant temperature sensor is input to engine controller, and then it is transmitted to machine monitor through CAN communication system. Coolant temperature can be checked with monitoring function. (Code: 04107)
Cause
Procedure, measuring location, criteria, and remarks Turn starting switch to ON position or start engine, and perform troubleshooting.
1
Defective machine monitor
40-422
Engine coolant temperature
Coolant temperature gauge level
Min. 135.0°C
10 or less is lit.
102.0 to 134.9°C
9 or less is lit.
96.0 to 101.9°C
8 or less is lit.
89.0 to 95.9°C
7 or less is lit.
83.0 to 88.9°C
6 or less is lit.
76.0 to 82.9°C
5 or less is lit.
70.0 to 75.9°C
4 or less is lit.
63.0 to 69.9°C
3 or less is lit.
50.0 to 62.9°C
2 or less is lit.
Max. 49.9°C
Only 1 is lit.
Coolant temperature gauge color Red (R)
Green (G)
White (W)
GD535-5 (03)
40 Troubleshooting
E-11 Engine coolant temperature is displayed abnormally.
Engine coolant temperature gauge and coolant temperature monitor
GD535-5 (03)
40-423
E-12 Articulated meter display is abnormal.
40 Troubleshooting
E-12 Articulated meter display is abnormal. Failure
1) Articulated meter display is abnormal. q
Related information
q q
No.
1
If an error occurs in articulated angle sensor system, failure code [DKD0KX] may be displayed and recorded. The articulated meter information (articulated angle sensor signal) is received by transmission controller through CAN communication. Input voltage from articulated angle sensor can be checked with monitoring function. (Code: 43900)
Cause
Procedure, measuring location, criteria, and remarks
1
An error occurred in articulated angle sensor system.
Perform troubleshooting for failure code [DKD0KX].
2
Defective machine monitor
If no failure is found by above checks, the machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-424
GD535-5 (03)
40 Troubleshooting
Failure
E-12 Articulated meter display is abnormal.
2) Articulated meter display is incorrect.
Related information
No. 1
Cause Zero-point adjustment failure
Procedure, measuring location, criteria, and remarks Perform zero-point adjustment of articulated meter by referring to Testing and adjusting, "Tuning " of "Special function of machine monitor". Start engine, change the articulated angle, and diagnose the articulated (body) angle.
2
Defective machine monitor
Articulated level (Pointer position)
Articulated angle sensor (Output voltage)
Articulated (body) angle
-
Min. 3.75 V
-25° and above (Abnormal)
7
Min. 3.7 V
-23° and above
6
2.6 to 2.8 V
-5° to -8°
5
2.5 to 2.6 V
-2° to -5°
4
2.2 to 2.5 V
± 2°
3
2.0 to 2.2 V
2° to 5°
2
1.9 to 2.0 V
5° to 8°
1
Max. 2 V
23° and above
-
Max. 1.1 V
-25° and above (Abnormal)
Articulated level meter
GD535-5 (03)
40-425
E-13 Torque converter oil temperature is displayed abnormally.
40 Troubleshooting
E-13 Torque converter oil temperature is displayed abnormally. Failure
1) While torque converter oil temperature is rising normally, it does not rise from white range (C). 2) While torque converter oil temperature is stabilized normally, it rises to red range (H). q
Related information
No.
1
q q
If an error occurs in torque converter oil sensor system, failure code [DGT1KX] may be displayed and recorded. Information of torque converter oil temperature gauge (signal of torque converter oil temperature sensor) is received by machine monitor through CAN communication from transmission controller. The input voltage sent from torque converter oil temperature sensor can be checked by the monitoring function. (Code: 30101)
Cause
Procedure, measuring location, criteria, and remarks
1
An error occurred in torque converter oil temperature sensor system.
Perform troubleshooting for failure code [DGT1KX].
2
Defective machine monitor
If no failure is found by check on cause 1, machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
3
Failure of transmission controller
If no failure is found by checks on cause 1, transmission controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Failure Related information
No.
3) Display of torque converter oil temperature and torque converter oil temperature gauge does not match. 4) Display of torque converter oil temperature gauge and torque converter oil temperature caution lamp does not match. The torque converter oil temperature caution lamp lights at 120°C or more.
Cause
Procedure, measuring location, criteria, and remarks Turn starting switch to ON position or start engine, and perform troubleshooting. Oil temperature gauge color Red (R)
1
Defective machine monitor Green (G)
White (W)
40-426
Torque converter oil temperature gauge level
Torque converter oil temperature
10 or less is lit.
Min. 135.0°C
9 or less is lit.
120.0 to 134.9°C
8 or less is lit.
111.0 to 119.9°C
7 or less is lit.
102.0 to 110.9°C
6 or less is lit.
93.0 to 101.9°C
5 or less is lit.
84.0 to 92.9°C
4 or less is lit.
75.0 to 83.9°C
3 or less is lit.
66.0 to 74.9°C
2 or less is lit.
20.0 to 65.9°C
Only 1 is lit.
Max. 19.9°C
GD535-5 (03)
40 Troubleshooting
E-13 Torque converter oil temperature is displayed abnormally.
Torque converter oil temperature gauge
GD535-5 (03)
40-427
E-14 Fuel gauge is displayed abnormally.
40 Troubleshooting
E-14 Fuel gauge is displayed abnormally. Failure Related information
No.
1) Fuel gauge is displayed abnormally. q q
If an error occurs in fuel level sensor system, failure code [DJF1KA] may be displayed and recorded. The input resistance and voltage from the fuel level sensor can be checked with monitoring function. (Code: 04201, 04200)
Cause
1
An error occurred in fuel level sensor system.
2
Ground fault in wiring harness
3
Short circuit in wiring harness
Procedure, measuring location, criteria, and remarks Perform troubleshooting for failure code [DJF1KA]. 1. Turn the starting switch to OFF position. 2. Disconnect connectors TM39 and ET39, and connect T-adapter to either female side. Between TM39 (female) (19) or ET39 (female) (1) and ground
Defective machine monitor
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM39 and ET39, and connect T-adapter to female side of TM39. Check by using multimeter in continuity mode. Between TM39 (female) (19) and each pin other than pin (19)
4
1
No continuity (No sound is heard.)
If no failure is found by above checks, the machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to fuel level sensor
40-428
GD535-5 (03)
40 Troubleshooting
Failure Related information
No.
E-14 Fuel gauge is displayed abnormally.
2) Indication of fuel gauge is different from actual fuel level. q
The resistance of fuel sensor can be measured between machine monitor's connectors FP2 (female) (10) and FP1 (female) (3)
Cause
Procedure, measuring location, criteria, and remarks a Turn starting switch to ON position or start engine, and perform troubleshooting. Fuel level
1
Defective machine monitor
Fuel gauge level
Resistance
FULL
210 l
6 or less is lit.
11.3 z
3/4
197 l
5 or less is lit.
16.1 z
1/2
144 l
4 or less is lit.
35.1 z
1/4
84 l
3 or less is lit.
68.7 z
EMPTY
76 l
2 or less is lit.
79.0 z
1 seg.
Max. 73 l
Only 1 is lit.
Min. 83.3 z
Fuel gauge color
Green (G)
Red (R)
Fuel level gauge and fuel monitor
GD535-5 (03)
40-429
E-15 Centralized warning lamps do not light or do not go out.
40 Troubleshooting
E-15 Centralized warning lamps do not light or do not go out. Failure
Centralized warning lamps do not light up or go out. q
Related information q q
No.
Centralized warning lamps light when: 1) An emergency stop event occurs. 2) Action code [L02] or [L03] is displayed on the machine monitor. 3) Two seconds after starting switch turning ON. When centralized warning lamps light, warning buzzer sounds intermittently. If a machine overrun occurs, only the warning buzzer sounds.
Cause
Procedure, measuring location, criteria, and remarks
1
Lamp bulb has burnt out.
Check the centralized warning lamps for burn-out or poor contact.
2
Defective lamp assembly (Internal failure)
Check the lamp assembly for internal failure (open circuit or short circuit).
3
Open circuit in wiring harness
4
1
Ground fault in wiring harness
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40 and FP3, and connect T-adapteras to each female side. Between FP3 (female) (11) and TM40 (female) (19)
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40 and FP3, and connect T-adapter to either female side. Between FP3 (female) (11) or FP1 (female) (19) and ground
Resistance
Max. 1 z
For approximately 2 seconds after starting switch is turned to ON position
Voltage
Max. 1 V
When 2 seconds have passed after starting switch turned ON
Voltage
20 to 30 V
1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector TM40. 3. Turn starting switch to ON position. 5
Failure of transmission controller
Between TM40 (19) and ground
Circuit diagram related to Machine monitor
40-430
GD535-5 (03)
40 Troubleshooting
E-16 Alarm buzzer does not sound or does not stop sounding.
E-16 Alarm buzzer does not sound or does not stop sounding. Failure Related information
No. 1
2
3
1
Alarm buzzer does not sound or does not stop sounding. q q
If an error occurs in warning buzzer system, failure code [DV00KB] may be displayed and recorded. If a machine overrun occurs, only the warning buzzer sounds.
Cause Failure of alarm buzzer system
Open circuit in wiring harness
Ground fault in wiring harness
Procedure, measuring location, criteria, and remarks Perform troubleshooting for failure code [DV00KB]. 1. Turn the starting switch to OFF position. 2. Disconnect connectors FP1 and FP4, and insert T-adapters into each female side. Between terminal ST9 and FP4 (female) (1)
Resistance
Max. 1 z
Between FP4 (female) (2) and FP1 (female) (5)
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors FP1 and FP4, and insert T-adapters into each female side. Between FP4 (female) (1) or FP1 (female) (3) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector FP4. 3. Turn starting switch to ON position, then perform troubleshooting. 4
Failure of alarm buzzer Between FP4 (1) and (2)
For approximately 2 seconds after starting switch is turned to ON position
Voltage
Max. 3 V
When 2 seconds have passed after starting switch turned ON
Voltage
20 to 30 V
1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector FP1. 3. Turn starting switch to ON position, then perform troubleshooting. 5
Defective machine monitor Between FP1 (5) and ground
GD535-5 (03)
For approximately 2 seconds after starting switch is turned to ON position
Voltage
Max. 3 V
When 2 seconds have passed after starting switch turned ON
Voltage
20 to 30 V
40-431
E-16 Alarm buzzer does not sound or does not stop sounding.
40 Troubleshooting
Circuit diagram related to the warning buzzer
40-432
GD535-5 (03)
40 Troubleshooting
E-17 Transmission mode cannot be switched.
E-17 Transmission mode cannot be switched. Failure
Transmission mode cannot be switched. q
Related information
No.
1
2
3
4
1
q
Manual mode: Direct power shift (Hydroshift) mode Auto mode: Torque converter mode Input condition (ON/OFF) from transmission mode selector switch can be checked with monitoring function. (Code: 02214)
Cause
Failure of transmission mode selector switch
Open circuit in wiring harness
Ground fault in wiring harness
Hot short circuit in wiring harness
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM30, and connect T-adapters to male side. Between TM30 (male) (5) and (6)
Switch ON (Manual mode)
Resistance
Max. 1 z
Switch OFF (Auto mode)
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM30 and TM39, and connect T-adapters to each female side. 3. Remove fuse No. 11 of the FB1 fuse box. Between TM39 (female) (17) and TM30 (female) (6)
Resistance
Max. 1 z
Between FB1-11 and TM30 (female) (5)
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM30 and TM39, and connect T-adapter to either female side. Between TM39 (female) (17) or TM30 (female) (6) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector TM30, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between TM30 (female) (6) and ground
Voltage
Max. 1 V
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
5
Failure of transmission controller
Reference 1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector TM39. 3. Turn starting switch to ON position. 4. Perform troubleshooting by operating the transmission mode selector switch. Between TM39 (17) and (4)
GD535-5 (03)
Switch ON (Manual mode)
Voltage
20 to 30 V
Switch OFF (Auto mode)
Voltage
Max. 1 V
40-433
E-17 Transmission mode cannot be switched.
40 Troubleshooting
Circuit diagram related to transmission switch
40-434
GD535-5 (03)
40 Troubleshooting
E-18 Engine mode cannot be switched.
E-18 Engine mode cannot be switched. Failure
Engine mode cannot be switched. q
Related information
No.
1
2
3
4
1
q
P-mode (Power mode): Switch ON E-mode (Economy mode): Switch OFF Input condition (ON/OFF) from engine mode selector switch can be checked with monitoring function. (Code: 02218)
Cause
Failure of engine mode selector switch
Open circuit in wiring harness
Ground fault in wiring harness
Hot short circuit in wiring harness
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM45, and connect T-adapters to male side. Between TM45 (male) (5) and (6)
Switch ON (P-mode)
Resistance
Max. 1 z
Switch OFF (E-mode)
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM45 and TM39, and connect T-adapters to each female side. 3. Remove fuse No. 11 of the FB1 fuse box. Between TM39 (female) (12) and TM45 (female) (6)
Resistance
Max. 1 z
Between FB1-11 and TM45 (female) (5)
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM45 and TM39, and connect T-adapter to either female side. Between TM39 (female) (12) or TM45 (female) (6) and ground
Resistance
Min. 1 Mz
Turn the starting switch to OFF position. 1. Disconnect connector TM45, and connect T-adapter to female side. 2. Turn starting switch to ON position. Between TM45 (female) (6) and ground
Voltage
Max. 1 V
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
5
Failure of transmission controller
Reference 1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector TM39. 3. Turn starting switch to ON position. 4. Perform troubleshooting by operating the engine mode selector switch. Between TM39 (12) and (4)
GD535-5 (03)
Switch ON (P-mode)
Voltage
20 to 30 V
Switch OFF (E-mode)
Voltage
Max. 1 V
40-435
E-18 Engine mode cannot be switched.
40 Troubleshooting
Circuit diagram related to engine mode switch
40-436
GD535-5 (03)
40 Troubleshooting
E-19 Differential gear lock function does not operate or is not canceled (for differential gear lock model).
E-19 Differential gear lock function does not operate or is not canceled (for 1 differential gear lock model). Failure
Differential gear lock function does not operate or is not canceled. q
Related information
q q
No. 1
2
3
4
The coil circuit (primary side circuit) of differential gear lock relay is monitored by the transmission controller. If an open or short circuit occurs, failure code [D19KKZ] is displayed. Input state (ON/OFF) from differential gear lock switch can be checked with monitoring function. (Code: 02218) Drive state (ON/OFF) of differential gear lock relay can be checked with monitoring function. (Code: 03705)
Cause Blown fuse
Failure of differential gear lock switch
Failure of differential gear lock relay
Failure of differential gear lock solenoid valve
Procedure, measuring location, criteria, and remarks If fuse No. 7 of FB1 fuse box blows, the circuit may be shorted to ground. (Go to check on causes 4 and 6.) 1. Turn the starting switch to OFF position. 2. Disconnect connector FP12, and connect T-adapter to male side. Between FP12 (male) (5) and (6)
6
Open circuit in wiring harness
Ground fault and short circuit in wiring harness
GD535-5 (03)
Resistance
Min. 1 Mz
Switch: ON
Resistance
Max. 1 z
Perform troubleshooting for failure code [D19KKZ]. 1. Turn the starting switch to OFF position. 2. Disconnect connector R9, and connect T-adapter to male side. Between R9 (male) (1) and (2)
Resistance
Approx. 25 z
Between R9 (male) (1) and ground
Resistance
Min. 1 Mz
1. 2. 3. 4.
5
Switch: OFF
Turn the starting switch to OFF position. Disconnect connectors TM40 and TM43, and connect T-adapter to each female side. Remove fuse No. 7 of the FB1 fuse box. Turn ON the differential gear lock switch.
Between TM40 (female) (12) and ground
Resistance
Max. 1 z
Between TM43 (female) (6) and ground (Resistance of differential gear lock solenoid valve coils)
Resistance
Approx. 25 z
Between FB1-7 and TM43 (female) (3)
Resistance
Max. 1 z
If no failure is found by above checks, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40, TM43, FP12 and R9, and connect T-adapters to each female side. Between TM40 (female) (12) and FP12 (female) (6)
Resistance
Max. 1 z
Between FP12 (female) (5) and ground
Resistance
Max. 1 z
Between TM43 (female) (6) and R9 (female) (1)
Resistance
Max. 1 z
Between R9 (female) (2) and ground
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40, TM43, FP12 and R9, and connect T-adapters to each female side. 3. Remove fuse No. 7 of the FB1 fuse box. 4. Turn ON the differential gear lock switch. Between FP12 (female) (5) and (6)
Resistance
Min. 1 Mz
Between R9 (female) (1) and (2)
Resistance
Min. 1 Mz
Between TM43 (female) (3) and (2)
Resistance
Min. 1 Mz
40-437
E-19 Differential gear lock function does not operate or is not canceled (for differential gear lock model).
No.
7
Cause Hot short circuit in wiring harness
40 Troubleshooting
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector TM43, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between TM43 (female) (6) and (2)
Voltage
Max. 1 V
If no failure is found by above checks, transmission controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
8
Failure of transmission controller
Reference 1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector TM40. 3. Turn starting switch to ON position. 4. Perform troubleshooting by operating the differential gear lock switch. Between TM40 (12) and ground
Switch: OFF
Voltage
Max. 1 V
Switch: ON
Voltage
7 to 12 V
Circuit diagram related to differential gear lock switch and differential gear lock solenoid valve
40-438
GD535-5 (03)
40 Troubleshooting
E-20 Cannot be locked or canceled by the lifter lock pin.
E-20 Cannot be locked or canceled by the lifter lock pin. Failure Related information
No. 1
1
1) Cannot be locked or canceled by the lifter lock pin. The lifter lock switch turns ON (the pin is released) when it is pressed. It turns OFF when pushed back (the pin is locked).
Cause Blown fuse
Procedure, measuring location, criteria, and remarks If fuse No. 7 of FB1 fuse box blows, the circuit may be shorted to ground. (Go to check on causes 3 and 5.) 1. Turn the starting switch to OFF position. 2. Disconnect connector SP28, and connect T-adapter to male side.
2
3
4
5
Failure of lifter lock switch
Failure of lifter lock solenoid valve
Open circuit in wiring harness
Ground fault and short circuit in wiring harness
Between SP28 (male) (1) and (2)
6
Min. 1 Mz
Switch: ON
Resistance
Max. 1 z
Between R10 (male) (1) and (2)
Resistance
2 to 100 z
Between R10 (male) (1) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connectors SP28 and R10, and connect T-adapters to each female side. 3. Remove fuse No. 7 of the FB1 fuse box. Between R10 (female) (1) and SP28 (2)
Resistance
Max. 1 z
Between R10 (female) (2) and ground
Resistance
Max. 1 z
Between FB1-7 and SP28 (female) (3)
Resistance
Max. 1 z
1. 2. 3. 4.
Turn the starting switch to OFF position. Disconnect connectors FP3 and R10, and connect T-adapter to female side of R10. Remove fuse No. 7 of the FB1 fuse box. Lifter lock switch ON Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector R10, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between R10 (female) (1) and (2)
GD535-5 (03)
Resistance
1. Turn the starting switch to OFF position. 2. Disconnect connector R10, and connect T-adapter to male side.
Between R10 (female) (1) and (2) Hot short circuit in wiring harness
Switch: OFF
Voltage
Max. 1 V
40-439
E-20 Cannot be locked or canceled by the lifter lock pin.
Failure Related information
No.
40 Troubleshooting
2) Only the display of lifter lock pin pilot lamp is abnormal (the function operates and releases normally). q q q
When lifter lock pin is locked: Pilot lamp goes out. When lifter lock pin is released: Pilot lamp lights. If the wiring harness is shorted to ground or if it is hot shorted, the function fails.
Cause
Procedure, measuring location, criteria, and remarks
1
Lamp bulb has burnt out.
Check the lamp bulb of lifter lock pin pilot lamp for burn-out or poor contact.
2
Defective lamp assembly
Check the lamp assembly for internal failure (open circuit or short circuit).
3
Open circuit in wiring harness
1. Turn the starting switch to OFF position. 2. Disconnect connectors FP3 and SP28, and connect T-adapters to each female side. Between FP3 (female) (9) and SP28 (2)
Resistance
Max. 1 z
Between FP3 (female) (12) and ground
Resistance
Max. 1 z
Circuit diagram related to lifter lock switch and lifter lock solenoid valve
40-440
GD535-5 (03)
40 Troubleshooting
E-21 Horn does not sound or does not stop sounding.
E-21 Horn does not sound or does not stop sounding. Failure
1
1) Horn does not sound.
Related information
No. 1
2
Cause Blown fuse
Failure of horn relay
Procedure, measuring location, criteria, and remarks If fuses No. 14 of FB1 fuse box is blown, the circuit may be shorted to ground. In this case, perform check on cause 7 first. 1. 2. 3. 4.
Turn the starting switch to OFF position. Replace horn relay SP27 with another relay (for example, headlight relay SP13) Turn starting switch to ON position. Sound the horn.
If horn sounds, original horn relay is defective. 1. Turn the starting switch to OFF position. 2. Disconnect connector FL7, and connect T-adapter to male side. 3
Failure of horn RH.
Between FL7 (male) (1) and (2) Between FL7 (male) (2) and ground
Continuity Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector FL8, and connect T-adapter to male side. 4
Failure of horn LH
Between FL8 (male) (1) and (2) Between FL8 (male) (2) and ground
Conductive Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector FP9, and connect T-adapter to male side. 5
Failure of horn switch
Between FP9 (male) (1) and Switch: ON ground Switch: OFF
Resistance
Max. 1 z
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connectors SP27, FP9 and FL8, and connect T-adapters to each female side. 3. Remove fuse No. 14 of FB1 fuse box.
6
7
Open circuit in wiring harness
Ground fault and short circuit in wiring harness
GD535-5 (03)
Between FP9 (female) (1) and SP27 (female) (6)
Resistance
Max. 1 z
Between FB1-14 and SP27 (female) (5)
Resistance
Max. 1 z
Between SP27 (female) (2) and FL7 (female) (2)
Resistance
Max. 1 z
Between SP27 (female) (2) and FL8 (female) (2)
Resistance
Max. 1 z
Between FL7 (female) (1) and ground
Resistance
Max. 1 z
Between FL8 (female) (1) and ground
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors FL7, FL8 and SP27, and connect T-adapters to each female side. 3. Remove fuse No. 14 of FB1 fuse box. Between FL7 (female) (1) and (2)
Resistance
Min. 1 Mz
Between SP27 (female) (1) and ground
Resistance
Min. 1 Mz
40-441
E-21 Horn does not sound or does not stop sounding.
Failure
40 Troubleshooting
2) Horn does not stop sounding.
Related information
No.
1
Cause
Failure of horn relay
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Remove horn relay SP27. 3. Turn starting switch to ON position. If horn stops sounding, original horn relay SP27 is defective.
2
Failure of horn switch
1. Turn the starting switch to OFF position. 2. Disconnect connector FP9. 3. Turn starting switch to ON position. If horn stops sounding, the horn switch is defective.
3
4
Ground fault and short circuit in wiring harness
Hot short circuit in wiring harness
1. Turn the starting switch to OFF position. 2. Disconnect connector SP27, and connect T-adapter to female side. Between SP27 (female) (6) and ground
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connector SP27, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between SP27 (female) (2) and ground
Voltage
Max. 1 V
Circuit diagram related to horn
40-442
GD535-5 (03)
40 Troubleshooting
E-22 Backup alarm does not sound or does not stop sounding.
E-22 Backup alarm does not sound or does not stop sounding. Failure
1) Backup alarm does not sound. q
Related information
No. 1
2
1
q q
If the gear lever is shifted to "R" and if the backup lamp lights, the fuses are OK, relay harness is not shorted to ground, and harness is not hot shorted. Check the operations. If a fuse blows, the stop lamp also does not light. If the backup lamp relay is turned ON by transmission controller, it can be checked with monitoring function. (Code: 03705)
Cause Blown fuse
Defective backup lamp relay
Procedure, measuring location, criteria, and remarks If fuse No. 13 of FB1 fuse box is blown, the circuit may be shorted to ground. In this case, perform check on cause 5 first. 1. Turn the starting switch to OFF position. 2. Replace the backup lamp relay TM42 with another relay (for example, stop lamp relay SP16). 3. Start engine. 4. Depress the brake pedal, and shift the lever to "R" position. If the back alarm sounds, original backup lamp relay TM42 is defective. 1. Turn the starting switch to OFF position. 2. Disconnect connector BZ, and connect T-adapter to male side.
3
Failure of back alarm
Between BZ (male) (1) and (2) Between BZ (male) (1) and ground
Conductive Resistance
Min. 1 Mz
Primary circuit side of backup lamp relay 1. Turn the starting switch to OFF position. 2. Disconnect connector TM40, and connect T-adapter to female side. a Coil resistance of backup lamp relay Between TM40 (female) (18) and ground
Resistance
200 to 400 z
Secondary circuit side of backup lamp relay 1. Turn the starting switch to OFF position. 2. Disconnect connector TM42, and connect T-adapter to female side. 3. Disconnect connector RL1 (in order to disconnect the back lamp circuit). 4. Remove fuse No. 13 of FB1 fuse box. 4
Open circuit in wiring harness
Between TM42 (female) (3) and FB1-13 Between TM42 (female) (5) and ground
Resistance
Max. 1 z
Conductive
If no failure is found by above checks, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40, TM42 and BZ, and connect T-adapter to each female side. 3. Disconnect connector RL1 (in order to disconnect the backup lamp circuit). 4. Remove fuse No. 13 of FB1 fuse box.
5
Ground fault and short circuit in wiring harness
GD535-5 (03)
Between TM40 (female) (18) and TM42 (female) (1)
Resistance
Max. 1 z
Between TM42 (female) (2) and ground
Resistance
Max. 1 z
Between TM42 (female) (5) and BZ (female) (1)
Resistance
Max. 1 z
Between BZ (male) (2) and ground
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40, TM42 and BZ, and connect T-adapter to female side of TM42. 3. Remove fuse (14) of FB1 fuse box. Between TM42 (female) (1) and (2)
Resistance
Min. 1 Mz
Between TM42 (female) (3) and (2)
Resistance
Min. 1 Mz
Between TM42 (female) (5) and (2)
Resistance
Min. 1 Mz
40-443
E-22 Backup alarm does not sound or does not stop sounding.
No.
6
Cause
Failure of transmission controller
Failure
40 Troubleshooting
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector TM40. 3. Start engine. 4. Depress the brake pedal, and shift the lever to "R" position. If the input voltage is normal with shift lever at "R" position, and if the relay output voltage is abnormal, the transmission controller is defective. Between TM40 (15) and (31) (Input voltage when lever is in "R" position)
Voltage
20 to 30 V
Between TM40 (18) and (31) (Relay output voltage)
Voltage
20 to 30 V
2) Backup alarm does not stop sounding.
Related information
No.
1
Cause Defective backup lamp relay
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Remove backup lamp relay TM42. 3. Turn starting switch to ON position. If the back alarm stops sounding, original backup lamp relay TM42 is defective.
2
3
Hot short circuit in wiring harness
Failure of transmission controller
40-444
1. Turn the starting switch to OFF position. 2. Disconnect connector TM42, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between TM42 (female) (1) and (2)
Voltage
Max. 1 V
Between TM42 (female) (5) and (2)
Voltage
Max. 1 V
1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector TM40. 3. Start engine. 4. Depress the brake pedal, and shift the lever to "R" position. If the input voltage is normal with shift lever at "R" position, and if the relay output voltage is abnormal, the transmission controller is defective. Between TM40 (15) and (31) (Input voltage when lever is in "R" position)
Voltage
20 to 30 V
Between TM40 (18) and (31) (Relay output voltage)
Voltage
20 to 30 V
GD535-5 (03)
40 Troubleshooting
E-22 Backup alarm does not sound or does not stop sounding.
Circuit diagram related to back alarm device
GD535-5 (03)
40-445
E-23 Headlamps, clearance lamps, and tail lamps do not light up or go out.
40 Troubleshooting
E-23 Headlamps, clearance lamps, and tail lamps do not light up or go out.1 Failure Related information
No. 1
1) All of headlamps, clearance lamps, and tail lamps do not light up or do not go out. q q
If fuse No. 12 of FB1 blows, all of headlamps, clearance lamps, and tail lamps do not light. If the small lamp relay fails or if fuse No. 9 of FB2 blows, the headlamps light. But all of clearance lamps, tail lamps, and machine monitor night lamp do not light.
Cause Blown fuse
Procedure, measuring location, criteria, and remarks If fuse No. 12 of FB1 fuse box is blown, the circuit may be shorted to ground. In this case, perform check on cause 4 first. 1. Turn the starting switch to OFF position. 2. Disconnect connector SP22, and connect T-adapter to male side.
2
Defective headlamp switch
Between SP22 (male) (5) and (6)
Switch: Headlamps ON
Resistance
Max. 1 z
Switch: OFF
Resistance
Min. 1 Mz
Between SP22 (male) (4) and (5)
Switch: Clearance lamps ON
Resistance
Max. 1 z
Switch: OFF
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connectors SP22 and SP13, and connect T-adapter to female side. 3. Remove fuse No. 12 of FB1 fuse box. 3
4
Open circuit in wiring harness
Ground fault and short circuit in wiring harness
40-446
Between SP13 (female) (6) and ground
Resistance
Max. 1 z
Between FB1-12 and SP22 (female) (5)
Resistance
Max. 1 z
Between FB1-12 and SP13 (female) (1)
Resistance
Max. 1 z
Between FB1-12 and SP13 (female) (3)
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors SP22 and SP13, and connect T-adapter to female side of SP13. 3. Remove fuse No. 12 of FB1 fuse box. Between SP13 (female) (1) and (2)
Resistance
Min. 1 Mz
Between SP13 (female) (1) and (6)
Resistance
Min. 1 Mz
GD535-5 (03)
40 Troubleshooting
E-23 Headlamps, clearance lamps, and tail lamps do not light up or go out.
Circuit diagram related to headlamps, clearance lamps, tail lamps, and front work lamps
GD535-5 (03)
40-447
E-23 Headlamps, clearance lamps, and tail lamps do not light up or go out.
Failure Related information
No. 1
2
40 Troubleshooting
2) Head lamps do not light up nor go out. q q
If headlamps or clearance lamps do not light, check the directional lamp and emergency lamp. If all front lamps do not light, check the ground circuits (FLG2) (the tail lamps light). Dimmer relay SP11 switches between Hi beam and Low beam.
Cause Lamp bulb has burnt out.
Defective headlamp relay
Procedure, measuring location, criteria, and remarks If only each lamp does not light up, burned-out bulb and defective contact are suspected. So check it. 1. 2. 3. 4.
Turn the starting switch to OFF position. Replace headlamp relay SP13 with another relay (for example, horn relay SP27) Turn starting switch to ON position. Light up the headlamps.
If the headlamps light, original headlamp relay SP13 is defective.
3
Defective dimmer relay
1. 2. 3. 4.
Turn the starting switch to OFF position. Replace dimmer relay SP11 with another relay (for example, stop lamp relay SP16) Turn starting switch to ON position. Light up the headlamps.
If headlamps light, original dimmer relay is defective.
4
Defective headlamp switch
1. Turn the starting switch to OFF position. 2. Disconnect connector SP22, and connect T-adapter to male side. Between SP22 (male) (5) and (6)
Switch: Headlamps ON
Resistance
Max. 1 z
Switch: OFF
Resistance
Min. 1 Mz
Defective headlamp relay (primary circuit side) 1. Turn the starting switch to OFF position. 2. Disconnect connector SP22, and connect T-adapter to female side. a Resistance of headlamp relay coils Between SP22 (female) (6) and ground
Resistance
200 to 400 z
Defective headlamp relay (secondary circuit side) 1. Turn the starting switch to OFF position. 2. Disconnect connector SP13, and connect T-adapter to female side. Make sure that dimmer (Hi beam) switch turns OFF. a A single lamp has approx. 8 z parallel resistance (8/2=4). Between SP13 (female) (2) and (6) 5
Open circuit in wiring harness
40-448
Resistance
Approx. 4 z
If no failure is found by above checks, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors SP11, SP13, SP22, FL1 and FL2, and connect T-adapters to each female side. Between SP22 (female) (6) and SP13 (female) (5)
Resistance
Max. 1 z
Between SP13 (female) (6) and ground
Resistance
Max. 1 z
Between SP13 (female) (2) and SP11 (female) (3)
Resistance
Max. 1 z
Between SP11 (female) (6) and FL1 (female) (2)
Resistance
Max. 1 z
Between SP11 (female) (6) and FL2 (female) (2)
Resistance
Max. 1 z
Between FL1 (female) (6) and ground
Resistance
Max. 1 z
Between FL2 (female) (6) and ground
Resistance
Max. 1 z
GD535-5 (03)
40 Troubleshooting
No.
Cause
E-23 Headlamps, clearance lamps, and tail lamps do not light up or go out.
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connectors SP11, SP13, SP22, FL1 and FL2, and connect T-adapter to female side of SP13. 3. Remove fuse No. 12 of FB1 fuse box.
6
Ground fault and short circuit in wiring harness
Between SP13 (female) (2) and (6)
Resistance
Min. 1 Mz
Between SP13 (female) (5) and (6)
Resistance
Min. 1 Mz
Between SP13 (female) (1) and (2)
Resistance
Min. 1 Mz
Between SP13 (female) (1) and (5)
Resistance
Min. 1 Mz
Circuit diagram related to headlamps, clearance lamps, tail lamps, and front work lamps
GD535-5 (03)
40-449
E-23 Headlamps, clearance lamps, and tail lamps do not light up or go out.
Failure Related information
No. 1
2
40 Troubleshooting
3) The headlamps cannot be switched between Hi and Low beams. q
The Hi and Low beams are switched by the dimmer switch and dimmer relay (SP11).
Cause Lamp bulb has burnt out.
Defective dimmer relay
Procedure, measuring location, criteria, and remarks If only each lamp does not light up, burned-out bulb and defective contact are suspected. So check it. 1. 2. 3. 4.
Turn the starting switch to OFF position. Replace dimmer relay SP11 with another relay (for example, stop lamp relay SP16) Turn starting switch to ON position. Light up headlamps, and turn the dimmer switch ON and OFF.
If the Hi and Low beams are switched, original dimmer relay SP11 is defective. 1. Turn the starting switch to OFF position. 2. Disconnect connector FP7, and connect T-adapter to male side. 3
Defective dimmer switch
Between FP7 (male) (5) and Switch: ON (6) Switch: OFF
Resistance
Max. 1 z
Resistance
Min. 1 Mz
Dimmer relay (primary circuit side) 1. Turn the starting switch to OFF position. 2. Disconnect connectors SP11 and SP13, and connect T-adapter to each female side. 3. Turn the dimmer (Hi beam) switch ON. Between SP13 (female) (2) and SP11 (female) (1)
Resistance
Max. 1 z
Between SP13 (female) (2) and SP11 (female) (3)
Resistance
Max. 1 z
Between SP11 (female) (2) and ground
Resistance
Max. 1 z
Dimmer relay (secondary circuit side) 1. Turn the starting switch to OFF position. 2. Disconnect connector SP11, and connect T-adapter to female side. a A single lamp has approx. 8 z parallel resistance (8/2=4). 4
Open circuit in wiring harness
Between SP11 (female) (5) and (2)
Resistance
Approx. 4 z
Between SP11 (female) (6) and (2)
Resistance
Approx. 4 z
If no failure is found by above checks, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors SP11, SP13, FP7, FL1 and FL2, and connect T-adapters to each female side. Between SP13 (female) (2) and FP7 (female) (6)
Resistance
Max. 1 z
Between SP11 (female) (1) and FP7 (female) (5)
Resistance
Max. 1 z
Between SP13 (female) (2) and SP11 (female) (3)
Resistance
Max. 1 z
Between SP11 (female) (5) and FL1 (female) (3)
Resistance
Max. 1 z
Between SP11 (female) (5) and FL2 (female) (3)
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors SP11, SP13, FL1 and FL2, and connect T-adapter to female side of SP11. Make sure that dimmer (Hi beam) switch turns OFF. 5
Ground fault and short circuit in wiring harness
40-450
Between SP11 (female) (1) and (2)
Resistance
Min. 1 Mz
Between SP11 (female) (1) and (5)
Resistance
Min. 1 Mz
Between SP11 (female) (2) and (5)
Resistance
Min. 1 Mz
Between SP11 (female) (3) and (5)
Resistance
Min. 1 Mz
GD535-5 (03)
40 Troubleshooting
Failure Related information
No.
E-23 Headlamps, clearance lamps, and tail lamps do not light up or go out.
4) Headlamp Hi-beam pilot lamp does not light or does not go out. If the wiring harness is shorted to ground or hot shorted, the headlamps cannot be switched between Hi and Low beams.
Cause
Procedure, measuring location, criteria, and remarks
1
Lamp bulb has burnt out.
Check the headlamp Hi-beam pilot lamp for bulb burn-out or poor contact.
2
Defective lamp assembly
Check the lamp assembly for internal failure (open circuit or short circuit).
3
Open circuit in wiring harness
Failure
Between FP3 (female) (3) and SP11 (female) (1)
Resistance
Max. 1 z
Between FP3 (female) (12) and ground
Resistance
Max. 1 z
5) Clearance lamps and tail lamps do not light up or do not go out. q
Related information
1. Turn the starting switch to OFF position. 2. Disconnect connectors FP3 and SP11, and connect T-adapters to each female side.
q q
If the small lamp relay fails or if fuse (9) of FB2 blows, the headlamps light. But all of clearance lamps and tail lamps do not light. If tail lamps light but clearance lamps do not light, check the headlamps, directional lamps and emergency lamp. If all front lamps do not light, check the ground circuits (FLG2) If clearance lamps light but tail lamps do not light, check the headlamps, directional lamps, emergency lamp, stop lamps, and backup lamps. If all rear lamps do not light, check the ground circuits (ET77)
44
No.
Cause
Procedure, measuring location, criteria, and remarks
1
Lamp bulb has burnt out.
If only each lamp does not light up, burned-out bulb and defective contact are suspected. So check it.
2
Blown fuse
If fuse No. 9 of FB2 fuse box is blown, the circuit may be shorted to ground. In this case, perform check on cause 5 first.
3
Defective headlamp switch
GD535-5 (03)
1. Turn the starting switch to OFF position. 2. Disconnect connector SP22, and connect T-adapter to male side. Between SP22 (male) (4) and (5)
Switch: Headlamps ON
Resistance
Max. 1 z
Switch: OFF
Resistance
Min. 1 Mz
40-451
E-23 Headlamps, clearance lamps, and tail lamps do not light up or go out.
No.
Cause
40 Troubleshooting
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connectors SP22, SP12 and SP13, and connect T-adapter to each female side. 3. Remove fuse No. 9 of FB2 fuse box.
4
Open circuit in wiring harness
Between SP12 (female) (2) and ground
Resistance
Max. 1 z
Between FB2-9 and SP12 (female) (3)
Resistance
Max. 1 z
Between SP12 (female) (1) and SP13 (female) (4)
Resistance
Max. 1 z
Between SP12 (female) (1) and SP22 (female) (4)
Resistance
Max. 1 z
Between SP12 (5) and (2) A single lamp has approx. 125 z (four) parallel resistance (125 / 4 = 31).
Resistance
Approx. 30 z
If no failure is found by above checks, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors SP42, FL1, FL2, RL2 and RL3, and connect T-adapter to each female side.
Resistance
Max. 1 z
Between SP42 (female) (5) and FL1 (female) (4)
Resistance
Max. 1 z
Between SP42 (female) (5) and FL2 (female) (4)
Resistance
Max. 1 z
Between SP42 (female) (5) and RL2 (female) (6)
Resistance
Max. 1 z
Between SP42 (female) (5) and RL3 (female) (6)
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors SP12 and SP13, and connect T-adapter to female side of SP12. 3. Remove fuse No. 9 of FB2 fuse box. 5
6
Ground fault and short circuit in wiring harness
Defective machine monitor
40-452
Between SP12 (female) (1) and (2)
Resistance
Min. 1 Mz
Between SP12 (female) (1) and (3)
Resistance
Min. 1 Mz
Between SP12 (female) (2) and (5)
Resistance
Min. 1 Mz
Between SP12 (female) (3) and (5)
Resistance
Min. 1 Mz
If no failure is found by above checks, the machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
GD535-5 (03)
40 Troubleshooting
E-23 Headlamps, clearance lamps, and tail lamps do not light up or go out.
Circuit diagram related to headlamps, clearance lamps, tail lamps, and front work lamps
GD535-5 (03)
40-453
E-24 Working lamps do not light up or go out.
40 Troubleshooting
E-24 Working lamps do not light up or go out. Failure Related information
No.
1
1) Front working lamps do not light up or do not go out. The front working lamps have the circuit that is completely separated from the circuit of headlamps, clearance lamps and tail lamps. The circuit has its own fuses and ground leads.
Cause
Procedure, measuring location, criteria, and remarks
1
Lamp bulb has burnt out.
If only each lamp does not light up, burned-out bulb and defective contact are suspected. So check it.
2
Blown fuse
If fuse No. 10 of FB1 fuse box is blown, the circuit may be shorted to ground. In this case, perform check on cause 7 first.
3
Failure of front working lamp relay
1. 2. 3. 4.
Turn the starting switch to OFF position. Replace front work lamp relay SP14 with another relay (for example, horn relay SP27) Turn starting switch to ON position. Front working lamps ON
If the front working lamps light, original front working lamp relay SP14 is defective.
4
Failure of front working lamp switch
1. Turn the starting switch to OFF position. 2. Disconnect connector SP23, and connect T-adapter to male side. Between SP23 (male) (5) and (6) 1. 2. 3. 4. a
5
Open circuit in wiring harness
Switch: ON
Resistance
Max. 1 z
Switch: OFF
Resistance
Min. 1 Mz
Turn the starting switch to OFF position. Disconnect connector SP14, and connect T-adapter to female side. Remove fuse No. 10 of FB1 fuse box. Front working lamp switch ON * A single lamp has approx. 8 z resistance.
Between SP14 (female) (6) and ground
Resistance
Max. 1 z
Between FB1-10 and SP14 (female) (1)
Resistance
Max. 1 z
Between SP14 (female) (1) and (5)
Resistance
Max. 1 z
Between SP14 (female) (2) and (6)
Resistance
* Approx. 8 z
Between SP14 (female) (4) and (6)
Resistance
* Approx. 8 z
If no failure is found by above checks, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors SP23, SP14, FL9 and FL10, and connect T-adapter to each female side.
6
Open circuit in wiring harness
40-454
Between SP23 (female) (5) and SP14 (female) (3)
Resistance
Max. 1 z
Between SP23 (female) (6) and SP14 (female) (5)
Resistance
Max. 1 z
Between SP14 (female) (1) and (3)
Resistance
Max. 1 z
Between SP14 (female) (2) and FL9 (female) (1)
Resistance
Max. 1 z
Between SP14 (female) (4) and FL10 (female) (1)
Resistance
Max. 1 z
Between FL9 (female) (2) and ground
Resistance
Max. 1 z
Between FL10 (female) (2) and ground
Resistance
Max. 1 z
GD535-5 (03)
40 Troubleshooting
No.
Cause
E-24 Working lamps do not light up or go out.
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connectors SP14, FP3, FL9 and FL10, and connect T-adapter to female side of SP14. 3. Remove fuse No. 10 of FB1 fuse box.
7
Ground fault and short circuit in wiring harness
Failure Related information
No.
Between SP14 (female) (1) and (2)
Resistance
Min. 1 Mz
Between SP14 (female) (1) and (4)
Resistance
Min. 1 Mz
Between SP14 (female) (1) and (5)
Resistance
Min. 1 Mz
Between SP14 (female) (1) and (6)
Resistance
Min. 1 Mz
Between SP14 (female) (6) and (2)
Resistance
Min. 1 Mz
Between SP14 (female) (6) and (4)
Resistance
Min. 1 Mz
Between SP14 (female) (6) and (5)
Resistance
Min. 1 Mz
2) The working pilot lamp does not light or does not go out. If the wiring harness is shorted to ground or hot shorted, the front working lamps do not operate normally.
Cause
Procedure, measuring location, criteria, and remarks
1
Lamp bulb has burnt out.
Check the working pilot lamp for bulb burn-out or poor contact.
2
Defective lamp assembly
Check the lamp assembly for internal failure (open circuit or short circuit).
3
Open circuit in wiring harness
GD535-5 (03)
Turn the starting switch to OFF position. Disconnect connectors FP3 and SP14, and connect T-adapters to each female side. Between FP3 (female) (5) and SP14 (female) (5)
Resistance
Max. 1 z
Between FP3 (female) (12) and ground
Resistance
Max. 1 z
40-455
E-24 Working lamps do not light up or go out.
40 Troubleshooting
Circuit diagram related to headlamps, clearance lamps, tail lamps, front working lamps, cab working lamps
40-456
GD535-5 (03)
40 Troubleshooting
Failure
3) The rear working lamps do not light up or go out. q
Related information
No.
E-24 Working lamps do not light up or go out.
q
The rear working lamp relay uses the primary circuit power supply (and fuses) that are common to the front working lamps. Check the front working lamps for abnormal operation. If tail lamps do not light, it may be shorted to ground. See "Headlamps, clearance lamps, and tail lamps do not light up or go out."
Cause
Procedure, measuring location, criteria, and remarks
1
Lamp bulb has burnt out.
If only each lamp does not light up, burned-out bulb and defective contact are suspected. So check it.
2
Blown fuse
If fuse No. 9 of FB1 fuse box is blown, the circuit may be shorted to ground. In this case, perform check on cause 6 first.
3
Failure of rear working lamp relay
1. Turn the starting switch to OFF position. 2. Replace rear working lamp relay SP15 with another relay (for example, stop lamp relay SP16) 3. Turn ON the rear working lamp switch. If the rear working lamps light, original rear working lamp relay SP15 is defective.
4
Failure of rear working lamp switch
1. Turn the starting switch to OFF position. 2. Disconnect connector SP24, and connect T-adapter to male side. Between SP24 (male) (5) and (6) 1. 2. 3. 4. a
5
Open circuit in wiring harness
GD535-5 (03)
Switch: ON
Resistance
Max. 1 z
Switch: OFF
Resistance
Min. 1 Mz
Turn the starting switch to OFF position. Disconnect connectors SP14 and SP15, and connect T-adapter to female side. Remove fuses No. 9 and No. 10 of FB1 fuse box. Turn ON the rear working lamp switch. * A single lamp has approx. 8 z parallel resistance (8/2=4).
Between SP15 (female) (2) and ground
Resistance
Max. 1 z
Between FB1-10 and SP14 (female) (1)
Resistance
Max. 1 z
Between FB1-9 and SP15 (female) (3)
Resistance
Max. 1 z
Between SP15 (female) (5) and ground
Resistance
* Approx. 4 z
If no failure is found by above checks, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors SP15, SP24, SP14, RL4 and RL5, and connect T-adapter to each female side. 3. Remove fuse No. 10 of FB1 fuse box. Between FB1-10 and SP14 (female) (1)
Resistance
Max. 1 z
Between SP14 (4) and SP24 (female) (5)
Resistance
Max. 1 z
Between SP15 (female) (1) and SP24 (female) (6)
Resistance
Max. 1 z
Between SP15 (female) (5) and RL5 (female) (1)
Resistance
Max. 1 z
Between SP15 (female) (5) and RL4 (female) (1)
Resistance
Max. 1 z
Between RL4 (female) (2) and ground
Resistance
Max. 1 z
Between RL5 (female) (2) and ground
Resistance
Max. 1 z
40-457
E-24 Working lamps do not light up or go out.
No.
6
Cause
Ground fault and short circuit in wiring harness
40 Troubleshooting
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connectors SP15, SP24, RL4 and RL5, and connect T-adapter to female side of SP15. 3. Remove fuse No. 9 of the FB1 fuse box. Between SP15 (female) (2) and (1)
Resistance
Min. 1 Mz
Between SP15 (female) (2) and (3)
Resistance
Min. 1 Mz
Between SP15 (female) (2) and (5)
Resistance
Min. 1 Mz
Circuit diagram related to rear working lamps
40-458
GD535-5 (03)
40 Troubleshooting
E-25 Turn indicator light or emergency flashing light does not flash.
E-25 Turn indicator light or emergency flashing light does not flash. Failure
1) Turn indicator light or emergency flashing light does not flash. q q
Related information
q q
No.
1
1
Hazard lamp relay 2 (SP19) switches the power supply of flasher (SP26). (Different fuses are used for directional indicators and emergency flashing lights.) Flasher (SP26) uses the circuit that is common to both turn indicator light and emergency flashing light. If the flasher fails, any turn indicator light may not flash but turn ON even when the right or left turn indicator light is turned ON or even when the emergency flashing light is turned ON. When troubleshooting the flasher failure, if only front or rear lights do not flash after diagnosis of wiring harnesses, the circuit may be shorted to ground. See "Headlamps, clearance lamps, and tail lamps do not light up or go out."
Cause
Failure of hazard lamp relay 2
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Replace hazard lamp relay 2 (SP19) with another relay (for example, stop lamp relay SP16). 3. Turn the Hazard switch ON. If the emergency flashing light flashes, original hazard lamp relay 2 (SP19) is defective.
2
3
Open circuit in wiring harness
Ground fault and short circuit in wiring harness
1. Turn the starting switch to OFF position. 2. Disconnect connectors SP26, SP18 and SP19, and connect T-adapters to each female side. Between SP26 (female) (1) and ground
Resistance
Max. 1 z
Between SP26 (female) (3) and SP19 (female) (3)
Resistance
Max. 1 z
Between SP26 (female) (4) and SP18 (female) (3)
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connector SP26, and connect T-adapter to female side. 3. Remove fuse No. 6 of the FB1 fuse box. Between SP26 (female) (1) and (3)
Resistance
Min. 1 Mz
Between SP26 (female) (1) and (4)
Resistance
Min. 1 Mz
Between SP26 (female) (3) and (4)
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector SP26. 3. Turn starting switch to ON position. 4
Defective flasher
GD535-5 (03)
Between SP26 (3) and (1)
Power supply
Voltage
20 to 30 V
Between SP26 (4) and (1)
Output
Voltage
20 to 30V and 1V or less pulses
40-459
E-25 Turn indicator light or emergency flashing light does not flash.
40 Troubleshooting
Circuit diagram related to turn indicator light and emergency flashing light
40-460
GD535-5 (03)
40 Troubleshooting
Failure
2) Turn indicator light does not flash. q
Related information
No.
E-25 Turn indicator light or emergency flashing light does not flash.
q q q
Check that the emergency flashing light operates normally. Hazard lamp relay 2 (SP19) switches the power supply of flasher (SP26). If only the right or left turn indicator light does not flash, the wiring harness is defective. If only front or rear lamps do not flash, it may be a ground fault. See "E-23 Headlamps, clearance lamps, and tail lamps do not light up or go out."
Cause
Procedure, measuring location, criteria, and remarks
1
Lamp bulb has burnt out.
If only each lamp does not light up, burned-out bulb and defective contact are suspected. So check it.
2
Blown fuse
If fuse No. 6 of FB1 fuse box is blown, the circuit may be shorted to ground. In this case, perform check on cause 5 first. 1. Turn the starting switch to OFF position. 2. Disconnect connector FP8, and connect T-adapter to male side.
3
Failure of turn indicator light lever
Between FP8 (male) (A) and Lever: Left turn (upper side) (B) Lever: Neutral Lever: Right turn (bottom Between FP8 (male) (A) and side) (C) Lever: Neutral
Resistance
Max. 1 z
Resistance
Min. 1 Mz
Resistance
Max. 1 z
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connectors SP18, SP19, FP8, FL1, FL2, RL2 and RL3, and connect Tadapters to each female side. 3. Remove fuse No. 6 of the FB1 fuse box.
4
5
Open circuit in wiring harness
Ground fault and short circuit in wiring harness
GD535-5 (03)
Between FB1 (6) and SP19 (female) (6)
Resistance
Max. 1 z
Between SP18 (female) (1) and (3)
Resistance
Max. 1 z
Between SP18 (female) (1) and FP8 (female) (A)
Resistance
Max. 1 z
Between FP8 (female) (B) and FL2 (female) (5)
Resistance
Max. 1 z
Between FP8 (female) (B) and RL3 (female) (1)
Resistance
Max. 1 z
Between FP8 (female) (C) and FL1 (female) (5)
Resistance
Max. 1 z
Between FP8 (female) (C) and RL2 (female) (1)
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors SP18, SP19, SP26, FP8, FL1, FL2, RL2 and RL3, and connect T-adapters to female side of SP19 and FP8. 3. Remove fuse No. 6 of the FB1 fuse box. Between SP19 (female) (2) and (6)
Resistance
Min. 1 Mz
Between FP8 (female) (B) and ground
Resistance
Min. 1 Mz
Between FP8 (female) (C) and ground
Resistance
Min. 1 Mz
40-461
E-25 Turn indicator light or emergency flashing light does not flash.
40 Troubleshooting
Circuit diagram related to turn indicator light and emergency flashing light
40-462
GD535-5 (03)
40 Troubleshooting
Failure
3) Emergency flashing light does not flash. q
Related information
q q q
No.
E-25 Turn indicator light or emergency flashing light does not flash.
Check that the turn indicator light operates normally. Hazard lamp relay 2 (SP19) switches the power supply of flasher (SP26). If the emergency flashing light flashes when starting switch is turned to ON position, hazard lamp relay 2 (SP19) is defective. For the related circuit diagrams, see cause of failure 1) or 2).
Cause
Procedure, measuring location, criteria, and remarks
1
Lamp bulb has burnt out.
If only each lamp does not light up, burned-out bulb and defective contact are suspected. So check it.
2
Blown fuse
If fuse No. 4 of FB1 fuse box is blown, the circuit may be shorted to ground. In this case, perform check on cause 8 first.
3
Failure of hazard lamp relay 2
1. Turn the starting switch to OFF position. 2. Replace hazard lamp relay 2 (SP19) with another relay (for example, stop lamp relay SP16). 3. Turn ON the hazard lamp switch. If the emergency flashing light flashes, original hazard lamp relay 2 (SP19) is defective.
4
Failure of hazard lamp relay 1
1. Turn the starting switch to OFF position. 2. Replace hazard lamp relay 1 (SP18) with another relay (for example, horn relay SP27). 3. Turn ON the hazard lamp switch. If the emergency flashing light flashes, original hazard lamp relay 1 (SP18) is defective.
5
Failure of hazard lamp switch
1. Turn the starting switch to OFF position. 2. Disconnect connector SP25, and connect T-adapter to male side. Between SP25 (male) (5) and (6)
Switch: ON
Resistance
Max. 1 z
Switch: OFF
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Disconnect connectors SP18, SP19, SP26, FL1, FL2, RL2 and RL3, and connect Tadapters to each female side. 3. Remove fuse No. 4 of the FB1 fuse box. 4. Turn ON the hazard lamp switch.
6
Open circuit in wiring harness
GD535-5 (03)
Between SP19 (female) (2) and ground
Resistance
Max. 1 z
Between FB1-4 and SP19 (female) (5)
Resistance
Max. 1 z
Between FB1-4 and SP19 (female) (1)
Resistance
Max. 1 z
Between SP18 (female) (1) and (3)
Resistance
Max. 1 z
Between SP18 (female) (2) and FL2 (female) (5)
Resistance
Max. 1 z
Between SP18 (female) (2) and RL3 (female) (1)
Resistance
Max. 1 z
Between SP18 (female) (4) and FL1 (female) (5)
Resistance
Max. 1 z
Between SP18 (female) (4) and RL2 (female) (1)
Resistance
Max. 1 z
40-463
E-25 Turn indicator light or emergency flashing light does not flash.
No.
Cause
40 Troubleshooting
Procedure, measuring location, criteria, and remarks If no failure is found by above checks, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors SP18, SP19 and SP25, and connect T-adapters to each female side. 3. Remove fuse No. 4 of the FB1 fuse box.
7
Open circuit in wiring harness
Between FB1-4 and SP25 (female) (5)
Resistance
Max. 1 z
Between SP25 (female) (6) and SP18 (female) (5)
Resistance
Max. 1 z
Between SP18 (female) (5) and SP19 (female) (1)
Resistance
Max. 1 z
Between SP18 (female) (6) and ground
Resistance
Max. 1 z
Between SP18 (female) (6) and SP19 (female) (2)
Resistance
Max. 1 z
1. Turn the starting switch to OFF position. 2. Disconnect connectors SP18 and SP19, and connect T-adapter to female side of SP18. Turn OFF the hazard lamp switch.
8
Ground fault and short circuit in wiring harness
40-464
Between SP18 (female) (5) and (6)
Resistance
Min. 1 Mz
Between SP18 (female) (3) and (2)
Resistance
Min. 1 Mz
Between SP18 (female) (3) and (4)
Resistance
Min. 1 Mz
Between SP18 (female) (2) and (5)
Resistance
Min. 1 Mz
Between SP18 (female) (4) and (5)
Resistance
Min. 1 Mz
Between SP18 (female) (2) and (6)
Resistance
Min. 1 Mz
Between SP18 (female) (4) and (6)
Resistance
Min. 1 Mz
GD535-5 (03)
40 Troubleshooting
E-25 Turn indicator light or emergency flashing light does not flash.
Circuit diagram related to turn indicator light and emergency flashing light
GD535-5 (03)
40-465
E-25 Turn indicator light or emergency flashing light does not flash.
Failure Related information
No.
40 Troubleshooting
4) Turn signal pilot lamp does not flash. If the wiring harness is shorted to ground or hot shorted, the turn indicator light does not flash.
Cause
Procedure, measuring location, criteria, and remarks
1
Lamp bulb has burnt out.
If the turn indicator pilot lamp does not light, its bulb may be burnt out or poor contact. Check them.
2
Defective lamp assembly
Check the lamp assembly for internal failure (open circuit or short circuit). 1. Turn the starting switch to OFF position. 2. Disconnect connectors FP3 and FP8, and connect T-adapters to each female side.
3
Open circuit in wiring harness
40-466
Between FP3 (female) (4) and FP8 (female) (B)
Resistance
Max. 1 z
Between FP3 (female) (2) and FP8 (female) (C)
Resistance
Max. 1 z
Between FP3 (female) (12) and ground
Resistance
Max. 1 z
GD535-5 (03)
40 Troubleshooting
E-25 Turn indicator light or emergency flashing light does not flash.
Circuit diagram related to turn indicator light and emergency flashing light
GD535-5 (03)
40-467
E-26 Stop lamp does not light up or does not go out.
40 Troubleshooting
E-26 Stop lamp does not light up or does not go out. Failure Related information
No.
1
The stop lamp does not light or does not go out. If tail lamps and back lamps do not light, ground ET77 failure or blown fuse No. 13 of FB1 fuse box is to be considered.
Cause
Procedure, measuring location, criteria, and remarks
1
Lamp bulb has burnt out.
If only each lamp does not light up, burned-out bulb and defective contact are suspected. So check it.
2
Blown fuse
If fuses No. 13 of FB1 fuse box is blown, the circuit may be shorted to ground. In this case, perform check on cause 6 first.
3
Defective stop lamp relay
1. 2. 3. 4.
Turn the starting switch to OFF position. Replace stop lamp relay SP16 with another relay (for example, small lamp relay SP12). Turn starting switch to ON position. Depress the brake pedal.
If the stop lamp lights, original stop lamp relay SP16 is defective.
4
Failure of brake lamp switch
1. Turn the starting switch to OFF position. 2. Disconnect connector B13, and connect T-adapter to male side. Between B13 (male) (1) and Depress the brake pedal. (2) Release the brake. 1. 2. 3. a
Open circuit in wiring harness
Max. 1 z
Resistance
Min. 1 Mz
Turn the starting switch to OFF position. Disconnect connector B13, and connect T-adapter to female side. Remove fuse No. 13 of FB1 fuse box. * Coil resistance of stop lamp relay
Between B13 (female) (2) and ground
Resistance
* 200 to 400 z
Between FB1-13 and B13 (female) (1)
Resistance
Max. 1 z
1. 2. 3. a 5
Resistance
Turn the starting switch to OFF position. Disconnect connector SP16, and connect T-adapter to female side. Remove fuse No. 13 of FB1 fuse box. * A single lamp has approx. 24 z parallel resistance.
Between FB1-13 and SP16 (female) (3)
Resistance
Max. 1 z
Between SP16 (female) (5) and (2)
Resistance
* Approx. 12 z
If no failure is found by above checks, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors B13, SP16, RL2 and RL3, and connect T-adapters to each female side.
40-468
Between B13 (female) (2) and SP16 (female) (1)
Resistance
Max. 1 z
Between SP16 (female) (5) and RL2 (female) (5)
Resistance
Max. 1 z
Between SP16 (female) (5) and RL3 (female) (5)
Resistance
Max. 1 z
Between SP16 (female) (2) and ground
Resistance
Max. 1 z
GD535-5 (03)
40 Troubleshooting
No.
E-26 Stop lamp does not light up or does not go out.
Cause
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connectors B13, SP16, RL2 and RL3, and connect T-adapter to female side of SP16. 3. Remove fuse No. 13 of FB1 fuse box.
6
Ground fault and short circuit in wiring harness
Between SP16 (female) (1) and (2)
Resistance
Min. 1 Mz
Between SP16 (female) (2) and (3)
Resistance
Min. 1 Mz
Between SP16 (female) (2) and (5)
Resistance
Min. 1 Mz
Between SP16 (female) (1) and (3)
Resistance
Min. 1 Mz
Between SP16 (female) (3) and (5)
Resistance
Min. 1 Mz
Circuit diagram related to the stop lamp
GD535-5 (03)
40-469
E-27 Backup lamp does not light up or does not go out
40 Troubleshooting
E-27 Backup lamp does not light up or does not go out Failure
Backup lamp does not light up or does not go out. q
Related information
q q q q
No.
1
If the gear shift lever is shifted to "R" and if the backup alarm sounds, none of blown fuse, relay failure, harness grounding, and harness hot short have occurred. Check the operations. If a fuse blows, the stop lamp also does not light. If tail lamps and stop lamp do not light, ground fault (ET77) is to be considered. For the back alarm troubleshooting, see E-22. If the backup lamp relay is turned ON by transmission controller, it can be checked with monitoring function. (Code: 03705)
Cause
Procedure, measuring location, criteria, and remarks
1
Lamp bulb has burnt out.
If only each lamp does not light up, burned-out bulb and defective contact are suspected. So check it.
2
Blown fuse
If fuses No. 13 of FB1 fuse box is blown, the circuit may be shorted to ground. In this case, perform check on cause 5 first.
3
Defective backup lamp relay
1. Turn the starting switch to OFF position. 2. Replace backup lamp relay TM42 with another relay (for example, small lamp relay SP12). 3. Start engine. 4. Depress the brake pedal, and shift the lever to "R" position. If the backup lamp lights, original backup lamp relay TM42 is defective. 1. 2. 3. a
Turn the starting switch to OFF position. Disconnect connector TM40, and connect T-adapter to female side. Remove fuse No. 13 of the FB1 fuse box. Coil resistance of backup lamp relay
Between TM40 (female) (18) and ground 1. 2. 3. a 4
Open circuit in wiring harness
Resistance
200 to 400 z
Turn the starting switch to OFF position. Disconnect connector TM42, and connect T-adapter to female side. Remove fuse No. 13 of the FB1 fuse box. * A single lamp has approx. 50 z parallel resistance.
Between FB1-13 and TM42 (female) (3)
Resistance
Max. 1 z
Between TM42 (female) (5) and (2)
Resistance
* Approx. 25 z
If no failure is found by above checks, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40, TM42, RL2 and RL3, and connect T-adapters to each female side.
40-470
Between TM40 (female) (18) and TM42 (female) (1)
Resistance
Max. 1 z
Between TM42 (female) (2) and ground
Resistance
Max. 1 z
Between TM42 (female) (5) and RL2 (female) (2)
Resistance
Max. 1 z
Between TM42 (female) (5) and RL3 (female) (2)
Resistance
Max. 1 z
GD535-5 (03)
40 Troubleshooting
No.
E-27 Backup lamp does not light up or does not go out
Cause
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connectors TM40, TM42, RL2 and RL3, and connect T-adapter to female side of TM42. 3. Remove fuse No. 13 of FB1 fuse box.
5
6
Ground fault and short circuit in wiring harness
Failure of transmission controller
Between TM42 (female) (1) and (2)
Resistance
Min. 1 Mz
Between TM42 (female) (2) and (3)
Resistance
Min. 1 Mz
Between TM42 (female) (2) and (5)
Resistance
Min. 1 Mz
Between TM42 (female) (1) and (3)
Resistance
Min. 1 Mz
Between TM42 (female) (3) and (5)
Resistance
Min. 1 Mz
1. Turn the starting switch to OFF position. 2. Insert T-adapter into connector TM40. 3. Start engine. 4. Depress the brake pedal, and shift the lever to "R" position. If the input voltage is normal with shift lever at "R" position, and if the relay output voltage is abnormal, the transmission controller is defective. Between TM40 (15) and (31) (Input voltage when lever is in "R" position)
Voltage
20 to 30 V
Between TM40 (18) and (31) (Relay output voltage)
Voltage
20 to 30 V
Circuit diagram related to backup lamp
GD535-5 (03)
40-471
E-28 All wipers do not operate
40 Troubleshooting
E-28 All wipers do not operate Failure Related information
No.
1
1
No wiper operates continuously or intermittently If any of wipers operates, see each of “FRONT WIPER DOES NOT OPERATE”, “REAR WIPER DOES NOT OPERATE”, “RIGHT DOOR WIPER DOES NOT OPERATE”, and “LEFT DOOR WIPER DOES NOT OPERATE” in E mode. Cause
Defective fuse
Procedure, measuring location, criteria, and remarks If fuse is blown out, the circuit probably has ground fault. Perform troubleshooting for “ground fault in wiring harness” first. REMARK If following fuse is blown out, each symptom occurs. q If fuse No.15 in fuse box FB2 is blown out, all the wipers do not work. q If fuse No.14 in fuse box FB2 is blown out, door wipers do not work. 1. Turn the starting switch to OFF position. 2. Disconnect connector L21, and connect T-adapter to male side. 3. Turn on and off wiper switch to perform troubleshooting. Between L21 (male) (7) and Front intermittent ON (2) Front intermittent OFF
2
Defective wiper intermittent switch Resistance
Between L21 (male) (7) and Front Hi/ON (4) Front Hi/OFF Between L21 (male) (7) and Front Lo/ON (5) Front Lo/OFF Between L21 (male) (7) and Rear ON (9) Rear OFF
3
Min. 1 MΩ Max. 1 Ω Min. 1 MΩ Max. 1 Ω Min. 1 MΩ Max. 1 Ω Min. 1 MΩ
1. Turn the starting switch to OFF position. 2. Check that fuse No.15 in fuse box FB2 is not blown out. Open circuit in wiring harness (wire breakage or 3. Disconnect connector L21, and connect T-adapter to female side. 4. Turn the starting switch to ON position. defective contact) Voltage
4
Max. 1 Ω
Ground fault in wiring harness (contact with ground circuit)
20 to 30 V
If no failure is found by checks on “open circuit in wiring harness”, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors L21, L48, C15, C16, and C53, and connect Tadapter to female side of L21. 3. Remove fuse No.15 in fuse box FB2. Resistance
40-472
Between L21 (female) (7) and ground
Between L21 (female) (7) and ground
Min. 1 MΩ
GD535-5 (03)
40 Troubleshooting
E-28 All wipers do not operate
Circuit diagram related to wiper
GD535-5 (03)
40-473
E-29 Front wiper does not operate
40 Troubleshooting
E-29 Front wiper does not operate Failure
Front wiper does not operate. q q
Related information
No.
If all the wipers do not operate, see “NO WIPER OPERATES CONTINUOUSLY OR INTERMITTENTLY” in E mode. By using combination of front Hi wiper relay and front Lo wiper relay, and front wiper intermittent unit, Hi/ Lo/Intermittent are switched as follows. q When 24 V power is supplied to pin 3 and pin 4 of wiper intermittent unit (front: L48), wiper operates intermittently. q Front Hi wiper relay (C14) switches 24 V power supply (pin 1: Hi, pin 2: Lo, INT) of wiper motor (front: C15). q "SW OFF" terminal of wiper motor is output of wiper motor which shows wiper is in end position. With this signal, wiper intermittent unit stops temporarily supplying 24 V power to wiper motor (makes output of L48 pin 5 to pulse state). q Front Lo wiper relay switches pulse output voltage from wiper intermittent unit at intermittent operation and constant voltage from C14 at Lo operation.
Cause
1
Defective fuse
2
Defective front wiper motor (internal open circuit)
3
1
Defective front Hi wiper relay
Procedure, measuring location, criteria, and remarks If fuse No.14 in fuse box FB2 is blown out, the circuit probably has ground fault. Perform troubleshooting for “ground fault in wiring harness” first. q If fuse No.15 in fuse box FB2 is blown out, front and rear wipers do not work. 1. Turn the starting switch to OFF position. 2. Disconnect connector C15, and connect T-adapter to male side. Continuity 1. 2. 3. 4.
Between C15 (male) (1) and (3)
Continuity
Between C15 (male) (2) and (3)
Continuity
Turn the starting switch to OFF position. Disconnect connector C14, and replace it with TM42 (backup lamp relay). Turn the starting switch to ON position. Turn on and off front Hi of wiper switch to perform troubleshooting.
If front wiper Hi operation is normal, original front Hi wiper relay is defective.
4
Defective front Lo wiper relay
1. 2. 3. 4.
Turn the starting switch to OFF position. Disconnect connector C12, and replace it with TM42 (backup lamp relay). Turn the starting switch to ON position. Turn on and off front Lo of wiper switch to perform troubleshooting.
If front wiper Lo and intermittent operation are normal, original front Lo wiper relay is defective.
5
Defective front wiper intermittent unit
1. 2. 3. 4.
Turn the starting switch to OFF position. Replace connector L48 with new one. Turn the starting switch to ON position. Turn on and off Intermittent of wiper switch to perform troubleshooting.
If front wiper intermittent operation is normal, original front wiper intermittent unit is defective.
40-474
GD535-5 (03)
40 Troubleshooting
No.
E-29 Front wiper does not operate
Cause
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to ON position. Voltage 1. 2. 3. 4.
Between FB2-14 and ground
20 to 30 V
Turn the starting switch to OFF position. Disconnect connector C12, and connect T-adapter to female side. Turn the starting switch to ON position. Turn on and off front Lo of wiper switch to perform troubleshooting.
Voltage
Between C12 (female) (1) and (2)
Front Lo
Between C12 (female) (1) and (2)
Front OFF
Between C12 (female) (6) and (2)
Front Intermittent
20 to 30 V 0V Pulse of 20 to 30 V and 0V
1. Turn the starting switch to OFF position. 2. Disconnect connector C14, and connect T-adapter to female side. 3. Turn on and off front Hi of wiper switch to perform troubleshooting. 6
Open circuit in wiring harness (wire breakage or defective contact) Voltage
Between C14 (female) (1) and (2)
Front Hi
Between C14 (female) (1) and (2)
Front OFF
Between C14 (female) (3) and (2) q
1. 2. 3. 4.
0V 20 to 30 V
Wiper motor Turn the starting switch to OFF position. Disconnect connector C15, and connect T-adapter to female side. Turn the starting switch to ON position. Turn on and off front Hi/Lo/Intermittent of wiper switch to perform troubleshooting.
Voltage
GD535-5 (03)
20 to 30 V
Between C15 (female) (6) and (3)
20 to 30 V
Between C15 (female) (2) and (3)
Front Lo
20 to 30 V
Between C15 (female) (2) and (3)
Front Intermittent
Pulse of 20 to 30 V and 0V
Between C15 (female) (1) and (3)
Front Hi
20 to 30 V
40-475
E-29 Front wiper does not operate
No.
40 Troubleshooting
Cause
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connectors L21, L48, C11, C12, C13, C14, C16, C51, C53, and C54, and connect T-adapter to female side of L21, C12, and C14. 3. Remove fuse No.14 and 15 in fuse box FB2.
Resistance 7
Ground fault in wiring harness (contact with ground circuit)
Between L21 (female) (2) and ground
Min. 1 MΩ
Between L21 (female) (4) and ground
Min. 1 MΩ
Between L21 (female) (5) and ground
Min. 1 MΩ
Between L21 (female) (7) and ground
Min. 1 MΩ
Between C12 (female) (3) and ground
Min. 1 MΩ
Between C12 (female) (5) and ground
Min. 1 MΩ
Between C14 (female) (3) and ground
Min. 1 MΩ
Between C14 (female) (5) and ground
Min. 1 MΩ
If no failure is found for “wiper motor” by checks on “open circuit in wiring harness”, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors C12, C14, and C15, and connect T-adapter to female side of C15.
Resistance
40-476
Between C15 (female) (1) and ground
Min. 1 MΩ
Between C15 (female) (2) and ground
Min. 1 MΩ
Between C15 (female) (6) and ground
Min. 1 MΩ
GD535-5 (03)
40 Troubleshooting
E-29 Front wiper does not operate
Circuit diagram related to wiper
GD535-5 (03)
40-477
E-30 Rear wiper does not operate
40 Troubleshooting
E-30 Rear wiper does not operate Failure
Rear wiper does not operate. q q q q q
Related information
q q
q
No. 1
2
1
If all the wipers do not operate, see “NO WIPER OPERATES CONTINUOUSLY OR INTERMITTENTLY” in E mode. If front wiper also does not operate, see “FRONT WIPER DOES NOT OPERATE” in E mode. With/without intermittent operation of rear wiper is switched by rear wiper intermittent relay through intermittent signal of front wiper switch. The rear wiper motor is driven by the power supplied from rear wiper intermittent unit C53 even during continuous operation. When rear wiper motor detects stop position, it converts input voltage (24 V) of pin 2 to pulse signal, and output it to pin 3. The rear wiper motor is driven by 24 V voltage pulse delivered between rear wiper intermittent unit C53 and rear wiper motor during intermittent operation. Pins which are associated with this failure in wiper intermittent unit C53 are as follows. q (1): GND 1 q (2): Output 1 (power supply 1 to wiper motor) q (3): Continuous input (24 V) q (4): Intermittent input (24 V) q (6): 24 V common input q (8): 24 V pulse input 1 from wiper motor Although T-adapter is not available for wiper intermittent unit C53, check the wiring harness of each pin of wiper intermittent unit C53 for open circuit.
Cause
Procedure, measuring location, criteria, and remarks
1. Turn the starting switch to OFF position. Defective rear wiper motor 2. Disconnect connector C16, and connect T-adapter to male side. (internal open circuit) Continuity Between C16 (2) and (4)
Defective rear wiper intermittent relay
1. 2. 3. 4.
Continuity
Turn the starting switch to OFF position. Disconnect connector C51, and replace it with TM42 (backup lamp relay). Turn the starting switch to ON position. Turn on rear wiper switch, and turn on and off intermittent of front wiper switch to perform troubleshooting.
If rear wiper operates normally, original rear wiper intermittent relay is defective.
3
Defective rear wiper intermittent unit
1. Turn the starting switch to OFF position. 2. Disconnect connectors C53 and C54, and interchange intermittent units with each other. 3. Turn the starting switch to ON position. 4. Turn on rear wiper switch, and turn on and off intermittent of front wiper switch to perform troubleshooting. If rear wiper operates normally, original rear wiper intermittent unit is defective.
40-478
GD535-5 (03)
40 Troubleshooting
No.
E-30 Rear wiper does not operate
Cause
Procedure, measuring location, criteria, and remarks 1. 2. 3. 4. 5.
Turn the starting switch to OFF position. Disconnect connector C16, and connect T-adapter to female side. Insert T-adapter into connector C51. Turn the starting switch to ON position. Turn on and off intermittent of rear and front wiper switches to perform troubleshooting. Between C16 (female) (1) and (4)
20 to 30 V
Check the wiring harness connected to pin 2 and 6 of C53 for open circuit. Rear ON Between C16 (female) (2) and (4)
20 to 30 V
q
Voltage
4
Open circuit in wiring harness (wire breakage or defective contact)
Between C16 (female) (2) and (4)
Rear OFF
Between C51 (1) and (2)
Rear intermittent
20 to 30 V
Between C51 (3) and (2)
Rear ON
20 to 30 V
Between C51 (3) and (2)
Rear OFF
0V
0V
Description hereafter is check of wiring harness of wiper intermittent unit for open circuit. q Check pin 2 and pin 8 of C53 for open circuit. 1. Turn the starting switch to OFF position. 2. Disconnect connector C16, and connect T-adapter to female side. q
Resistance
Between C16 (female) (2) and (3)
Max. 1 Ω
1. Turn the starting switch to OFF position. 2. Disconnect connector C51, and connect T-adapter to female side. REMARK q Since there are many diodes in internal circuit, take care about polarity of multimeter. q If "OFF" is not displayed for resistance value in multimeter, this means that open circuit does not occur. Check the wiring harness connected to pin 1 and 3 of C53 for open circuit. Between C51 (female) (6) (+) and (2) (-)
1 to 50 MΩ
Check the wiring harness connected to pin 4 and 1 of C53 for open circuit. Between C51 (female) (5) (+) and (2) (-)
1 to 50 MΩ
q
Resistance
q
1. Turn the starting switch to OFF position. 2. Disconnect connectors L21, C16, C51, and C53, and connect T-adapter to female side of C16 and C51. 3. Remove fuse No.15 in fuse box FB2. 5
Ground fault in wiring harness (contact with ground circuit) Resistance
GD535-5 (03)
Between C51 (female) (3) and ground
Min. 1 MΩ
Between C51 (female) (5) and ground
Min. 1 MΩ
Between C51 (female) (6) and ground
Min. 1 MΩ
Between C16 (female) (2) and ground
Min. 1 MΩ
Between C16 (female) (3) and ground
Min. 1 MΩ
40-479
E-30 Rear wiper does not operate
40 Troubleshooting
Circuit diagram related to wiper
40-480
GD535-5 (03)
40 Troubleshooting
E-31 Left and right door wiper does not operate
E-31 Left and right door wiper does not operate Failure
Right and left door wipers do not operate. q q q q q q
Related information
q q
q
No. 1
2
1
If all the wipers do not operate, see “NO WIPER OPERATES CONTINUOUSLY OR INTERMITTENTLY” in E mode. If front wiper also does not operate, see “FRONT WIPER DOES NOT OPERATE” in E mode. If either one of right and left door wipers does not operate, see “LEFT DOOR WIPER DOES NOT OPERATE” or “RIGHT DOOR WIPER DOES NOT OPERATE” in E mode. With/without intermittent operation is switched by door wiper intermittent unit through intermittent signal of front wiper switch. Power is supplied from wiper intermittent unit C54 even in continuous operation, and each door wiper motor on right and left operates. When each door wiper motor on right and left detects stop position, it converts input voltage (24 V) of 1 pin to pulse signal, and output it to 3 pins. While intermittent operation, door wiper intermittent unit C54 and each door wiper motor on right and left receive/deliver 24 V voltage pulse, and each door wiper motor on right and left operates. Door wiper intermittent unit C54 has 2 wiper intermittent circuits. q (1): GND 1 q (2): Output 1 (power supply 1 to wiper motor) q (3): Continuous input (24 V) q (4): Intermittent input (24 V) q (5): Output 2 (power supply 2 to wiper motor) q (6): 24 V common input q (7): 24 V pulse input 2 from wiper motor q (8): 24 V pulse input 1 from wiper motor q (9): GND2 Although T-adapter is not available for wiper intermittent unit C54, check the wiring harness of each pin of wiper intermittent unit C54 for open circuit.
Cause Defective fuse
Defective door wiper intermittent unit
Procedure, measuring location, criteria, and remarks If fuse No.14 in fuse box FB2 is blown out, the circuit probably has ground fault. Perform troubleshooting for “ground fault in wiring harness” first. q If fuse No.14 in fuse box FB2 is blown out, door wipers do not work. REMARK If door wiper does not work at Intermittent, check following. 1. Turn the starting switch to OFF position. 2. Disconnect connectors C53 and C54, and interchange intermittent units with each other. 3. Turn the starting switch to ON position. 4. Turn on and off Intermittent of wiper switch to perform troubleshooting. If right and left door wipers operate normally at Lo and Intermittent, original door wiper intermittent unit is defective. Set the front wiper switch to Hi, and if right and left door wiper do not operate, perform this check. 1. Turn the starting switch to OFF position. 2. Disconnect connector SP36, and connect T-adapter to male side. q
3
Defective diode (internal defect)
Continuity
GD535-5 (03)
Between SP36 (male) (1) (+) and (2) (-)
No continuity
Between SP36 (male) (2) (+) and (1) (-)
Continuity
40-481
E-31 Left and right door wiper does not operate
No.
40 Troubleshooting
Cause
Procedure, measuring location, criteria, and remarks Description hereafter is check of wiring harness of wiper intermittent unit for open circuit. 1. Turn the starting switch to OFF position. 2. Disconnect connectors L21, L48, C51, C12, and SP36, and connect Tadapter to female side of L21. REMARK q There are many diodes in internal circuit. Pay attention to polarity of multimeter. q If "OFF" is not displayed for resistance value in multimeter, this means that open circuit does not occur. q
Check wiring harness connected 1 and 3 pin, 9 and 3 pin of C54 for open circuit. Between L21 (female) (5) (+) and ground
1 to 50 MΩ
Check wiring harness connected 1 and 3 pin, 9 and 3 pin of C54 for open circuit. Between L21 (female) (2) (+) and ground
1 to 50 MΩ
q
4
Open circuit in wiring harness (wire breakage or defective contact)
Resistance
q
1. 2. 3. 4.
Turn the starting switch to OFF position. Insert T-adapter into connectors C11 and C13. Turn the starting switch to ON position. Turn the front wiper switch to Lo position. Check the wiring harness connected to pin 2 and 6 of C54 for open circuit. Between C13 (2) and (4)
20 to 30 V
Check the wiring harness connected to pin 5 and 6 of C54 for open circuit. Between C11 (2) and (4)
20 to 30 V
q
Voltage
q
5
Ground fault in wiring harness (contact with ground circuit)
If front wiper works at Lo, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors C11, C13, C14, and C54, and connect T-adapter to female side of C13. 3. Remove fuse No.14 in fuse box FB2. Resistance
40-482
Between C13 (female) (1) and ground
Min. 1 MΩ
GD535-5 (03)
40 Troubleshooting
E-31 Left and right door wiper does not operate
Circuit diagram related to wiper
GD535-5 (03)
40-483
E-32 Left door wiper does not operate
40 Troubleshooting
E-32 Left door wiper does not operate Failure
Left door wiper does not operate. q q
Related information
q q q
No. 1
2
1
If all the wipers do not operate, see “NO WIPER OPERATES CONTINUOUSLY OR INTERMITTENTLY” in E mode. If front wiper also does not operate, see “FRONT WIPER DOES NOT OPERATE” in E mode. If right and left wipers do not operate, see “RIGHT AND LEFT DOOR WIPERS DO NOT OPERATE” in E mode. With/without intermittent operation of door wiper is switched by door wiper intermittent relay through intermittent signal of front wiper switch. Although T-adapter is not available for wiper intermittent unit C54, check the wiring harness of wiper intermittent unit C54 for open circuit.
Cause Defective left door wiper motor
Defective door wiper intermittent unit
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector C11, and connect T-adapter to male side. Continuity
Between C11 (male) (2) and (4)
Continuity
REMARK Check that rear wiper operates normally. 1. Turn the starting switch to OFF position. 2. Disconnect connectors C53 and C54, and interchange intermittent units with each other. 3. Turn the starting switch to ON position. 4. Perform troubleshooting with front wiper switch at Lo and Intermittent. If left door wiper operates normally at Lo and Intermittent, original door wiper intermittent unit is defective. q
1. 2. 3. 4.
3
Open circuit in wiring harness (wire breakage or defective contact of connector)
Wiper motor Turn the starting switch to OFF position. Disconnect connector C11, and connect T-adapter to female side. Turn the starting switch to ON position. Turn on and off Lo wiper switch to perform troubleshooting.
Voltage
Between C11 (female) (1) and (4)
20 to 30 V
Between C11 (female) (2) and (4)
Front Lo
20 to 30 V
Between C11 (female) (2) and (4)
Front OFF
0V
q Check pin 5 and pin 7 of C54. 1. Turn the starting switch to OFF position. 2. Disconnect connector C11, and connect T-adapter to female side.
Resistance
Between C11 (female) (2) and (3)
Max. 1 Ω
If no failure is found for wiper motor by checks on open circuit of wiring harness, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors C11 and C54, and connect T-adapter to female side of C11. q
4
Ground fault in wiring harness (contact with ground circuit)
Resistance
40-484
Between C11 (female) (2) and ground
Min. 1 MΩ
Between C11 (female) (3) and ground
Min. 1 MΩ
GD535-5 (03)
40 Troubleshooting
E-32 Left door wiper does not operate
Circuit diagram related to wiper
GD535-5 (03)
40-485
E-33 Right door wiper does not operate
40 Troubleshooting
E-33 Right door wiper does not operate Failure
Right door wiper does not operate. q q
Related information
q q q
If all the wipers do not operate, see “NO WIPER OPERATES CONTINUOUSLY OR INTERMITTENTLY” in E mode. If front wiper also does not operate, see “FRONT WIPER DOES NOT OPERATE” in E mode. If right and left wipers do not operate, see “RIGHT AND LEFT DOOR WIPERS DO NOT OPERATE” in E mode. With/without intermittent operation is switched by door wiper intermittent unit through intermittent signal of front wiper switch. Although T-adapter is not available for wiper intermittent unit C54, check the wiring harness of wiper intermittent unit C54 for open circuit.
No.
Cause
1
Defective right door wiper motor
2
1
Defective door wiper intermittent unit
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector C13, and connect T-adapter to male side. Continuity
Between C13 (2) and (4)
Continuity
REMARK Check that rear wiper operates normally. 1. Turn the starting switch to OFF position. 2. Disconnect connectors C53 and C54, and interchange intermittent units with each other. 3. Turn the starting switch to ON position. 4. Perform troubleshooting with front wiper switch at Lo and Intermittent. If right door wiper operates normally at Lo and Intermittent, original door wiper intermittent unit is defective. q
1. 2. 3. 4.
3
Open circuit in wiring harness (wire breakage or defective contact)
Wiper motor Turn the starting switch to OFF position. Disconnect connector C13, and connect T-adapter to female side. Turn the starting switch to ON position. Turn on and off Lo of wiper switch to perform troubleshooting.
Voltage
Between C13 (female) (1) and (4)
20 to 30 V
Between C13 (female) (2) and (4)
Front Lo
20 to 30 V
Between C13 (female) (2) and (4)
Front OFF
0V
q Check pin 2 and pin 8 of C54. 1. Turn the starting switch to OFF position. 2. Disconnect connector C13, and connect T-adapter to female side.
Resistance
Between C13 (female) (2) and (3)
Max. 1 Ω
If no failure is found for "wiper motor" by checks on open circuit in wiring harness, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connectors C13 and C54, and connect T-adapter to female side of C13. q
4
Ground fault in wiring harness (contact with ground circuit)
Resistance
40-486
Between C13 (female) (2) and ground
Min. 1 MΩ
Between C13 (female) (3) and ground
Min. 1 MΩ
GD535-5 (03)
40 Troubleshooting
E-33 Right door wiper does not operate
Circuit diagram related to wiper
GD535-5 (03)
40-487
E-34 Front or door washer does not operate
40 Troubleshooting
E-34 Front or door washer does not operate Failure Related information
No.
1
Front washer or door washer does not operate. q q
If all the wipers do not operate, see “NO WIPER OPERATES CONTINUOUSLY OR INTERMITTENTLY” in E mode. T-adapter is not provided to the connector of a washer motor (check without a T-adapter).
Cause
Defective front wiper switch (internal defect)
Procedure, measuring location, criteria, and remarks 1. Turn the starting switch to OFF position. 2. Disconnect connector L21, and connect T-adapter to male side. 3. Turn on and off wiper switch to perform troubleshooting. Resistance
2
3
1
Defective front washer motor (internal open circuit)
Defective door washer motor
Between L21 (male) (7) and Front washer switch: ON (6) Front washer switch: OFF
Max. 1 Ω Min. 1 MΩ
q If front washer operates, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connector B16, and connect T-adapter to male side.
Continuity
Between B16 (male) (1) and (2)
Continuity
q When door washer works, this check is not required. 1. Turn the starting switch to OFF position. 2. Disconnect connector B15, and connect T-adapter to male side.
Continuity
Between B15 (male) (1) and (2)
Continuity
Perform the following troubleshooting when both front washer and door washer do not operate. 1. Turn the starting switch to OFF position. 2. Disconnect connectors B20 and B21, and connect T-adapter to each male side. q
4
Defective diode (internal defect) Continuity
Between B20 (male) (1) (+) and (2) (-)
No continuity
Between B20 (male) (2) (+) and (1) (-)
Continuity
Between B21 (male) (1) (+) and (2) (-)
No continuity
Between B21 (male) (2) (+) and (1) (-)
Continuity
q Front washer system 1. Turn the starting switch to OFF position. 2. Disconnect connectors L21, B15, B20, and B21, and connect T-adapter to female side of L21.
5
Open circuit in wiring harness (wire breakage or defective contact)
Continuity
Between L21 (female) (6) and ground
Continuity
q Door washer system 1. Turn the starting switch to OFF position. 2. Disconnect connectors L21, B16, B20, and B21, and connect T-adapter to female side of L21.
Continuity
Between L21 (female) (6) and ground
Continuity
Perform the following troubleshooting when both front washer and door washer do not operate. 1. Turn the starting switch to OFF position. 2. Disconnect connectors L21, B15, B16, B20, and B21, and connect Tadapter to female side of L21. q
6
Ground fault in wiring harness (contact with ground circuit)
Resistance
40-488
Between L21 (female) (6) and ground
Min. 1 MΩ
GD535-5 (03)
40 Troubleshooting
E-34 Front or door washer does not operate
Circuit diagram related to windshield washer
GD535-5 (03)
40-489
E-35 Rear washer does not operate
40 Troubleshooting
E-35 Rear washer does not operate Failure Related information
No.
1
Rear washer does not operate. q q
If wiper also do not operate, see “NO WIPER OPERATES CONTINUOUSLY OR INTERMITTENTLY” or “REAR WIPER DOES NOT OPERATE” in E mode. T-adapter is not provided to the connector of a washer motor (check without a T-adapter).
Cause
Defective rear wiper switch
Procedure, measuring location, criteria, and remarks 1. 2. 3. 4.
Turn the starting switch to OFF position. Disconnect cable from negative (-) battery terminal. Disconnect connector L21, and connect T-adapter to male side. Turn on and off rear wiper switch to perform troubleshooting.
Resistance
2
3
1
Defective rear washer motor (internal open circuit)
Defective diode (internal defect)
Between L21 (male) (7) and Rear washer switch: ON (10)
Max. 1 Ω
Between L21 (male) (7) and Rear washer switch: OFF (10)
Min. 1 MΩ
1. Turn the starting switch to OFF position. 2. Disconnect connector B17, and connect T-adapter to male side. Continuity
Between B17 (male) (1) and (2)
Continuity
1. Turn the starting switch to OFF position. 2. Disconnect connector B22, and connect T-adapter to male side. Continuity
Between B22 (male) (1) (+) and (2) (-)
No continuity
Between B22 (male) (2) (+) and (1) (-)
Continuity
4
1. Turn the starting switch to OFF position. Open circuit in wiring harness (wire breakage or 2. Disconnect connectors B22 and L21, and connect T-adapter to female side of L21. defective contact) Continuity Between L21 (female) (10) and ground Continuity
5
Ground fault in wiring harness (contact with ground circuit)
40-490
1. Turn the starting switch to OFF position. 2. Disconnect connectors L21, B17, B22, and connect T-adapter to female side of L21. Resistance
Between L21 (female) (10) and ground
Min. 1 MΩ
GD535-5 (03)
40 Troubleshooting
E-35 Rear washer does not operate
Circuit diagram related to windshield washer
GD535-5 (03)
40-491
E-36 KOMTRAX system does not operate normally.
40 Troubleshooting
E-36 KOMTRAX system does not operate normally. Failure
KOMTRAX system does not operate normally. q q
Related information
q q q
No.
1
1
Perform following troubleshooting if administrator of KOMTRAX system requests to check whether failure occurs in system on machine. Even when KOMTRAX system is defective, no problem appears on machine. All troubleshooting can be checked on the service menu of the machine monitor. For checking the terminal settings, see Testing and adjusting "Checking the KOMTRAX setting display (terminal setting status)". For checking the GPS and communication status, see Testing and adjusting "Checking the KOMTRAX setting display (GPS and communication status)".
Cause
Transmitting error 1
Procedure, measuring location, criteria, and remarks 1. Turn starting switch to ON position. 2. Display the "Terminal Setting Status" screen. Monitoring display
Check item: Radio station establishment state
Established
1. Turn starting switch to ON position. 2. Display the "GPS & Communication Status" screen. N ###.##.## (Latitude) 2
Defective GPS positioning
Monitoring display
Check item: Positioning
E ###.##.## (Longitude) Positioning in Progress
If the latitude and longitude are not displayed within 5 minutes in an open-sky area, call the KOMTRAX service hot-line for advice. 1. Turn starting switch to ON position. 2. Display the "GPS & Communication Status" screen.
3
Defective communication environment
Monitoring display
Check item: Communication
Communication reception range level 1 to communication reception range level 3
Contact KOMTRAX Service hot-line if Communication reception range is not within level 1 to 3.
4
Transmitting error 2
1. Turn starting switch to ON position. 2. Display the "GPS & Communication Status" screen. Monitoring display
40-492
Check item: Number of message(s) not yet sent
0 to 100 (normally 0)
GD535-5 (03)
40 Troubleshooting
GD535-5 (03)
E-36 KOMTRAX system does not operate normally.
40-493
How to use troubleshooting table
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-mode)
1
How to use troubleshooting table
1
This troubleshooting chart indicates the location where the problem occurring on the machine and categorizes the problem under one of the main components, such as the steering system or work equipment hydraulic system. Use the following procedure to perform accurate troubleshooting swiftly. Step 1. Ask operator questions q The questions to ask the operator are given under the problem. If the answer to the question matches the description given, the cause given after "o" is the probable cause. Keeping the description of the questions in mind, read the matrix and proceed with Step 2 and Step 3 to pinpoint the correct cause. Example: Machine does not turn Ask the operator and check the following points. q Did the problem suddenly start? -> Broken device related to steering q Was the steering wheel operation heavy before? -> Worn part or defective seal in device related to steering Step 2. Checks before troubleshooting Before measuring the oil pressure or starting the troubleshooting, perform the checks before starting, check for oil leakage, or for loose bolts. This will prevent wasting time when troubleshooting. The items given under Checks before troubleshooting are checks that must be performed with special care taking the condition of the machine into consideration before starting the actual troubleshooting.
q
Example: Check before starting troubleshooting Is oil level and type of oil in hydraulic tank correct? q Is there any oil leakage from steering valve or demand valve? q Is steering linkage adjusted properly? q
40-494
Step 3. How to read matrix 1. Operate the machine and perform troubleshooting introduced in the Diagnosis column. If any problems occur as the result of the troubleshooting, put a check in the corresponding box. a Perform troubleshooting for easier items first. It is not necessary to follow the number order. (Example) No
Remedy Diagnosis
1
Machine turns neither right nor left
2
Machine turns only right or left
3
Steering wheel operation is heavy in both right and left directions
4
Steering wheel is too heavy to turn in either right or left direction
5
Work equipment operates.
2. Find the corresponding cause in the cause column. If a problem is found, the Q marks on the same line for the troubleshooting item are the causes. (In Diagnosis item 2 in the diagram below, the cause is c or e.) [Where there is 1 Q mark] Perform troubleshooting for the other items marked with Q in the same column for the cause to check if the problem occurs, then make repairs. [Where there are 2 or more Q marks] Go to step 3 to narrow down the cause.
GD535-5 (03)
40 Troubleshooting
3. Operate the machine and perform troubleshooting for the items not checked in step 2, and if any problem occurs, put a check in the corresponding line. (In troubleshooting item 5 in the figure below, the problem was re-produced.) 4. Find the corresponding cause in the cause column. If a problem is found, the Q marks on the same line for the troubleshooting item are the causes. (In Diagnosis item 5 in the figure below, the cause is "b" or "e".)
How to use troubleshooting table
6. Repeat the operation in Step 3 to 5 until the cause is narrowed down to 1 item (1 common item). If cause items are 2 or more, continue until number of items becomes minimum. 7. Remedy After narrowing down the common causes, taken the action given in the remedy line. [Symbols in remedy column and their meanings] x=Replace; E=Repair; A=Adjust; C=Clean
5. Narrow down the causes. Of the causes found in Step 2 and Step 5, there is a common cause (Q marks on the line for each troubleshooting item and in the common cause column for both) is a cause common to the problem items found in the troubleshooting in Step 2 and Step 3. a The items that are not common (items that do not have Q marks in the same cause column) are probably not the cause, so they can be eliminated. (The causes for troubleshooting item 2 in the figure below are "c" or "e", and the causes in troubleshooting item 5 are "b" or "e", so cause e is a common cause.)
GD535-5 (03)
40-495
How to use troubleshooting table
40-496
40 Troubleshooting
GD535-5 (03)
40 Troubleshooting
GD535-5 (03)
How to use troubleshooting table
40-497
How to use troubleshooting table
40-498
40 Troubleshooting
GD535-5 (03)
40 Troubleshooting
GD535-5 (03)
How to use troubleshooting table
40-499
H-1 Engine speed drops significantly or engine stalls
40 Troubleshooting
H-1 Engine speed drops significantly or engine stalls
1
Checks before troubleshooting Check the hydraulic oil tank level.
Cause a b c
Malfunction of main pump (servo piston) Internal failure of main pump Engine failure
q
Remedy No. 1 2 3
Diagnosis Main pump assembly is abnormal. Main pump is abnormal. Basic engine may be defective.
EEE X X X Q Q Q
* Perform troubleshooting of engine (S-mode).
40-500
GD535-5 (03)
40 Troubleshooting
H-2 Machine does not move off.
H-2 Machine does not move off.
1
Internal defect of PTO Defective connection of power train pump (drive system) Clogged transmission case suction strainer Air sucked into suction circuit of power train pump Internal defect of power train pump Malfunction of power train main relief valve Malfunction of torque converter main relief valve Internal defect of torque converter Internal defect of transmission
Checks before troubleshooting Cause q Check that transmission case oil level is normal. a b c d e f g h i q Check the oil pressure while torque converter oil temperature gauge is in operator range.
Remedy No. 1 2 3 4 5 6 7
Diagnosis Machine does not move off in any gear position. Machine does not move off in specific gear position. When transmission oil temperature is low, noise is generated in the strainer or transmission filter. Oil pressure of power train main relief valve is abnormal. Torque converter inlet pressure is low. Torque converter outlet pressure is abnormal. The transmission system is abnormal.
GD535-5 (03)
EEEEEEEEE X X C X X X X X X Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q
40-501
H-3 Gear speed does not shift.
40 Troubleshooting
H-3 Gear speed does not shift.
1
Malfunction of transmission clutch valve (ECMV) Defective sealing of transmission clutch piston Wear or damage of transmission clutch disc or plate
Checks before troubleshooting Cause q Check that transmission case oil level is normal. a b c q Check the oil pressure while torque converter oil temperature gauge is in operator range. Move gear shift lever to each gear speed and check that gear cannot be shifted only for forward or reverse travel. Then, perform troubleshooting.
Remedy No. 1 2 3 4
Diagnosis
EEE X X X
Machine does not travel forward or reverse. Gear is not shifted up or down. Defective sealing of transmission clutch piston Wear or damage of transmission clutch disc or plate
Q Q Q Q Q Q Q Q
40-502
GD535-5 (03)
40 Troubleshooting
H-4 Travel speed or power is low.
H-4 Travel speed or power is low.
1
Checks before troubleshooting Cause Check that transmission case oil level is normal. a b c d e f g h i j q Check the oil pressure while torque converter oil temperature gauge is in operator range. q Check that wheel brake and parking brake are not dragging, and then perform troubleshooting.
Clogged transmission case suction strainer Internal defect of power train pump (pump body) Malfunction of power train main relief valve Malfunction of torque converter main relief valve Internal defect of torque converter Internal defect of transmission Internal defect of final drive Malfunction of corresponding clutch valve (ECMV) Defective sealing of corresponding clutch piston Wear or damage of corresponding clutch disc or plate
q
Remedy No. 1 2 3 4 5 6 7 8 9 10 11
Diagnosis Metal powder (such as aluminum, copper and iron powder) is adhered to transmission filter and strainer. When transmission oil temperature is low, noise is generated in the pump or transmission filter. Overheat of torque converter oil temperature Abnormal main relief pressure of power train Low oil pressure of ECMV output (clutch) Defective seal of torque converter lockup clutch piston Wear or damage of torque converter lockup clutch disc or plate Defective sealing of transmission clutch piston Wear or damage of transmission clutch disc or plate Torque converter main relief inlet pressure is low. Abnormal final drive
C EEEEE X * * * X X X X X X Q
Q Q
Q
Q
Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q
* Go to "Locating the failure clutch and ECMV (Check by remodeling code)".
GD535-5 (03)
40-503
H-4 Travel speed or power is low.
40 Troubleshooting
* Locating the failure clutch and ECMV (Check by failure code) (H-4) a For checking the failure code display, see Testing and adjusting "Special functions of machine monitor ". a If replacing the ECMV for troubleshooting, remove mud and dust, and clean the ECMV. Then, tighten mounting bolts with the specified torque. a Start the engine, select the Manual mode, and perform the following troubleshooting. Cause
ECMV operation table
F8
4th
3rd
2nd
1st
W W
W
W
W W
F6 F7
W
W
F4 F5
W W
F2 F3
R
W
Operation failure of FL-clutch ECMV (fill switch) Operation failure of FH-clutch ECMV (fill switch) Operation failure of R-clutch ECMV (fill switch) Operation failure of 1st clutch ECMV (fill switch) Operation failure of 2nd clutch ECMV (fill switch) Operation failure of 3rd clutch ECMV (fill switch) Operation failure of 4th clutch ECMV (fill switch)
F1
FH
SPEED RANGE
FL
No.
a b c d e f g
W
W
W W
W
N R1
W
R2
W
R3
W
R4
W
W W W W
a When the lever is in N position in Manual mode, the clutch of the gear (Q mark) selected by the lever is ON. a When the lever is in N position, the clutch is not switched. Remedy No.
Diagnosis
Failure code "15SDL1" is not displayed in F1, F3, F5 and F7 positions. It is displayed in R1 to R4, F2, F4, F6 and F8 positions. After Step (1), failure code 15SDL1 is not displayed if F1 fill switch connector (T36) is (2) disconnected. Failure code 15SDMA is not displayed if ECMV (other than F) is replaced. Failure code "15SCL1" is not displayed in F2, F4, F6 and F8 positions. It is displayed in R1 (1) to R4, F1, F3, F5 and F7 positions. After Step (1), failure code 15SCL1 is not displayed if FH fill switch connector (T37) is (2) disconnected. Failure code 15SCMA is not displayed if ECMV (other than FH) is replaced. (1)
1
2
Failure code "15SBL1" is not displayed in R1 to R4 positions, but displayed in F1 to F8 positions. After Step (1), failure code 15SBL1 is not displayed if R fill switch connector (T38) is (2) disconnected. Failure code 15SBMA is not displayed if ECMV (other than R) is replaced. Failure code "15SEL1" is not displayed in F1 and F2 positions. It is displayed in F3 to F8 (1) and R1 to R4 positions. (1)
3
4
Failure Code
X X X X X X X
15SDL1 Q 15SDMA 15SCL1
Q
15SCMA 15SBL1
Q
15SBMA 15SEL1
After Step (1), failure code 15SEL1 is not displayed if 1st fill switch connector (T39) is 15SEMA disconnected. Failure code 15SEMA is not displayed if ECMV (other than 1st) is replaced. Failure code "15SFL1" is not displayed in F3 and F4 positions. It is displayed in F1, F2, F5 (1) 15SFL1 to F8 and R1 to R4 positions. After Step (1), failure code 15SFL1 is not displayed if 2nd fill switch connector (T40) is 15SFMA (2) disconnected. Failure code 15SFMA is not displayed if ECMV (other than 2nd) is replaced.
Q
(2)
5
Failure code "15SGL1" is not displayed in F5 and F6 positions. It is displayed in F1 to F4, 15SGL1 F7, F8, and R1 to R4 positions. Step (1), failure code 15SGL1 is not displayed if 3rd fill switch connector (T41) is (2) 15SGMA disconnected. Failure code 15SGMA is not displayed if ECMV (other than 3rd) is replaced. Failure code "15SHL1" is not displayed in F7 and F8 positions. It is displayed in F1 to F6 15SHL1 (1) and R1 to R4 positions. (1)
6
7
(2)
40-504
Q
Q
Q
After Step (1), failure code 15SHL1 is not displayed if 4th fill switch connector (T42) is 15SHMA disconnected. Failure code 15SHMA is not displayed if ECMV (other than 4th) is replaced.
GD535-5 (03)
40 Troubleshooting
H-4 Travel speed or power is low.
* Locating the failure ECMV (Check by failure code) a For checking the failure code display, see Testing and adjusting "Special functions of machine monitor". a If replacing the ECMV for troubleshooting, remove mud and dust, and clean the ECMV. Then, tighten mounting bolts with the specified torque. a Start the engine, select the Manual mode, and perform the following troubleshooting. ECMV operation table
F8
4th
3rd
2nd
1st
R
W W
W
W
W W
F6 F7
W
W
F4 F5
W W
F2 F3
FH
W
W
W
W W
W
N R1
W W
R2
W
R3
W
R4
W
W W W
a When the lever is in N position in Manual mode, the clutch of the gear (Q mark) selected by the lever is ON. Remedy No.
Diagnosis
Cause j k l m n
Wear or seizure of FL clutch disc, or wear of piston seal Wear or seizure of FH clutch disc, or wear of piston seal Wear or seizure of R clutch disc, or wear of piston seal Wear or seizure of 1st clutch disc, or wear of piston seal Wear or seizure of 2nd clutch disc, or wear of piston seal Wear or seizure of 3rd clutch disc, or wear of piston seal Wear or seizure of 4th clutch disc, or wear of piston seal
F1
FL
No. SPEED RANGE
h i
Failure code
X X X X X X X
Failure code 15G0MW is not displayed in F1 to F8 positions, but displayed in R1 to R4 positions. 15G0MW See the Testing and adjusting, "Testing power train oil pressure", and make sure that R(2) clutch oil pressure is normal. Failure code15H0MW is not displayed in F1, 3, 5, 7 and R1 to R4 positions, but displayed (1) in F2, 4, 6 and 8 positions. (1)
1
2
15H0MW
See the Testing and adjusting, "Testing power train oil pressure", and make sure that FHclutch oil pressure is normal. Failure code15J0MW is not displayed in F2, 4, 6, 8 and R1 to R4 positions, but displayed (1) in F1, 3, 5 and 7 positions. 15J0MW Q See the Testing and adjusting, "Testing power train oil pressure", and make sure that FL(2) clutch oil pressure is normal.
Q
Q
(2)
3
Failure code 15K0MW is not displayed in F3 to F8 and R2 to R4 positions, but displayed in F1 to F2 and R1 positions. 15K0MW See the Testing and adjusting, "Testing power train oil pressure", and make sure that 1st (2) clutch oil pressure is normal. Failure code 15L0MW is not displayed in F1 to F2, F5 to F8, and R1, 3 and 4 positions, (1) but displayed in F3, F4 and R2 positions.
(1) 4
5
15L0MW
See the Testing and adjusting, "Testing power train oil pressure", and make sure that 2nd clutch oil pressure is normal. Failure code 15M0MW is not displayed in F1 to F4, F7 to F8, and R1, 2 and 4 positions, (1) but displayed in F5, F6 and R3 positions. 15M0MW See the Testing and adjusting, "Testing power train oil pressure", and make sure that 3rd (2) clutch oil pressure is normal.
Q
Q
(2)
6
Failure code 15N0MW is not displayed in F1 to F6 and R1 to R3 positions, but displayed in F7, F8 and R4 positions. 15N0MW See the Testing and adjusting, "Testing power train oil pressure", and make sure that 4th (2) clutch oil pressure is normal.
Q
(1)
7
GD535-5 (03)
Q
40-505
H-5 Torque converter lockup does not operate or is not canceled.
40 Troubleshooting
H-5 Torque converter lockup does not operate or is not canceled.
1
Failure of lockup clutch ECMV operation Defective seal of lockup clutch piston Wear or damage of lockup clutch disc or plate
Checks before troubleshooting Cause q Check that transmission case oil level is normal. a b c q Check the oil pressure while torque converter oil temperature gauge is in operator range. q Because the lockup clutch (L/C) of the torque converter is not engaged, the torque converter is in the torque converter mode regardless of the selection of the transmission mode selector switch.
Remedy No. 1 2
Diagnosis Lockup oil pressure is low or zero. Lockup oil pressure is zero, but not turned OFF.
40-506
X X X Q Q Q
GD535-5 (03)
40 Troubleshooting
H-6 Machine starts or gear speed shifts with long time lag.
H-6 Machine starts or gear speed shifts with long time lag.
1
Checks before troubleshooting Cause Check that transmission case oil level is normal. a b c q Check the oil pressure while torque converter oil temperature gauge is in operator range. q Move gear shift lever to each gear speed and check gear speed or forward/reverse travel causing long time lag. Then, perform troubleshooting. q Check that travel speed is normal before performing troubleshooting. (If it is not normal, perform troubleshooting for "H-4 Travel speed or power is low" first.)
Malfunction of corresponding ECMV Defective sealing of corresponding clutch piston Wear or damage of corresponding clutch disc or plate
q
Remedy No. 1 2 3
Diagnosis Time lag is large in specific gears. ECMV output (clutch) oil pressure is low in specific gears. Wear or damage of transmission clutch disc or plate
* * * Q Q Q Q Q
* Go to "Locating the failure clutch and ECMV (Check by remodeling code)".
GD535-5 (03)
40-507
H-6 Machine starts or gear speed shifts with long time lag.
40 Troubleshooting
* Locating the failure clutch and ECMV (Check by failure code) a For checking the failure code display, see Testing and adjusting "Special functions of machine monitor". a If replacing the ECMV for troubleshooting, remove mud and dust, and clean the ECMV. Then, tighten mounting bolts with the specified torque. a Start the engine, select the Manual mode, and perform the following troubleshooting. Cause a b c d e f g
F3
F8
4th
3rd
2nd
W
W
W W
W
W
W W
F6 F7
W W
F4 F5
R
W
F2
Operation failure of FL-clutch ECMV (fill switch) Operation failure of FH-clutch ECMV (fill switch) Operation failure of R-clutch ECMV (fill switch) Operation failure of 1st clutch ECMV (fill switch) Operation failure of 2nd clutch ECMV (fill switch) Operation failure of 3rd clutch ECMV (fill switch) Operation failure of 4th clutch ECMV (fill switch)
F1
1st
SPEED RANGE
FH
No.
FL
ECMV operation table
W
W
W W
W
N R1
W W
R2
W
R3
W
R4
W
W W W
a When the lever is in N position in Manual mode, the clutch of the gear (Q mark) selected by the lever is ON. Remedy
No. (1)
1 (2) (1)
2 (2) (1)
3 (2) (1)
4 (2) (1)
5 (2) (1)
6 (2) (1)
7 (2)
40-508
Diagnosis Failure code "15SDL1" is not displayed in F1, F3, F5 and F7 positions. It is displayed in R1 to R4, F2, F4, F6 and F8 positions. After Step (1), failure code 15SDL1 is not displayed if FL fill switch connector (T36) is disconnected. Failure code 15SDMA is not displayed if ECMV (other than F) is replaced. Failure code "15SCL1" is not displayed in F2, F4, F6 and F8 positions. It is displayed in R1 to R4, F1, F3, F5 and F7 positions. After Step (1), failure code 15SCL1 is not displayed if FH fill switch connector (T37) is disconnected. Failure code 15SCMA is not displayed if ECMV (other than FH) is replaced. Failure code "15SBL1" is not displayed in R1 to R4 positions, but displayed in F1 to F8 positions. After Step (1), failure code 15SBL1 is not displayed if R fill switch connector (T38) is disconnected. Failure code 15SBMA is not displayed if ECMV (other than R) is replaced. Failure code "15SEL1" is not displayed in F1 and F2 positions. It is displayed in F3 to F8 and R1 to R4 positions. After Step (1), failure code 15SEL1 is not displayed if 1st fill switch connector (T39) is disconnected. Failure code 15SEMA is not displayed if ECMV (other than 1st) is replaced. Failure code "15SFL1" is not displayed in F3 and F4 positions. It is displayed in F1, F2, F5 to F8 and R1 to R4 positions. After Step (1), failure code 15SFL1 is not displayed if 2nd fill switch connector (T40) is disconnected. Failure code 15SFMA is not displayed if ECMV (other than 2nd) is replaced. Failure code "15SGL1" is not displayed in F5 and F6 positions. It is displayed in F1 to F4, F7, F8, and R1 to R4 positions. After Step (1), failure code 15SGL1 is not displayed if 3rd fill switch connector (T41) is disconnected. Failure code 15SGMA is not displayed if ECMV (other than 3rd) is replaced. Failure code "15SHL1" is not displayed in F7 and F8 positions. It is displayed in F1 to F6 and R1 to R4 positions. After Step (1), failure code 15SHL1 is not displayed if 4th fill switch connector (T42) is disconnected. Failure code 15SHMA is not displayed if ECMV (other than 4th) is replaced.
Failure Code
X X X X X X X
15SDL1 Q 15SDMA 15SCL1
Q
15SCMA 15SBL1
Q
15SBMA 15SEL1
Q
15SEMA 15SFL1
Q
15SFMA 15SGL1
Q
15SGMA 15SHL1
Q
15SHMA
GD535-5 (03)
40 Troubleshooting
H-6 Machine starts or gear speed shifts with long time lag.
* Locating the failure ECMV (Check by failure code) a For checking the failure code display, see Inspection and adjusting "Special functions of machine monitor (EMMS)". a If replacing the ECMV for troubleshooting, remove mud and dust, and clean the ECMV. Then, tighten mounting bolts with the specified torque. a Start the engine, select the Manual mode, and perform the following troubleshooting.
W
F3
F8
W
W W
W
W
W
W W
W
N R1
W W
R2
W
R3
W
R4
W
W W W
a When the lever is in N position in Manual mode, the clutch of the gear (Q mark) selected by the lever is ON. Remedy No. (1) 1 (2) (1) 2 (2) (1) 3 (2) (1) 4 (2) (1) 5 (2) (1) 6 (2) (1) 7 (2)
Diagnosis
Cause j k l m n
4th
3rd
2nd W
W
F6 F7
W
W
F4 F5
W W
F2
h i
Wear or seizure of FL clutch disc, or wear of piston seal Wear or seizure of FH clutch disc, or wear of piston seal Wear or seizure of R clutch disc, or wear of piston seal Wear or seizure of 1st clutch disc, or wear of piston seal Wear or seizure of 2nd clutch disc, or wear of piston seal Wear or seizure of 3rd clutch disc, or wear of piston seal Wear or seizure of 4th clutch disc, or wear of piston seal
F1
1st
SPEED RANGE
R
FL
No.
FH
ECMV operation table
Failure Code
X X X X X X X
Failure code "15SDL1" is not displayed in F1, F3, F5 and F7 positions. It is displayed in 15SDL1 Q R1 to R4, F2, F4, F6 and F8 positions. After Step (1), failure code 15SDL1 is not displayed if F fill switch connector (T36) is 15SDMA Q unplugged. Failure code 15SDMA is not displayed if ECMV (other than F) is replaced. Failure code "15SCL1" is not displayed in F2, F4, F6 and F8 positions. It is displayed in 15SCL1 Q R1 to R4, F1, F3, F5 and F7 positions. After Step (1), failure code 15SCL1 is not displayed if FH fill switch connector (T37) is unplugged. ***No Translation*** Failure code 15SCMA is not displayed if ECMV (other 15SCMA Q than FH) is replaced. Failure code "15SBL1" is not displayed in R1 to R4 positions, but displayed in F1 to F8 15SBL1 Q positions. After Step (1), failure code 15SBL1 is not displayed if R fill switch connector (T38) is 15SBMA Q unplugged. Failure code 15SBMA is not displayed if ECMV (other than R) is replaced. Failure code "15SEL1" is not displayed in F1 and F2 positions. It is displayed in F3 to F8 15SEL1 Q and R1 to R4 positions. After Step (1), failure code 15SEL1 is not displayed if 1st fill switch connector (T39) is 15SEMA Q unplugged. Failure code 15SEMA is not displayed if ECMV (other than 1st) is replaced. Failure code "15SFL1" is not displayed in F3 and F4 positions. It is displayed in F1, F2, 15SFL1 Q F5 to F8 and R1 to R4 positions. After Step (1), failure code 15SFL1 is not displayed if 2nd fill switch connector (T40) is 15SFMA Q unplugged. Failure code 15SFMA is not displayed if ECMV (other than 2nd) is replaced. Failure code "15SGL1" is not displayed in F5 and F6 positions. It is displayed in F1 to F4, 15SGL1 Q F7, F8, and R1 to R4 positions. After Step (1), failure code 15SGL1 is not displayed if 3rd fill switch connector (T41) is 15SGMA Q unplugged. Failure code 15SGMA is not displayed if ECMV (other than 3rd) is replaced. Failure code "15SHL1" is not displayed in F7 and F8 positions. It is displayed in F1 to F6 15SHL1 Q and R1 to R4 positions. After Step (1), failure code 15SHL1 is not displayed if 4th fill switch connector (T42) is 15SHMA Q unplugged. Failure code 15SHMA is not displayed if ECMV (other than 4th) is replaced.
GD535-5 (03)
40-509
H-7 Torque converter oil temperature is high.
40 Troubleshooting
H-7 Torque converter oil temperature is high.
1
Checks before troubleshooting Cause Check that transmission case oil level is normal. a b c d e f g h i j q Check the oil pressure while torque converter oil temperature gauge is in operator range. q Check that wheel brake and parking brake are not dragging, and then perform troubleshooting. Malfunction of power train main relief valve Malfunction of torque converter relief valve Internal defect of torque converter Malfunction of torque converter lockup clutch valve (ECMV) Defective seal of torque converter lockup clutch piston Wear or damage of torque converter lockup clutch disc or plate Malfunction of corresponding ECMV Defective sealing of corresponding clutch piston Wear or damage of corresponding clutch disc or plate Internal defect of transmission
q
Remedy No. 1 2 3 4 5 6
Diagnosis
EE EEE E X * * * X X X X X X
Insufficient travel speed, thrust and gradeability in all gears Insufficient travel speed, thrust and gradeability in specific gears Abnormal speed during engine low idle or during high idle Torque converter stall speed is too high. ECMV output (clutch) oil pressure is low in specific gears. Torque converter main relief inlet pressure is low.
Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q
* Go to "Locating the failure clutch and ECMV (Check by failure code)".
40-510
GD535-5 (03)
40 Troubleshooting
H-7 Torque converter oil temperature is high.
* Locating the failure clutch and ECMV (Check by failure code) a For checking the failure code display, see Testing and adjusting "Special functions of machine monitor". a If replacing the ECMV for troubleshooting, remove mud and dust, and clean the ECMV. Then, tighten mounting bolts with the specified torque. a Start the engine, select the Manual mode, and perform the following troubleshooting. Cause
ECMV operation table
F3
F8
4th
3rd
2nd
1st W
W
W W
W
W
W W
F6 F7
W W
F4 F5
R
W
F2
Operation failure of FL-clutch ECMV (fill switch) Operation failure of FH-clutch ECMV (fill switch) Operation failure of R-clutch ECMV (fill switch) Operation failure of 1st clutch ECMV (fill switch) Operation failure of 2nd clutch ECMV (fill switch) Operation failure of 3rd clutch ECMV (fill switch) Operation failure of 4th clutch ECMV (fill switch)
F1
FH
SPEED RANGE
FL
No.
a b c d e f g
W
W
W W
W
N R1
W W
R2
W
R3
W
R4
W
W W W
a When the lever is in N position in Manual mode, the clutch of the gear (Q mark) selected by the lever is ON. Remedy No. (1) 1 (2) (1) 2 (2) (1) 3 (2) (1) 4 (2) (1) 5 (2)
Diagnosis Failure code "15SDL1" is not displayed in F1, F3, F5 and F7 positions. It is displayed in R1 to R4, F2, F4, F6 and F8 positions. After Step (1), failure code 15SDL1 is not displayed if FL fill switch connector (T36) is disconnected. Failure code 15SDMA is not displayed if ECMV (other than F) is replaced. Failure code "15SCL1" is not displayed in F2, F4, F6 and F8 positions. It is displayed in R1 to R4, F1, F3, F5 and F7 positions. After Step (1), failure code 15SCL1 is not displayed if FH fill switch connector (T37) is disconnected. Failure code 15SCMA is not displayed if ECMV (other than FH) is replaced. Failure code "15SBL1" is not displayed in R1 to R4 positions, but displayed in F1 to F8 positions. After Step (1), failure code 15SBL1 is not displayed if R fill switch connector (T38) is disconnected. Failure code 15SBMA is not displayed if ECMV (other than R) is replaced. Failure code "15SEL1" is not displayed in F1 and F2 positions. It is displayed in F3 to F8 and R1 to R4 positions. After Step (1), failure code 15SEL1 is not displayed if 1st fill switch connector (T39) is disconnected. Failure code 15SEMA is not displayed if ECMV (other than 1st) is replaced. Failure code "15SFL1" is not displayed in F3 and F4 positions. It is displayed in F1, F2, F5 to F8 and R1 to R4 positions. After Step (1), failure code 15SFL1 is not displayed if 2nd fill switch connector (T40) is disconnected. Failure code 15SFMA is not displayed if ECMV (other than 2nd) is replaced.
Failure Code
15SDL1 Q 15SDMA 15SCL1
7
15SBL1
Q
15SBMA 15SEL1
Q
15SEMA 15SFL1
Q
15SFMA
Failure code "15SGL1" is not displayed in F5 and F6 positions. It is displayed in F1 to F4, 15SGL1 F7, F8, and R1 to R4 positions. After Step (1), failure code 15SGL1 is not displayed if 3rd fill switch connector (T41) is 15SGMA (2) disconnected. Failure code 15SGMA is not displayed if ECMV (other than 3rd) is replaced. Failure code "15SHL1" is not displayed in F7 and F8 positions. It is displayed in F1 to F6 (1) 15SHL1 and R1 to R4 positions. (2)
Q
15SCMA
(1) 6
X X X X X X X
Q
Q
After Step (1), failure code 15SHL1 is not displayed if 4th fill switch connector (T42) is 15SHMA disconnected. Failure code 15SHMA is not displayed if ECMV (other than 4th) is replaced.
GD535-5 (03)
40-511
H-7 Torque converter oil temperature is high.
40 Troubleshooting
* Locating the failure ECMV (Check by failure code) a For checking the failure code display, see Testing and adjusting "Special functions of machine monitor". a If replacing the ECMV for troubleshooting, remove mud and dust, and clean the ECMV. Then, tighten mounting bolts with the specified torque. a Start the engine, select the Manual mode, and perform the following troubleshooting. Cause
F7
W
W
W W
W
W
W W
W
N R1
W W
R2
W
R3
W
R4
W
W W W
a When the lever is in N position in Manual mode, the clutch of the gear (Q mark) selected by the lever is ON. Remedy No.
j k l m n
4th
3rd
2nd W
W
F6 F8
W
W
F4 F5
W W
F2 F3
R
W
h i
Wear or seizure of FL clutch disc, or wear of piston seal Wear or seizure of FH clutch disc, or wear of piston seal Wear or seizure of R clutch disc, or wear of piston seal Wear or seizure of 1st clutch disc, or wear of piston seal Wear or seizure of 2nd clutch disc, or wear of piston seal Wear or seizure of 3rd clutch disc, or wear of piston seal Wear or seizure of 4th clutch disc, or wear of piston seal
F1
1st
SPEED RANGE
FH
No.
FL
ECMV operation table
Diagnosis
Failure Code
X X X X X X X
Failure code "15SDL1" is not displayed in F1, F3, F5 and F7 positions. It is displayed in R1 15SDL1 Q to R4, F2, F4, F6 and F8 positions. After Step (1), failure code 15SDL1 is not displayed if F fill switch connector (T36) is 15SDMA Q (2) disconnected. Failure code 15SDMA is not displayed if ECMV (other than F) is replaced. Failure code "15SCL1" is not displayed in F2, F4, F6 and F8 positions. It is displayed in R1 15SCL1 Q (1) to R4, F1, F3, F5 and F7 positions. After Step (1), failure code 15SCL1 is not displayed if FH fill switch connector (T37) is (2) 15SCMA Q disconnected. Failure code 15SCMA is not displayed if ECMV (other than FH) is replaced.
(1) 1
2
Failure code "15SBL1" is not displayed in R1 to R4 positions, but displayed in F1 to F8 positions. After Step (1), failure code 15SBL1 is not displayed if R fill switch connector (T38) is (2) disconnected. Failure code 15SBMA is not displayed if ECMV (other than R) is replaced. Failure code "15SEL1" is not displayed in F1 and F2 positions. It is displayed in F3 to F8 (1) and R1 to R4 positions. (1)
3
4
15SBL1
Q
15SBMA
Q
15SEL1
After Step (1), failure code 15SEL1 is not displayed if 1st fill switch connector (T39) is 15SEMA disconnected. Failure code 15SEMA is not displayed if ECMV (other than 1st) is replaced. Failure code "15SFL1" is not displayed in F3 and F4 positions. It is displayed in F1, F2, F5 15SFL1 (1) to F8 and R1 to R4 positions. After Step (1), failure code 15SFL1 is not displayed if 2nd fill switch connector (T40) is (2) 15SFMA disconnected. Failure code 15SFMA is not displayed if ECMV (other than 2nd) is replaced.
(2)
5
Failure code "15SGL1" is not displayed in F5 and F6 positions. It is displayed in F1 to F4, 15SGL1 F7, F8, and R1 to R4 positions. After Step (1), failure code 15SGL1 is not displayed if 3rd fill switch connector (T41) is 15SGMA (2) disconnected. Failure code 15SGMA is not displayed if ECMV (other than 3rd) is replaced. Failure code "15SHL1" is not displayed in F7 and F8 positions. It is displayed in F1 to F6 (1) 15SHL1 and R1 to R4 positions. (1)
6
7
(2)
40-512
After Step (1), failure code 15SHL1 is not displayed if 4th fill switch connector (T42) is 15SHMA disconnected. Failure code 15SHMA is not displayed if ECMV (other than 4th) is replaced.
Q Q Q Q Q Q Q Q
GD535-5 (03)
40 Troubleshooting
H-8 Differential gear lock function does not operate or is not canceled.
H-8 Differential gear lock function does not operate or is not canceled. Checks before troubleshooting q Check that final drive case oil level is normal. q Check oil pressure when final drive case oil temperature is 60 to 80°C.
Defective connection of differential lock pump (drive system) Clogged final drive case suction strainer Air sucked into suction circuit of differential lock pump Internal defect of differential lock pump (pump body) Malfunction and defective adjustment of differential lock valve Defective sealing of differential lock clutch piston Wear or damage of differential lock clutch disc or plate
Cause a b c d e f g
Remedy No. 1 2 3 4
GD535-5 (03)
1
Diagnosis
EC EEE E X X X X X X
Differential lock pump does not rotate. Noise is heard from strainer when final drive case oil temperature is low. Differential lock (pump outlet or valve outlet) oil pressure is abnormal. Differential lock caution lamp lights up and caution buzzer sounds.
Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q
40-513
H-9 Steering speed or power is insufficient.
40 Troubleshooting
H-9 Steering speed or power is insufficient.
1
Malfunction of priority valve (relief valve) Malfunction of steering valve Defective sealing of steering cylinder
Checks before troubleshooting Cause q Check that the hydraulic oil tank level is normal. a b c q Check oil pressure and oil leakage of cylinder when hydraulic oil temperature is 45 to 55°C. q Check that the work equipment operates normally before performing troubleshooting. q (If it is not normal, perform troubleshooting for "H-15 Travel speed or power is low" first.) q Since steering valve (Orbitrol) is variable ratio type, steering speed varies depending on steering wheel speed.
Remedy No. 1 2 3 4
40-514
Diagnosis
EEE X X X
Response is low in both right and left steering directions. Steering wheel operation is heavy in both right and left directions. Work equipment operates. Steering relief oil pressure is low in both right and left directions.
Q Q Q Q Q Q Q Q Q
GD535-5 (03)
40 Troubleshooting
H-10 Steering wheel does not move
H-10 Steering wheel does not move
1
Remedy No. 1 2
GD535-5 (03)
Diagnosis Steering wheel idles. Steering wheel operation is heavy in both right and left directions.
Cause a b c Defective connection between steering wheel and steering valve Malfunction of steering valve Deformed steering cylinder
Checks before troubleshooting q Check that the hydraulic oil tank level is normal. q Check that the work equipment operates normally before performing troubleshooting. (If it is not normal, perform troubleshooting for "H-16 All work equipment do not operate" first.)
EE X X X Q
Q Q Q
40-515
H-11 Wheel brakes do not work or are weak
40 Troubleshooting
H-11 Wheel brakes do not work or are weak
1
Malfunction of brake accumulator charge valve (pressure governor valve) Malfunction of brake accumulator charge valve (LS relief valve) Lowered gas pressure of brake accumulator Defective brake valve Defective brake piston seal Wear or damage of brake disc or plate Insufficient bleeding air from brake circuit
Checks before troubleshooting Cause q Check that the hydraulic oil tank level is normal. a b c d e f g q Check oil pressure and oil leakage of cylinder when hydraulic oil temperature is 45 to 55°C. q Check that the work equipment operates normally before performing troubleshooting. (If abnormal, perform troubleshooting for "H-15 Travel speed or power is low" or "H16 All work equipment do not operate" first.)
Remedy No. 1 2 3 4 5 6 7 8 9 10 11
40-516
Diagnosis No resistance when brake pedal is depressed The brake pedal is heavy when depressed. Need to depress too much to get the specified braking force. Abnormal noise is heard from axle brake during braking. Machine does not travel (due to insufficient traction). Air flows during brake circuit air vent. Then machine operates normally. Excessive leakage of brake oil from axle Insufficient braking force although force and stroke of brake pedal are normal Insufficient braking force when engine is stopped Accumulator is not charged, and buzzer sounds. Time lag occurs during braking.
EEEEEE E X X X X X X Q Q
Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q
GD535-5 (03)
40 Troubleshooting
H-12 Wheel brakes are not released or drag
H-12 Wheel brakes are not released or drag
1
Checks before troubleshooting q Check that the brake pedal is returned completely. q Check that the parking brake is released completely. Check of abnormality The brake is abnormally heated. q Machine can coast on a flat place. q
Wheel brake
Brake valve
Cause
Internal failure of brake valve (piston fixed) Failure of brake disc in axle Malfunction of brake piston in axle
a b c
Remedy No. 1 2 3
GD535-5 (03)
Diagnosis
EEE X X X
Braking continues even when the brake pedal is released. Q Q Q When brake pedal is released and when oil is removed from air vent breather, circuit pressure Q drops and brake is released. Machine is jacked up, engine is stopped, and parking brake is released. Specific wheels are heavy Q Q when rotated by hand.
40-517
H-13 Parking brake does not work or it is weak
40 Troubleshooting
H-13 Parking brake does not work or it is weak
1
Parking brake
Checks before troubleshooting Did you mechanically release the parking brake?
q
Cause Solenoid
Ask the operator about the following: q Does the brakes fail suddenly? o Damage of related parts q Is abnormal noise heard? Where is the noise generated? q Does the braking capacity drop gradually? o Wear of related parts or damaged seal
Failure of parking brake solenoid valve Failure of parking brake spring Malfunction of parking brake piston Wear of parking brake disc
a b c d
Remedy No. 1 2 3 4 5 6
40-518
Diagnosis
X X
E X X
Parking brake does not work even when engine is stopped. Q Q Q The thickness of parking brake disc is below standard. Q Oil pressure is zero with parking brake switch Q Q turned ON. (Normal) When the parking brake inlet pressure is measured Oil pressure is present with parking brake Q Q switch turned ON Oil pressure is zero with parking brake switch Q turned ON. (Normal) When the parking brake solenoid valve output pressure is measured Oil pressure is present with parking brake Q switch turned ON.
GD535-5 (03)
40 Troubleshooting
H-14 Parking brake (including emergency release system) is not released or drags
H-14 Parking brake (including emergency release system) is not released or drags
1
Clogged parking brake or bank valve (filter) Malfunction of parking brake or bank valve (parking solenoid valve) Clogged elbow filter Malfunction of parking brake caliper, or poor adjustment of parking brake Poor adjustment of parking brake
Checks before troubleshooting Cause q Check that the hydraulic oil tank level is normal. a b c d e q Check oil pressure and oil leakage of cylinder when hydraulic oil temperature is 45 to 55°C. q Check that the operating pressure of the wheel brake is normal before measurement. (If abnormal, perform troubleshooting for failure of "H-11 Wheel brakes do not work or are weak." in H mode.
Remedy No. 1 2 3 4
GD535-5 (03)
Diagnosis Parking brake does not work even when engine is stopped. When parking brake switch is turned ON, the parking brake solenoid valve output pressure exists. (Normal) Clogged elbow filter Malfunction of parking brake caliper
EEE X X X Q Q Q Q Q Q Q Q
40-519
H-15 All work equipment operates slowly or lacks power
40 Troubleshooting
H-15 All work equipment operates slowly or lacks power Checks before troubleshooting q Check the hydraulic oil tank level. q Check oil pressure when hydraulic oil temperature is 45 to 55°C.
Clogged hydraulic tank suction strainer Looseness of piston pump suction piping joint, or crack of hose Malfunction and poor adjustment of main pump (PC valve) Clogged main pump (orifice plug) Internal defect of main pump (pump body) Malfunction or poor adjustment of control valve (main relief valve)
Cause a b c d e f
Remedy No. 1 2 3 4 5
40-520
1
Diagnosis Clogging of hydraulic tank strainer Looseness of pipe joints between hydraulic tank and pump, or cracking of hose Too much metal powder adhered to pump discharge side No oil is output when main pump pressure measuring plug is removed and engine is cranked. Abnormal relief pressure of main relief valve
C EE A E A X X X X X X Q
Q Q
Q
Q Q Q
GD535-5 (03)
40 Troubleshooting
H-16 Work equipment does not operate.
H-16 Work equipment does not operate.
1
Remedy No. 1 2 3
GD535-5 (03)
Diagnosis No oil is output when main pump pressure measuring plug is removed and engine is cranked. Main pump does not rotate. Abnormal oil pressure after main relief valve has been adjusted
Cause a b c d Internal defect of PTO Incorrect connection of main pump (drive system) Internal defect of main pump (pump body) Malfunction or poor adjustment of control valve (main relief valve)
Checks before troubleshooting q Check the hydraulic oil tank level. q Check oil pressure and oil leakage of cylinder when hydraulic oil temperature is 45 to 55°C.
EEE A X X X Q
Q Q Q
40-521
H-17 Unusual noise is heard from around hydraulic pump
40 Troubleshooting
H-17 Unusual noise is heard from around hydraulic pump
1
Cause q Lowered hydraulic tank oil level q Air mixed in hydraulic oil q Clogged hydraulic oil tank cap q Clogging of hydraulic tank strainer q Internal failure of main pump q Lowered transmission case oil level q Air mixed in transmission oil q Clogged transmission case strainer q Internal defect of power train pump If no failure is found in above causes, move the machine for a while to check whether symptom changes or not.
40-522
GD535-5 (03)
40 Troubleshooting
H-18 Blade lift speed or power is low.
H-18 Blade lift speed or power is low.
1
Insufficient stroke of blade lift control valve (spool) Malfunction of blade lift control valve (check valve) Malfunction of pilot check valve (relief valve) Defective sealing of blade lift cylinder Deformed blade lift cylinder
Checks before troubleshooting Cause q Check the hydraulic oil tank level. a b c d e q Check oil pressure and oil leakage of cylinder when hydraulic oil temperature is 45 to 55°C.
No. 1 2 3
GD535-5 (03)
Diagnosis Blade lifting speed is low. Improper operation of check valve Low relief valve oil pressure of work equipment valve
Remedy A EE E X X X X X Q
Q Q Q Q Q
40-523
H-19 Hydraulic drift of lifted blade is large.
H-19 Hydraulic drift of lifted blade is large.
40 Troubleshooting
1
Checks before troubleshooting q Check that the hydraulic oil tank level is normal. q Check oil pressure and oil leakage of cylinder when hydraulic oil temperature is 45 to 55°C. Cause Malfunction of pilot check valve (check valve) q Malfunction of pilot check valve (relief valve) q Defective sealing of blade lift cylinder q
40-524
GD535-5 (03)
40 Troubleshooting
H-20 Drawbar side shift speed or power is low
H-20 Drawbar side shift speed or power is low
1
No. 1 2 3
Diagnosis Drawbar side shift speed is low. Improper operation of check valve Low relief valve oil pressure of work equipment valve
GD535-5 (03)
Cause a b c d Insufficient stroke of drawbar side shift control valve (spool) Malfunction of pilot check valve (check valve) Defective sealing of drawbar side shift cylinder. Deformed drawbar side shift cylinder
Checks before troubleshooting q Check the hydraulic oil tank level. q Check oil pressure and oil leakage of cylinder when hydraulic oil temperature is 45 to 55°C.
Remedy A E E X X X X Q Q Q Q
40-525
H-21 Blade side shift speed or power is low.
40 Troubleshooting
H-21 Blade side shift speed or power is low.
1
Insufficient stroke of blade cross slide control valve (spool) Malfunction of pilot check valve (check valve) Defective sealing of swivel joint Defective sealing of blade cross slide cylinder Deformed blade cross slide cylinder
Checks before troubleshooting Cause q Check the hydraulic oil tank level. a b c d e q Check oil pressure and oil leakage of cylinder when hydraulic oil temperature is 45 to 55°C.
No. 1 2 3
Diagnosis Blade side shift speed is low. Improper operation of check valve Low relief valve oil pressure of work equipment valve
40-526
Remedy A EE E X X X X X Q
Q Q Q Q Q
GD535-5 (03)
40 Troubleshooting
H-22 Power tilt speed or power is low.
H-22 Power tilt speed or power is low.
1
Insufficient stroke of power tilt control valve (spool) Malfunction of pilot check valve (check valve) Malfunction of pilot check valve (relief valve) Defective sealing of swivel joint Defective sealing of power tilt cylinder Deformed power tilt cylinder
Checks before troubleshooting Cause q Check that the hydraulic oil tank level is normal. a b c d e f q Check oil pressure and oil leakage of cylinder when hydraulic oil temperature is 45 to 55°C.
No. 1 2 3
Diagnosis Power tilt speed is low. Improper operation of check valve Low relief valve oil pressure of work equipment valve
GD535-5 (03)
Remedy A EE E X X X X X X Q
Q Q Q Q Q Q
40-527
H-23 Articulate speed or power is low.
40 Troubleshooting
H-23 Articulate speed or power is low.
1
Cause a b c d
Insufficient stroke of articulate control valve (spool) Malfunction of pilot check valve Defective sealing of articulate cylinder Deformed articulate cylinder
Checks before troubleshooting q Check the hydraulic oil tank level. q Check oil pressure and oil leakage of cylinder when hydraulic oil temperature is 45 to 55°C.
No. 1 2 3
Diagnosis Articulate speed is low. Improper operation of check valve Low relief valve oil pressure of work equipment valve
40-528
Remedy A E E X X X X Q Q Q Q
GD535-5 (03)
40 Troubleshooting
H-24 Leaning speed or power is insufficient.
H-24 Leaning speed or power is insufficient.
1
Cause a b c d
Insufficient stroke of leaning control valve (spool) Malfunction of pilot check valve Defective sealing of leaning cylinder Deformed leaning cylinder
Checks before troubleshooting q Check the hydraulic oil tank level. q Check oil pressure and oil leakage of cylinder when hydraulic oil temperature is 45 to 55°C.
No. 1 2 3
Diagnosis Leaning speed is low. Improper operation of check valve Low relief valve oil pressure of work equipment valve
GD535-5 (03)
Remedy A E E X X X X Q Q Q Q
40-529
H-25 Hydraulic drift (tilting) of leaning is large.
H-25 Hydraulic drift (tilting) of leaning is large.
40 Troubleshooting
1
Checks before troubleshooting q Check that the hydraulic oil tank level is normal. q Check oil pressure and oil leakage of cylinder when hydraulic oil temperature is 45 to 55°C. Cause Malfunction of pilot check valve q Defective sealing of leaning cylinder q
40-530
GD535-5 (03)
40 Troubleshooting
H-26 Blade does not rotate.
H-26 Blade does not rotate.
1
No. 1 2
Diagnosis Blade does not rotate. Low relief valve oil pressure of work equipment valve
GD535-5 (03)
Malfunction of blade rotator
Cause a b Insufficient stroke of circle rotation control valve (spool)
Checks before troubleshooting q Check the hydraulic oil tank level. q Check that oil level of circle rotation gear case is normal before performing troubleshooting.
Remedy A E X X Q Q
40-531
H-27 Lifter lock pin is not locked or is not canceled.
40 Troubleshooting
H-27 Lifter lock pin is not locked or is not canceled.
1
Cause a b c d
Displacement of lifter and lock pin Clogged parking brake or bank valve (filter) Malfunction of parking brake or bank valve (bank solenoid valve) Malfunction or internal defect of lifter lock cylinder
Checks before troubleshooting q Check oil pressure and oil leakage of cylinder when hydraulic oil temperature is 45 to 55°C.
No. 1 2 3 4
Diagnosis Lifter lock pin is not locked. Displacement of lifter and lock pin Clogging of parking brake valve filter Cylinder head pressure or bottom pressure of bank solenoid valve is abnormal.
40-532
Remedy A EE E X X X X Q Q Q Q Q Q Q
GD535-5 (03)
40 Troubleshooting
How to read matrix
Troubleshooting of engine (S-mode)
1
How to read matrix
1
The troubleshooting matrix consists of "Question" "Checkpoints", "Cause" and "Diagnosis" blocks. Answer to the "Question" and "Checkpoints" without using troubleshooting devices. You can narrow down the trouble by referring to the "Cause" block. After you have narrowed the causes, locate the final "Cause" by using troubleshooting devices or by direct inspection. "Question": The user or operator is asked. This is parts A and B as shown at right. Questions A ask the basic items, and Questions B are asked by user or operator. "Checkpoints": The service person briefly checks the points, and this is part C at right. "Cause": The cause is narrowed by the Question and Checkpoints. The service person reads parts A, B and C, and narrows the possible cause. "Diagnosis": The located cause is finally determined to be a failure or not. The troubleshooting devices are used, and direct inspection may be selected. On the troubleshooting matrix, the items relating to the "Cause" are marked by "E", "Q or "W according to the answer to "Question" and "Checkpoints". E mark: The Cause can be referred to the Question or Checkpoints. Q mark: The Cause is related to the Question or Checkpoints. W mark: Among the above Q mark items, the possibility of Cause is high. a When narrowing the "Cause", the priority of Q mark is higher than that of W mark. E mark shows the item is not counted when narrowing the Cause. (However, if each level has no difference and if you cannot narrow down the Cause without using this leveling, you can use the leveling.)
GD535-5 (03)
40-533
How to read matrix
40 Troubleshooting
Exhaust gas color is black. If, for example, the "Exhaust gas color is black" is caused by the "Clogged air cleaner", three causes of failure, such as "Exhaust color becomes gradually black", "Power is gradually lost" and "Air cleaner clogging caution lamp flashes" can be considered.
40-534
GD535-5 (03)
40 Troubleshooting
How to read matrix
From these 3 causes of failure, we can consider the 5 causes of failure. The following explains how to narrow the highest probability of failure from these causes.
GD535-5 (03)
40-535
S-1 Engine startability is poor.
40 Troubleshooting
S-1 Engine startability is poor.
1
q q q q
Abnormal electric system Insufficient fuel supply Insufficient intake air volume Incorrect selection of fuel The common rail fuel injection system (CRI) controls the fuel injection timing electrically. When you start the engine, the injection does not start until crankshaft rotates 2 times maximum. This is not a problem.
Check the recent repair history. Machine operation state
Diagnosis
Checkpoints
Question
Startability
E Q w w
Machines operated for a long period Gradually dropped. Starts when weather is warm.
E Q
E
w w Unspecified fuel is used. Q Q Q Filter is not replaced as specified by the Operating Manual. w w Q Q Engine oil supply rate has increased. w Preheat monitor display is abnormal during preheating or during low temperature (if w the monitor is mounted). The charge monitor display is abnormal during operation (if the monitor is w w mounted). The dust indicator lights in red (if the indicator is mounted). w Fuel tank cap air vent hole is clogged. w Fuel leaks from the fuel pipe. w Q The priming pump has no response during operation, or it is heavy to operate. w Q When engine is rotated by starting motor, its speed is low. No fuel is output when air vent plug of fuel filter w Start the engine by cranking with is removed. the starting motor. Too much fuel is returned from injector. w Some cylinder is found to be cool when exhaust manifolds are touched by hand w immediately after engine is started. Engine does not pick-up smoothly, and combustion is unstable. Q Q w Engine rotation is hunting (poor rotation). Q w Q Too much blowby gas is output. w Check the air cleaner. q The compression pressure is low. q q Air is output during air blow of fuel system. Check the fuel filter. Troubleshoot for "Supply pump pressure low" according to the failure code (*1). When engine runs in cylinder cutout mode with some cylinder cut out, engine speed does not change. The intake air heater mounting section is not heated during preheating. Yes Is voltage (20 to 30V) output between alternator B terminal and E terminal during low idle? No The specific gravity and voltage of battery are low. Remedy
40-536
q q q q q q q q
Clean Replace Replace Clean Repair Replace Replace Replace Replace Replace Replace Replace
q
Cause Clogged air cleaner element Incorrect matching of valve and valve sheet Wear of piston ring or cylinder Clogging of fuel tank cap air vent hole Leakage, clogging or air mixing in fuel piping Clogging of fuel filter Fixture or burn-out of supply pump plunger Defective injector Defective intake air heater system Defective alternator (regulator portion) Defective alternator (generator) Defective or degraded battery
Generally, the poor startability is caused by:
GD535-5 (03)
40 Troubleshooting
S-2 Engine does not start.
S-2 Engine does not start.
1
a) Engine does not start.
Cause
q
Diagnosis
Checkpoints
Question
q
Inside of engine is burnt out. o See "S-4 Engine stops during operation". Abnormal electric system Failure of power train
Check the recent repair history. Machine operation Machines operated for a long period EE state Q Q w When starting switch Horn does not sound. is ON Sound is small. w Insufficient battery fluid level w Battery cables are loosely connected. w When starting switch is ON, battery relay operation sound is not heard. Q w When starting switch is turned to START position, the starter pinion is not output. Q Q w The starter pinion is output but speed is low. w When starting switch Scratchy noise is heard. w w is turned to START Released in intermediate position w position Noise is heard, but not rotated. Q Q w Check the flywheel ring gear. q The specific gravity and voltage of battery are low. q Voltage (20 to 30V) is not output between B terminal and E terminal of battery relay. When B terminal and C terminal of starting switch are Turn starting switch to connected, the engine starts. OFF position, connect When B terminal and C terminal of safety relay output are cords, turn switch ON, connected, the engine starts. and perform When B terminal and C terminal of safety relay output are troubleshooting. connected, the engine does not start. When the safety switch terminal and B terminal are connected, the engine starts. Remedy
GD535-5 (03)
Replace Replace Repair Replace Replace Replace Replace Perform troubleshooting in E-mode. -
q
Damaged flywheel ring gear Defective or degraded battery Poor connection of battery terminals Defective battery relay Defective starting switch Defective safety relay Defective starting motor (motor section) Defective harness of starting switch circuit
Generally, engine does not start if:
q
q
q
q q
40-537
S-2 Engine does not start.
40 Troubleshooting
Cause Inappropriate fuel is used. Insufficient fuel in tank Clogging of fuel tank cap air vent hole Leakage, clogging or air mixing in fuel piping Clogging of fuel filter Burn-out or abnormal wearing of feed pump Damaged supply pump shaft Fixture or burn-out of supply pump plunger Defective supply pump IMV Malfunction of pressure relief valve Defective common rail pressure limiter Defective fuel injector
b) Engine rotates but smoke is not output. Generally, the engine rotates but the smoke is not output if:
q
Diagnosis
Checkpoints
Question
q
No fuel is supplied. Fuel supply is too few. Incorrect selection of fuel (especially in winter season)
Check the recent repair history. Machine Machines operated for a long period EE operation state Smoke was suddenly stopped to output (during restarting). w Q Unspecified fuel is used. w Filter is not replaced as specified by the Operation Manual. w The fuel tank is empty. w Fuel tank cap air vent hole is clogged. Q w When fuel was drained, rusting and water are drained from fuel tank. Q E When fuel filter is removed, no fuel is found in the filter. w Fuel leaks from the fuel pipe. w The priming pump has no response during operation, or it is heavy to w Q operate. Start the engine No fuel is output when air vent plug of fuel filter is Q Q w Q by cranking with removed. the starting When spill hose is disconnected from injector, the spill Q w motor. rate is low. Air is output during air blow of fuel system. Check the fuel filter and strainer. Check the feed pump. Troubleshoot for "Supply pump pressure low" according to the failure code (*1). Troubleshoot for "Supply pump IMV error" according to the failure code (*2). Check the pressure relief valve. Fuel is output when pressure limiter return pipe is removed.
Remedy
w w
E
E
Q
EE
w w
Q
q q q q q q q q Replace Refilling with oil Clean Repair Replace Replace Replace Replace Replace Replace Replace Replace
q
*1: Failure codes [CA559] and [CA2249] *2: Failure codes [CA271] and [CA272]
40-538
GD535-5 (03)
40 Troubleshooting
S-2 Engine does not start.
c) Smoke comes out but engine does not start (fuel is injected). Generally, smoke comes out but engine does not start if:
q q
Diagnosis
Checkpoints
Question
q
The rotation power is insufficient due to defective electric system. Fuel supply is too few. Intake air volume is insufficient. Incorrect selection of fuel
Check the recent repair history. Machine operation Machines operated for a long period E E E state Machine was suddenly stopped to start. w w Q Unspecified fuel is used. Q Q Filter is not replaced as specified by the Operation Manual. w w Engine oil supply rate has increased. w Preheat monitor display is abnormal during preheating or during low w temperature (if the monitor is mounted). The dust indicator lights in red (if the indicator is mounted). w Fuel tank cap air vent hole is clogged. Q When fuel was drained, rusting and water are drained from fuel tank. w Fuel leaks from the fuel pipe. w The priming pump has no response during operation, or it is heavy to operate. w Q When engine is rotated by starting motor, its speed is low. w When engine is rotating, abnormal noise is generated around the cylinder w head. When fuel filter air vent plug is removed, no fuel is output. Q w When engine is cranked by When spill hose is disconnected from injector, the spill w starting motor rate is low. Check the air cleaner. Check the valve operating system. The compression pressure is low. Air is output during air blow of fuel system. Check the fuel filter and strainer. Troubleshoot for "Supply pump pressure low" according to the failure code (*1). The specific gravity and voltage of battery are low. Display of coolant temperature gauge is abnormal (if coolant temperature gauge is mounted). The intake air heater mounting section is not heated during preheating. Remedy
q q q q q q q q q Clean Replace Replace Replace Clean Repair Replace Replace Replace Replace Replace Replace
q
Clogged air cleaner element Wear of valve operating system (valve and rocker lever) Wear of piston ring or cylinder Inappropriate fuel is used. Clogging of fuel tank cap air vent hole Leakage, clogging or air mixing in fuel system Clogging of fuel filter Fixture or burn-out of supply pump plunger Clogging or injection failure of injector Defective or degraded battery Defective coolant sensor, or defective wiring harness Defective intake air heater system
Cause
*1: See failure codes [CA559] and [CA2249].
GD535-5 (03)
40-539
S-3 Engine does not pick-up smoothly.
40 Troubleshooting
S-3 Engine does not pick-up smoothly.
1
Generally, engine does not pick-up smoothly if:
q q
Diagnosis
Checkpoints
Question
q
Intake air volume is insufficient. Fuel supply is insufficient. Fuel injection is abnormal. Incorrect selection of fuel This is controlled by the controller in Derate mode. (If an electric system error occurs, the fuel injection (output) is controlled.)
Check the recent repair history. Machine Machines operated for a long period Suddenly, engine does not pick-up smoothly. Unspecified fuel is used. Filter is not replaced as specified by the Opearation Manual. Engine oil supply rate has increased. The dust indicator lights in red (if the indicator is mounted). Fuel tank cap air vent hole is clogged. When fuel was drained, rusting and water are drained from fuel tank. Fuel leaks from the fuel pipe. The priming pump has no response during operation, or it is heavy to Some cylinder is found to be cool when exhaust manifolds are touched by hand immediately after engine is started. It is blue under small load. Exhaust gas It is black When engine is rotating, abnormal noise is generated around the cylinder When engine is rotated, interference noise is generated around the Although no-load and high idle speed is normal, the rotation speed suddenly drops when loaded. Engine rotation is hunting (poor rotation). Too much blowby gas is output.
Clogged air cleaner element Incorrect matching of valve and valve sheet Incorrect valve clearance Burn-out or interference of turbocharger Wear of piston ring or cylinder Clogging of fuel tank cap air vent hole Leakage, clogging or air mixing in fuel piping Clogging of fuel filter Fixture or burn-out of supply pump plunger Clogging or injection failure of injector
q
EE
E w
w
Q w w w w
w w w w w w Q Q w w w Q
w
w
w w Q
w
Q
Q
Q
w
Check the air cleaner. q The compression pressure is low. q q Check the valve clearance. q Turbocharger is heavy to rotate when tried by hand. q Air is output during air blow of fuel system. Check the fuel filter and strainer. Troubleshoot for "Supply pump pressure low" according to the failure code When a certain cylinder is cutout, engine speed does not change. Remedy
E Q Q
q q q q
Clean Repair Adjust Replace Replace Replace Repair Replace Replace Replace
q
Cause
*1: Failure codes [CA559] and [CA2249]
40-540
GD535-5 (03)
40 Troubleshooting
S-4 Engine stops during operation.
S-4 Engine stops during operation.
1
Cause
q
Diagnosis
Checkpoints
Question
q
Inside of engine is burnt out. Fuel supply is insufficient. Overheating Hydraulic pump has failed.
Check the recent repair history. Machine operation state Machines operated for a long period It has noise and stopped suddenly. It was overheated and stopped. Engine It stopped slowly. It was hunting and stopped. Unspecified fuel is used. Filter is not replaced as specified by the Opeation Manual. Fuel level monitor shows the dropped fuel level. The fuel tank is empty. Fuel tank cap air vent hole is clogged. Fuel leaks from the fuel pipe. When fuel was drained, rusting and water are drained from fuel tank. Metal powder is output when oil is drained to oil pan. It does not rotate at all. It rotates in reverse direction. When the engine is rotate by hand It moves for the backlash of gears. The supply pump shaft does not rotate. Engine rotates, but it stops when loaded at the machine side. Check the valve operating system. Check the piston and connecting rod. Check the crankshaft metal. Check the gear train. Check the fuel filter. Check the feed pump gauze filter. Check the feed pump. Troubleshoot for "Supply pump pressure low" according to the failure code (*1).
EE w
w w w w Q
Q w Q w w w Q
Q Q Q w
Q Q Q Q Q w
Q Q Q Q Q
w w w w
w Q Q
w w w w w w
w w w
q q q q q q q q q q
Engine rotates if auxiliaries (pump and compressor) are removed.
Perform troubleshooting in H-mode.
q
q
Check the controller power cables. Check the starting switch cables
Remedy
Replace
q Replace Replace Replace Refilling with oil Clean Repair Replace Clean Clean Replace Replace Replace Repair Repair
q
Damage of valve operating system (valve and rocker lever) Damage or burn-out of piston and connecting rod Damage or burn-out of crankshaft metal Damage or burn-out of gear train Insufficient fuel in tank Clogging of fuel tank cap air vent hole Leakage or clogging of fuel piping Clogging of fuel filter Clogging of feed pump gauze filter Damage or burn-out of feed pump Damage of supply pump shaft spline Fixture or burn-out of supply pump plunger Damage of auxiliaries (pump and compressor) Defective hydraulic pump Defective engine controller power cables Defective starting switch cables
Generally, engine stops during operation if:
* 1: See failure codes [CA559] and [CA2249].
GD535-5 (03)
40-541
S-5 Engine runs rough or is unstable.
40 Troubleshooting
S-5 Engine runs rough or is unstable.
1
Cause
Diagnosis
Checkpoints
Question
q
Air is inserted into fuel system. The rotation sensor is abnormal (at the level where no error is displayed).
Check the recent repair history. Machine operation state Machines operated for a long period It occurs in specific speed range. It occurs during low idle. Hunting It occurs even when speed is increased. It occurs on a slope. Filter is not replaced as specified by the Opeation Manual. The fuel tank is empty. Fuel tank cap air vent hole is clogged. When fuel was drained, rusting and water are drained from fuel tank. Fuel leaks from the fuel pipe. The priming pump has no response during operation, or it is heavy to operate. Air is output during air blow of fuel system. Check the fuel filter and strainer. When a certain cylinder is cutout, engine speed does not change. Troubleshoot for "Ne speed sensor error" according to the failure code (*1). Troubleshoot for "Bkup speed sensor error" according to the failure code (*2). Remedy
E Q Q Q Q Q Q Q Q Q Q w w w w Q w w Q q q q q q Clean Clean Replace Replace Replace Replace Replace
q
Insufficient fuel in tank Clogging of fuel tank cap air vent hole Leakage, clogging or air insertion in fuel piping Clogging of fuel filter Clogging or injection failure of injector (dust clogging) Defective Ne speed sensor, or defective wiring harness Defective Bkup speed sensor, or defective wiring harness
Generally, the engine runs rough if:
*1: Failure code [CA689] *2: Failure code [CA778]
40-542
GD535-5 (03)
40 Troubleshooting
S-6 Engine lacks power.
S-6 Engine lacks power.
1
Generally, engine lacks power if:
Defective boost pressure sensor, or defective wiring harness
Clogging of fuel spill pipe
Incorrect mounting of boost pressure sensor (air leakage)
Drive failure of injector (signal and solenoid valve)
Clogging or injection failure of injector (dust clogging)
Fixture or burn-out of supply pump plunger
Clogging of fuel filter
Leakage or clogging of fuel piping
Clogging of fuel tank cap air vent hole
Wear of piston ring or cylinder
q
Incorrect valve clearance
q
Incorrect matching of valve and valve sheet
q
Burn-out or interference of turbocharger
q
Intake air volume is insufficient. Fuel supply is insufficient. Fuel injection is abnormal. Incorrect selection of fuel Overheating See "S-14 Coolant temperature rises too high (overheating)". This is controlled by the controller in Derate mode. (If an electric system error occurs, the fuel injection (output) is controlled.)
Air leakage from air intake pipe
q
Clogged air cleaner element
q
Cause
Q
Q
Check the recent repair history.
E
E
E
Q
Q
Q Q Q Q Q w
Q
Q
Q w
It lacks power suddenly.
Q
It lacks power gradually.
Q
Unspecified fuel is used.
w
Filter is not replaced as specified by the Opeation Manual. Engine oil supply rate has increased.
w w
The dust indicator lights in red (if the indicator is mounted).
w
Fuel tank cap air vent hole is clogged.
w w
Fuel leaks from the fuel pipe.
w
Engine output is insufficient after short stop. Exhaust gas
w
It is black.
w w
It is blue under small load.
Checkpoints
Some cylinder is found to be cool when exhaust manifolds are touched by hand immediately after engine is started.
w
When engine is rotated, interference noise is generated around the turbocharger.
w
w
When engine is rotating, abnormal noise is generated around the cylinder head.
w Q
High idle speed is high. Although no-load and high idle speed is normal, the rotation speed suddenly drops when loaded.
Q w w
Engine does not pick-up smoothly, and combustion is unstable.
w
Too much blowby gas is output. Check the air cleaner.
q
Check the air intake pipe.
q q q q
The boost pressure is low.
w Q
Q
w
q
The compression pressure is low.
w Q Q
Q Q Q Q Q
Engine rotation is hunting (poor rotation).
q q
Check the valve clearance. Diagnosis
Q Q
q
Check the fuel pipe.
q
Check the fuel filter and strainer.
q
Check the spill port check valve. Troubleshoot for "Supply pump pressure low" according to the failure code (*1).
q q
When a certain cylinder is cutout, engine speed does not change.
q q
Check the mounting of boost pressure sensor. Troubleshoot for "Boost pressure sensor error" according to the failure code (*2).
GD535-5 (03)
Replace
Replace
Replace
Replace
Replace
Repair
Clean
Replace
Adjust
Replace
Replace
Clean
Remedy
Repair
*1: Failure codes [CA559] and [CA2249] *2: Failure codes [CA122] and [CA123]
q Replace
Engine
E
Machines operated for a long period
Repair
Question
Machine operation state
40-543
S-7 Exhaust smoke is black (Incomplete combustion)
40 Troubleshooting
S-7 Exhaust smoke is black (Incomplete combustion)
1
Generally, exhaust smoke is black if:
q q q
Checkpoints
Question
q
Intake air volume is insufficient. Fuel injection is abnormal. Incorrect selection of fuel Overheating See "S-14 Coolant temperature rises too high (overheating)". This is controlled by the controller in Derate mode. (If an electric system error occurs, the fuel injection (output) is controlled.)
Check the recent repair history. Machine operation state Machines operated for a long period It becomes black suddenly. Exhaust gas It becomes black gradually. It is blue under small load. Unspecified fuel is used. Engine oil supply rate has increased. It lacks power suddenly. Engine It lacks power gradually. The dust indicator lights in red (if the indicator is mounted). Muffler is crushed. Air leakage between turbocharger and cylinder head, or loosened clamps Machine is operated in Low Temperature mode although in normal temperature range. Some cylinder is found to be cool when exhaust manifolds are touched by hand immediately after engine is started. When engine is rotated, interference noise is generated around the turbocharger. When engine is rotating, abnormal noise is generated around the cylinder head. Torque converter stalls or pump relief speed is high (excessive fuel injection). Exhaust noise is abnormal. Engine does not pick-up smoothly, and combustion is unstable. Too much blowby gas is output.
Clogged air cleaner element Burn-out or interference of turbocharger Incorrect matching of valve and valve sheet Incorrect valve clearance Air leakage between turbocharger and cylinder head Crush or clogging of muffler Wear of piston ring or cylinder Fixture or burn-out of supply pump plunger Clogging or burn-out of injector Abnormal wear of injector Incorrect fuel injection timing Incorrect fuel injection pressure Defective coolant sensor, or defective wiring harness
q
Cause
E
E
E
w
w Q
w
E Q Q Q Q
w Q Q w w Q w
Q Q
Q
Q Q Q
w w Q Q Q Q w w w Q Q Q
w Q Q Q
Q Q w w w
Check the air cleaner. q Turbocharger is heavy to rotate when tried by hands. q The compression pressure is low. q Check the valve clearance. q Exhaust noise becomes better if muffler is removed. Perform troubleshooting for "Supply pump pressure low error (*1)" according to the failure code. When a certain cylinder is cut out, engine speed does not change in specific cylinder. Perform troubleshooting for "Coolant temperature sensor error (*2)" according to the failure code. Check it using the INSITE or monitoring function at the installed machine side.
Remedy
q q q
q q q q q
Clean Replace Repair Adjust Repair Replace Replace Replace Replace Replace Replace Replace Replace
Diagnosis
Too much fuel is returned from injector.
*1: Failure codes [CA559] and [CA2249] *2: Failure codes [CA144] and [CA145] 40-544
GD535-5 (03)
40 Troubleshooting
S-8 Large oil consumption (or blue exhaust gas)
S-8 Large oil consumption (or blue exhaust gas)
1
Generally, the oil consumption becomes large if:
q
Diagnosis
Checkpoints
Question
q
Oil is burned abnormally. Machine is operated in low idle or high idle state for a long time. (Unloaded machine operation exceeding 20 minutes or longer time is not allowed.) Oil is leaking to the outside. Lubrication system is worn.
Suction of dust from air intake system Wear or damage of valves (stem, guide, and seal) Wear of seal at turbine side Turbocharger Wear of seal at blower side Clogging of breather or breather hose Damaged piston ring Wear of piston ring or cylinder Wear or damage of rear oil seal Defective oil cooler Oil leakage from oil cooler Oil leakage from oil filter Oil leakage from oil pipe Oil leakage from oil drain plug Oil leakage from oil pan, cylinder head or others
q
Check the recent repair history. Machine operation Machines operated for a long period EEE E state Oil consumption has increased suddenly. w Q Oil supply rate has increased. w Q Oil becomes contaminated early. Q Q w Engine surface is contaminated with oil. w w w w w Pipe clamps of air intake system are loose. w Inside of turbocharger intake air outlet pipe is contaminated with oil. w Inside of turbocharger exhaust air outlet pipe is contaminated with oil. Q w Oil is mixed in the coolant. w Oil of gear chamber has increased. w Exhaust gas is blue under small load. Q w w Excessive amount of gas is discharged. Q Q w w Blowby gas No gas is discharged. w q
Dust enters if the intake air manifold is removed. Inside of intake air manifold is largely contaminated. Turbocharger shaft has a large play (looseness). Check the breather or breather hose. The compression pressure is low. Check the rear oil seal. During pressure resistance test, oil leaks from oil cooler. Oil leaks to the outside of engine.
q q q q q q q q q q q q q Remedy
GD535-5 (03)
Repair Repair Replace Replace Clean Replace Replace Repair Replace Replace Repair Repair Repair Repair
q
Cause
40-545
S-9 Oil becomes contaminated early.
40 Troubleshooting
S-9 Oil becomes contaminated early.
1
Generally, the oil becomes contaminated if:
q
Diagnosis
Checkpoints
Question
q
Check the recent repair history. Machine operation Machines operated for a long period state Unspecified fuel is used. Engine oil supply rate has increased. Metal powder is output when oil is drained from oil filter. Inside of exhaust pipe is contaminated with oil. Engine oil temperature increases rapidly. It is blue under small load. Exhaust gas It is black Excessive amount of gas is discharged. Blowby gas No gas is discharged.
EEE Q w Q Q w
w w
w w Q Q w
Q w
q
Turbocharger shaft has a large play (looseness). The compression pressure is low. Check the breather or breather hose. Check the oil cooler. Check the oil filter. It is hooked by the spring of oil filter safety valve, and broken. Check the turbocharger lubrication drain tube.
q q q q q q q Remedy
40-546
Q
See S-7.
q
Exhaust gas is mixed in the oil due to internal wearing. Lubrication path is clogged. Unspecified fuel is used. Unspecified oil is used. Machine is overloaded.
Damaged seal at turbocharger turbine side Wear of valve or valve guide Wear of piston ring or cylinder Clogging of breather or breather hose Clogging of oil cooler Clogging of oil filter Damage of oil filter safety valve Clogging of turbocharger lubrication drain tube Exhaust smoke color is bad.
q
Replace Replace Replace Clean Replace Replace Replace Clean -
q
Cause
GD535-5 (03)
40 Troubleshooting
S-10 Fuel consumption is excessive.
S-10 Fuel consumption is excessive.
1
Generally, the fuel consumption becomes large if:
Diagnosis
Checkpoints
Question
q
Fuel leakage inside of head cover Fuel leakage from fuel filter or piping Defective feed pump oil seal Defective supply pump plunger Defective common rail injection pressure Defective fuel injection by injector Malfunction of injector Incorrect fuel injection timing Defective coolant sensor, or defective wiring harness
q
The fuel leaks. Fuel injection status (fuel pressure, injection timing) is abnormal. Fuel is injected too much.
Check the recent repair history. Machine Machines operated for a long period operation state It is higher than the same model. Fuel consumption It increases gradually. It increases suddenly. Fuel leaks to the outside of engine. Engine combustion is unstable. Oil leaks more and diesel oil is smelled. Some cylinder is found to be cool when exhaust manifolds are touched by hand immediately after engine is started. Low idle speed is high. Torque converter stalls or pump relief speed is high. It becomes black Exhaust gas It becomes white Remove the head cover and check it. Check the supply pump oil seal. Troubleshoot for "Supply pump pressure low" according to the failure code (*1). When a certain cylinder is cutout, engine speed does not change. Too much fuel is returned from injector. Troubleshoot for "Coolant temperature sensor error" according to the failure code (*2). Check it with the monitoring function of machine monitor. Remedy
EE
E Q
Q
Q Q Q Q
Q Q W W W
W W Q Q Q Q
Q Q
Q q q q q q q q
q
Repair Repair Replace Replace Repair Replace Replace Replace Replace
q
Cause
*1: Failure codes [CA559] and [CA2249] *2: Failure codes [CA144] and [CA145]
GD535-5 (03)
40-547
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
40 Troubleshooting
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
Damage of oil cooler core or O-ring
Perforation by pitching
E E Q
Q Q Q Q Q Q Q Q w
w w w
Water is output when hydraulic oil or power train oil is drained. q
Oil leaks during pressure resistance test of cylinder head. Check the cylinder block.
q q
40-548
Replace
Replace
Replace
Remedy
Replace
q
Oil leaks during pressure resistance test of oil cooler. Replace
Question Diagnosis Checkpoints
Check the recent repair history. Machine operation Machines operated for a long period state It increases rapidly. Oil level It increases gradually. Hard water is used as the coolant. Oil increases and becomes cloudy. Too much bubbles in the radiator, and coolant spurts back. Hydraulic oil or power train oil becomes cloudy.
Internal cracking of cylinder block
Internal leak occurs in the lubrication system. Internal leak occurs in the cooling system.
Damage of cylinder head or head gasket
q
Damage of hydraulic oil cooler or power train oil cooler
Cause
Generally, oil is mixed in the coolant if: q
1
GD535-5 (03)
40 Troubleshooting
S-12 Oil pressure drops.
S-12 Oil pressure drops.
1
Generally, oil pressure drops if:
Diagnosis
Checkpoints
Question
q
Check the recent repair history. Machine Machines operated for a long period operation state The oil pressure monitor shows the dropped oil pressure (if the monitor is mounted). Unspecified oil is used. Filter is not replaced as specified by the Opeartion Manual. It shows the dropped oil pressure during low idle. The oil pressure It shows the dropped oil pressure during low idle and monitor display high idle. (when monitor is Dropped oil pressure is shown on a slope. mounted) Dropped oil pressure is shown sometimes. The oil pressure monitor shows the dropped oil level (if the monitor is mounted). Oil level is insufficient in engine oil pan. External hydraulic pipe leaks or it is crushed. Oil becomes cloudy, or diesel oil is smelled. Metal powder is output when oil is drained from oil pan.
w
Metal powder is output when oil is drained from oil filter.
w
Metal powder is output from oil filter. Check the oil pan strainer and piping. Oil pump is heavy to rotate, or it has play. Regulator valve spring has settling or damage. Check the oil filter. Display of oil level monitor becomes normal after replacement of oil level sensor.
q
Remedy
GD535-5 (03)
E
E
E Q w
Q
Q w
w Q
w w w Q
w w
Q
w
w
w w w Q q q See S-13.
q
Lubrication system has leaked, is clogged or worn. Hydraulic pressure control is abnormal. The correct oil shown by the Opeartion Manual is not used in ambient temperature. Oil has degraded due to overheating.
Worn metal journal Insufficient capacity in engine oil pan Water and fuel mixing in the oil Clogging of strainer in engine oil pan Clogging or damage of pipe in engine oil pan Defective oil pump Defective regulator valve Clogging of oil filter Leakage, crushing or clogging of hydraulic piping Defective oil level sensor, or defective wiring harness
q
q q q q
Replace Refilling with oil Clean Clean and replace Replace Adjust Replace Repair Replace
q
Cause
40-549
S-13 Oil amount increases (due to water or fuel mixing).
40 Troubleshooting
S-13 Oil amount increases (due to water or fuel mixing).
1
Generally, oil is mixed in the coolant if:
Check the recent repair history. Machine Machines operated for a long period operation state Fuel consumption is excessive. Oil supply rate has increased. Oil is mixed in the coolant. Oil leaks more and diesel oil is smelled. Oil becomes cloudy. When engine is started, water drops from the muffler. If radiator cap is opened and engine is idled at low speed, bubbles may come out or spurt back. Exhaust smoke is white. Oil of gear chamber has decreased. Oil of hydraulic oil tank has decreased.
Defective inside of supply pump
Damage of oil cooler or O-ring
Wear or damage of rear oil seal
Perforation by pitching
Internal cracking of cylinder block
E E
w
w
Q Q Q Q Q Q w Q Q Q w
Q w w
Q w
q
The compression pressure is low. Remove the injector, and check the O-ring. Check the cylinder block. Check the rear oil seal. Oil leaks during pressure resistance test of oil cooler. Remove the supply pump and check it.
q q q q q Replace
Replace
Repair
Replace
Replace
q Remedy
40-550
E
Replace
Diagnosis
Checkpoints
Question
Damage of cylinder head or head gasket
q
Coolant is mixed (and becomes cloudy). Fuel is mixed (diluted diesel oil is smelled). If oil is mixed in coolant, perform troubleshooting for "S-11 Oil is in coolant".
Damage of injector O-ring
q
Replace
q
Cause
GD535-5 (03)
40 Troubleshooting
S-14 Coolant temperature rises too high (overheating).
S-14 Coolant temperature rises too high (overheating). Cause
q
Diagnosis
Checkpoints
Question
q
Cooling airflow rate is low (due to deformed or damaged fans). Cooling efficiency has dropped. Cooling circulation system has failed. Power train oil temperature has increased.
Check the recent repair history. Machine Machines operated for a long period E E EE operation state It occurs suddenly. Q w Overheating It tends to be in the overheating state most of the time. Q Q w w Coolant It increases rapidly. Q Q w temperature (if temperature It does not drop from the red range. w gauge is mounted) The radiator level monitor shows the dropped coolant level (if the monitor Q w is mounted). Engine oil increases and becomes cloudy. w w Q The cloudy oil flows on the coolant. Q Q w w Too much bubbles in the radiator, and coolant spurts back. w When radiator core is illuminated by electric light, the illumination light w cannot be seen. Radiator shroud and under cover are clogged with dust and sand. w Radiator hose is cracked or clamps are loosened, and coolant leaks. w Coolant flows through radiator overflow hose. w Pointer of power train oil temperature gauge enters the red range before the engine coolant temperature gauge enters (if oil and coolant w temperature gauges are mounted). The compression pressure is low. Check the cylinder. Check the oil cooler. Temperature difference is large between radiator top and bottom tanks. The thermostat does not open at the valve open temperature. Temperature difference is small between radiator top and bottom tanks. Check the radiator core. When radiator cap operation is tested, the valve open pressure is low. The coolant temperature is normal.
Remedy
GD535-5 (03)
Replace q Replace q Replace q Replace q Refilling with oil Repair q Replace q Repair q Repair q Replace q Replace q Perform troubleshooting in H-mode.
q
Damage of cylinder head or head gasket Internal cracking of cylinder block Perforation by pitching Clogging or damage of oil cooler Insufficient coolant Defective fans Operation failure of thermostat Clogging or crush of radiator fin Clogging of radiator core Defective radiator cap (pressure valve) Defective coolant temperature gauge Increased power train oil temperature
Generally, the coolant temperature rises too high if: q
1
40-551
S-15 Unusual noise is heard.
40 Troubleshooting
S-15 Unusual noise is heard.
1
Generally, unusual noise is heard if:
Check the recent repair history. Machine E operation state Machines operated for a long period It is emitted gradually. Q Unusual noise It is emitted suddenly. Q Q Q Unspecified fuel is used. Q Oil supply rate has increased. w Metal powder is output when oil is drained from oil filter. w w Air leakage between turbocharger and cylinder head w When engine is rotated, interference noise is generated around the turbocharger. w When engine is rotated, abnormal noise is generated around the cylinder head. w w When engine is rotated, chatter sound is heard around the muffler. w Some cylinder is found to be cool when exhaust manifolds are touched by hand w immediately after engine is started. It is blue under small load. w Exhaust gas It is black Q w Q Engine does not pick-up smoothly, and combustion is unstable. w Abnormal noise is generated during acceleration. Q Q Q Too much blowby gas is output. w Turbocharger is heavy to rotate when tried by hands. Check the valve operating system. Unusual noise disappears when the muffler is removed. Check the valve clearance. The compression pressure is low. Check the gear train. When engine runs in cylinder cutout mode with some cylinder cut out, engine speed does not change. Unusual noise is heard only when engine is started. Check it with the monitoring function of machine monitor. Remedy
40-552
Q
q q q q q q q q q q q Replace Replace Replace Replace Adjust Replace Replace Replace Replace Replace
Diagnosis
Checkpoints
Question
q
Replace
Some parts are defective. Abnormal combustion occurs. q Air is taken from intake air system. q Determine the noise location, and troubleshoot it. a If engine is not warmed enough, engine sound slightly increases for low-temperature operation. This is not a problem. a When engine is accelerated, engine sound increases approx. 3 second MAX. This is not a problem. q
Air leakage between turbocharger and cylinder head Burn-out or interference of turbocharger Damage of valve operating system (valve and rocker lever) Damage inside of muffler (dropped partition plate) Incorrect valve clearance Wear of piston ring or cylinder Incorrect gear train backlash Missing or burn-out of bushing Clogging or burn-out of injector Dust clogging of injector Incorrect fuel injection timing (coolant low-temperature sensor error or boost temperature sensor error)
Cause
GD535-5 (03)
40 Troubleshooting
S-16 Vibration is excessive.
S-16 Vibration is excessive.
1
Generally, excessive vibration occurs if:
Cause
Parts are defective (abnormal wearing or damage). Alignment with the installed equipment is incorrect. q Abnormal combustion occurs. a If unusual noise is heard and vibration is excessive, perform troubleshooting for "S-15 Unusual noise is heard" as well. q
Check the recent repair history. Machine Machines operated for a long period operation state It increased rapidly. Vibration It increased gradually. Unspecified oil is used. Metal powder is output when oil is drained from oil filter. Metal powder is output when oil is drained from oil pan. Oil pressure is low during low idle. Vibration is excessive during medium speed traveling. Vibration increases according to the engine speed.
Loose engine mounting bolts or defective cushions Displacement between engine and installed equipment Damage of output shaft or inside of gear chamber
Incorrect fuel injection timing (coolant temperature sensor error or boost temperature sensor error)
Damage of valve operating system (valve and rocker arm) Wear of main metal and connecting rod metal Incorrect gear train backlash Worn camshaft bushing E
E
Q Q w w Q
Q Q w w Q
Q
Q
Q
Q Q Q Q Q
Q
Exhaust smoke is black.
w
Check the valve operating system. Check the main metal and connecting rod metal. Check the gear train. Check the camshaft bushing. Check it with the monitoring function of machine monitor. Check the engine mounting bolts and cushions. A runout or surface deflection was found by checking. Check the output shaft or inside of gear chamber.
q
Q q q q q q q Replace Adjust Replace
Replace
q Remedy
GD535-5 (03)
E
Replace Replace Replace Replace
Diagnosis
Checkpoints
Question
q
40-553
S-16 Vibration is excessive.
40-554
40 Troubleshooting
GD535-5 (03)
50 Disassembly and assembly
GD535-5 (01)
50-1
Contents
Contents
50 Disassembly and assembly
1
Acronyms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-3 Related information on disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-8 How to read this manual- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-8 Coating materials list - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-10 Special tool list - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-14 Sketches of special tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-22 Engine and cooling system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-49 Removal and installation of supply pump assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-49 Removal and installation of injector assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-53 Removal and installation of cylinder head assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-62 Removal and installation of air conditioner compressor belt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-78-1 Removal and installation of alternator belt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-79 Removal and installation of engine front oil seal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-81 Removal and installation of engine rear oil seal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-83 Removal and installation of radiator assembly (Canopy specification)- - - - - - - - - - - - - - - - - - - - - - - - - 50-86 Removal and installation of radiator assembly (Cab specification) - - - - - - - - - - - - - - - - - - - - - - - - - - 50-89-1 Removal and installation of aftercooler assembly (Canopy specification) - - - - - - - - - - - - - - - - - - - - - - 50-90 Removal and installation of aftercooler assembly (Cab specification) - - - - - - - - - - - - - - - - - - - - - - - - 50-93-1 Removal and installation of power train oil cooler assembly (Canopy specification) - - - - - - - - - - - - - - - 50-94 Removal and installation of power train oil cooler assembly (Cab specification)- - - - - - - - - - - - - - - - - 50-98-1 Removal and installation of fuel tank assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-99 Removal and installation of engine hood assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-104 Removal and installation of air conditioner compressor assembly - - - - - - - - - - - - - - - - - - - - - - - - - 50-105-1 Power train - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-106 Removal and installation of engine, transmission, and torque converter assembly (Canopy specification) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-106 Removal and installation of engine, transmission, and torque converter assembly (Cab specification) - - 50-112 Disconnection and connection of engine, transmission, and torque converter assembly - - - - - - - - - - - - 50-113 Disassembly and assembly of torque converter assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-115 Disassembly and assembly of transmission assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-126 Removal and installation of tandem drive and final drive assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - 50-161 Disassembly and assembly of tandem drive assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-164 Disassembly and assembly of differential assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-170 Disassembly and assembly of final drive assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-183 Steering system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-192 Removal and installation of Orbitrol valve assembly (Canopy specification) - - - - - - - - - - - - - - - - - - - - 50-192 Removal and installation of Orbitrol valve assembly (Cab specification) - - - - - - - - - - - - - - - - - - - - - 50-196-1 Brake system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-197 Disassembly and assembly of wheel brake assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-197 Undercarriage and frame - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-205 Removal and installation of center hinge pin - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-205 Hydraulic system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-215 Removal and installation of hydraulic tank, battery, and frame assembly- - - - - - - - - - - - - - - - - - - - - - - 50-215 Removal and installation of hydraulic tank assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-223 Removal and installation of control valve assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-227 Disassembly and assembly of hydraulic cylinder assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-232 Work equipment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-236 Removal and installation of blade assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-236 Removal and installation of circle drawbar assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-237 Removal and installation of circle rotation gear assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-239 Disassembly and assembly of circle rotation gear assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-241 Canopy, cab and attachments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-246 Removal and installation of canopy assembly (Canopy specification) - - - - - - - - - - - - - - - - - - - - - - - - - 50-246
50-2
GD535-5 (03)
50 Disassembly and assembly
Contents
Removal and installation of operator's cab assembly (Cab specification) - - - - - - - - - - - - - - - - - - - - - 50-250-1 Removal and installation of operator cab glass (adhered glass) (Cab specification) - - - - - - - - - - - - 50-250-10 Removal and installation of floor frame assembly (Canopy specification) - - - - - - - - - - - - - - - - - - - - - - 50-251 Removal and installation of floor frame assembly (Cab specification)- - - - - - - - - - - - - - - - - - - - - - - - 50-253-1 Removal and installation of canopy and floor frame assembly (Canopy specification) - - - - - - - - - - - - - 50-254 Removal and installation of operator's cab and floor frame assembly (Canopy specification) - - - - - - 50-256-1 Removal and installation of air conditioner unit assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-256-8 Removal and installation operator's seat - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-256-14 Removal and installation seat belt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-256-15 Electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-257 Removal and installation of engine controller assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-257 Removal and installation of machine monitor assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-259 Removal and installation of transmission controller assembly (Canopy specification) - - - - - - - - - - - - - 50-260 Removal and installation of transmission controller assembly (Cab specification) - - - - - - - - - - - - - - 50-260-1 Removal and installation of KOMTRAX terminal assembly (Canopy specification) - - - - - - - - - - - - - - - 50-261 Removal and installation of KOMTRAX terminal assembly (Cab specification) - - - - - - - - - - - - - - - - - - 50-262
GD535-5 (03)
50-2-1
Contents
50-2-2
50 Disassembly and assembly
GD535-5 (03)
50 Disassembly and assembly
Acronyms
Acronyms q q q q
1
The abbreviations of unknown parts, equipment and functions have been extracted from the Shop Manual, and their official names and details are defined in this Acronyms. Abbreviations that are commonly used in society might not be described. Special and rarely used abbreviations are described in the supplementary explanation in the text. The acronyms consist of two parts: the list of abbreviations that are used in the text, and the list of abbreviations that are used in circuit diagrams.
Abbreviations that are used in the text Abbreviations
Official name
Application (Applicable models (*1) and equipment) Traveling, brake
ABS
Antilock Brake System
AISS
Automatic Idling Setting Engine System
AJSS
Advanced Joystick Steering System
ARAC
Automatic Retarder Accelerator Control
(HD series, HM series)
Steering (WA series) Traveling, brake (HD series, HM series) Traveling, brake
ARSC
Automatic Retarder Speed Control
ASR
Automatic Spin Regulator
ATT
Attachment
BCV
Brake Cooling oil control Valve
CAN
(HD series, HM series) Traveling, brake (HD series, HM series) Work equipment
Explanation With this function, when the tires skid (wheels stop rotating), the brakes are released, and when the wheels start to rotate, the brakes are applied again. This function automatically sets the idle speed. A lever is used to perform the steering operations instead of a steering wheel. Moreover, it shifts gear and changes direction (FORWARD or REVERSE). When the accelerator pedal is released while the machine is traveling downhill, this function automatically applies the retarder with a constant braking force. When the accelerator pedal is released while the machine is traveling downhill, this function automatically applies the retarder to ensure that the machine speed does not accelerate above the speed set by the operator. When the tires spin on soft ground surfaces, this function automatically uses the optimum braking force to drive both wheels. The function or parts which are attached to the standard model and used
(HD series)
When the retarder is not being used, this valve bypasses part of the brake cooling oil to reduce the load on the hydraulic pump.
Controller Area Network
Communication, electronic control
One of communication standards that is used in the network on the machine
CDR
Crankcase Depression Regulator
Engine
A regulator valve which is installed to KCCV ventilator. It is written as CDR valve and it is not used independently.
CLSS
Closed-center Load Sensing System
Hydraulic system
This system can simultaneously actuate multiple actuators regardless of the load (provides better combined operation than OLSS).
Engine
Engine controller electronically controls supply pump, common rail, and injector. This function maintains optimum fuel injection amount and fuel injection timing.
Electronic control
Electronic control device that receives signals from each sensor of the machine and that specifies the optimum operation to the actuators. (Same as ECU)
CRI
Common Rail Injection
ECM
Electronic Control Module
GD535-5 (03)
Brake
1
50-3
Acronyms
Abbreviations
50 Disassembly and assembly
Official name
ECMV
Electronic Control Modulation Valve
ECSS
Electronically Controlled Suspension System
Application (Applicable models (*1) and equipment) Transmission (D series, HD series, WA series and others) Traveling (WA series)
Explanation Proportional solenoid valve that reduces the connection shock by gradually increasing the hydraulic pressure to engage the clutch. This system ensures smooth high-speed travel by absorbing vibration of machine during travel with hydraulic spring effect of accumulator.
ECU
Electronic Control Unit
Electronic control
Electronic control device that receives signals from each sensor of the machine and that specifies the optimum operation to the actuators. (Same as ECM)
EGR
Exhaust Gas Recirculation
Engine
This function recirculates part of exhaust gas to the combustion chamber in order to reduce combustion temperature and control the emission of NOx.
Equipment Management Monitoring System
Machine monitor
This system allows data (filter, oil replacement interval, malfunctions on machine, failure code, and failure history) from each sensor on the machine to be checked on the monitor.
EPC
Electromagnetic Proportional Control
Hydraulic system
Electromagnetic proportional control This mechanism allows actuators to be operated in proportion to the current supplied.
FOPS
Falling Object Protective Structure
Operator's cab, canopy
F-N-R
Forward-NeutralReverse
Operation
Forward-Neutral-Reverse
Communication
GPS
Global Positioning System
Global positioning system The satellite positioning system to determine the current position on the earth
GNSS
Global Navigation Satellite System
EMMS
This performance is standardized as ISO 3449.
(KOMTRAX, KOMTRAX Plus) Communication (KOMTRAX, KOMTRAX Plus) Steering
50-4
This structure protects the operator's head from falling objects. (Falling Object Protective Structure)
Global navigation satellite system A general term for positioning system using satellites such as GPS, GALILEO, etc. This function uses a combination of hydraulic motor and bevel shaft to control difference in travel speed of right and left tracks. Accordingly machine can turn without using steering clutch.
HSS
Hydrostatic Steering System
HST
Hydro Static Transmission
ICT
Information and Communication Technology
Communication, electronic control
A general term for the engineering and its socially applied technology of information processing and communication.
IMA
Inlet Metering Actuator
Engine
Valve that adjusts fuel intake amount at inlet port of pump in order to control fuel discharged volume of supply pump. (Same as IMV)
IMU
Inertial Measurement Unit
Engine
This is a device to detect the angle (or angular velocity) and acceleration of the 3 axes that control motions.
IMV
Inlet Metering Valve
Engine
Valve adjusting fuel intake amount at inlet port of pump in order to control fuel discharged volume of supply pump. (Same as IMA)
(D series) Transmission (D series, WA series)
This function uses a combination of hydraulic pump and hydraulic motor to shift the speed range steplessly without using gears.
GD535-5 (01)
50 Disassembly and assembly
Abbreviations
Official name
Acronyms
Application (Applicable models (*1) and equipment)
KCCV
KOMATSU Closed Crankcase Ventilation
Engine
KCSF
KOMATSU Catalyzed Soot Filter
Engine
KDOC
KOMATSU Diesel Oxidation Catalyst
Engine
KDPF
KOMATSU Diesel Particulate Filter
Explanation The mechanism for oil separation from gas in order to re-burn the blow-by gas and for oil return to the intake system. It is mainly composed of filters. The filter to capture the soot from exhaust gas. It is built in the KDPF. The catalyst for exhaust gas purification.
Engine
It may be built in the KDPF or combined with the muffler. This component is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it. It is used instead of the conventional muffler.
Traveling, brake
This function recovers the drive force of the wheels by braking automatically with the optimum force and at the same time activates the inter-axle differential lock when the wheels idle while the machine travels on the soft ground road.
KOMATSU Traction Control System
(HM series)
LCD
Liquid Crystal Display
Machine monitor
The liquid crystal display panel. Image display device such as a monitor which assembles in the liquid crystal element.
LED
Light Emitting Diode
Electronic components
Light emitting diode It refers to semiconductor element that emits light when the voltage is applied in forward direction.
LIN
Local Interconnect Network
Communication, electronic control
One of communication standards that is used in the network on the machine
LS
Load Sensing
Hydraulic system
Function that detects differential pressure of pump and controls discharged volume corresponding to load.
KTCS
Low Voltage Differential Communication, electronic Signaling control
One of communication standards that is used in the network on the machine
MAF
Mass Air Flow
Engine
The intake airflow rate of the engine. It is not used alone, but used in combination with sensors. The intake airflow sensor may be called the MAF sensor.
MMS
Multimedia Messaging Service
Communication
The service to allow transmission and reception of short messages such as characters, voice and images between mobile phones.
Normally Closed
Electric system, hydraulic system
The characteristics of an electric or hydraulic circuit that is normally closed when the system is not operating, and that is normally opened when the system is operating.
Normally Open
Electric system, hydraulic system
The characteristics of an electric or hydraulic circuit that is normally opened when the system is not operating, and that is normally closed when the system is operating.
Open-center Load Sensing System
Hydraulic system
The hydraulic system that can simultaneously operate multiple actuators regardless of the load.
Pressure Compensation
Hydraulic system
The function to compensate for the hydraulic pressure.
LVDS
NC
NO
OLSS PC
GD535-5 (01)
50-5
Acronyms
Abbreviations
50 Disassembly and assembly
Official name
Application (Applicable models (*1) and equipment)
Explanation
Steering Palm Command Control System (D series)
The function to make the controller analyze the lever, pedal, and dial data instantaneously, and to allow the electronic control of engine, transmission and others appropriately.
PCV
Pre-stroke Control Valve
Engine
This valve is installed at inlet port of pump and it adjusts fuel intake amount in order to control fuel discharged volume of supply pump.
PPC
Proportional Pressure Control
Hydraulic system
Used for controlling proportional pressure. This system moves actuators in proportion to the hydraulic pressure.
PPM
Piston Pump and Motor
PTO
Power Take Off
Power transmission
Power take-off mechanism
PTP
Power Tilt and power Pitch dozer
Work equipment (D series)
This function performs hydraulic control of the tilt and pitch of the bulldozer blade.
Operator's cab, canopy
The structure to protect the operator (fastened with seat belt) if the machine falls. (Roll-over protective structure for operator)
PCCS
ROPS
Roll-Over Protective Structure
Hydraulic system (D series, PC series, others)
Piston hydraulic pump and motor.
This performance is standardized as ISO 3471.
Selective Catalytic Reduction
Urea SCR system
The exhaust gas purification device, that uses urea water and converts the nitrogen oxides (NOx) into harmless nitrogen and water (by reduction reaction). It may be called part of the exhaust gas purifying catalyst or the related device name.
Le Systeme International d’ Unites
Unit
Abbreviated for the "International System of Units". It is the universal unit system and "A single unit for a single quantity" is the basic principle applied.
SOL
Solenoid
Electrical system
It refers to an actuator consisting of a solenoid and an iron core that is moved by the magnetic force when the solenoid is energized.
TWV
2-Way Valve
Hydraulic system
Solenoid valve that switches over direction of flow.
VGT
Variable Geometry Turbocharger
Engine
Turbocharger having the variable geometry of exhaust passage
SCR
SI
*1: Applicable model codes D: Bulldozer HD: Dump truck HM: Articulated dump truck PC: Hydraulic excavator WA: Wheel loader
50-6
GD535-5 (03)
50 Disassembly and assembly
Acronyms
Abbreviations used in circuit diagrams Abbreviations
Official name
A/C
Air Conditioner
A/D
Analogue-to-Digital
A/M
Air Mix damper
ACC
Accessory
ADD
Additional
AUX
Auxiliary
BR
Battery Relay
CW
Clockwise
CCW
Counter Clockwise
ECU
Electronic Control Unit
ECM
Electronic Control Module
ENG
Engine
EXGND
External Ground
F.G.
Frame Ground
GND
Ground
IMA
Inlet Metering Actuator
NC
No Connection
S/T STRG
Steering
SIG
Signal
SOL
Solenoid
STD
Standard
OPT OP PRESS SPEC SW TEMP
Option Pressure Specification Switch Temperature
T/C
Torque Converter
T/M
Transmission
GD535-5 (01)
1
50-7
How to read this manual
50 Disassembly and assembly
Related information on disassembly and assembly How to read this manual
1
1
(Rev.2013.05)
Removal and installation of assembly Special tools q
q
q
The special tools required for removal and installation work are described in the list as symbols such as A1, ..., X1. Part number, part name, necessity, and quantity are described. Mark used in the column of necessity are explained below. ■: Tools are not substituted, must always be equipped (used). q: Tools extremely useful if available or tools that can be substituted with commercially available tool. For details and the sketches of the special tools, see "Special tool list" and "Sketches of special tools."
k:
This mark indicates safety-related precautions which must be followed when preforming the work. a : This mark gives knowledge or precautions when performing the work. 4 2 3 5
Removal In "removal" section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be drained are described. q The general tools required for "Removal" are listed as [1], [2], ..., without description of part number, part name, and quantity. q Marks used in "Removal" section are explained below. k : This mark indicates safety-related precautions which must be followed when preforming the work. a :This mark gives knowledge or precautions when performing the work. [*1]: This mark indicates that knowledge or precautions for the assembly installation work are given in the installation section. q
6 4
: This mark shows the amount of oil or coolant to be drained. : This mark shows the weight of the part or equipment.
Installation q
q
q
q
The work procedure of "Installation" is in the reversed order to removal unless otherwise specified. For knowledge and precautions required for "Installation", a [*1] mark is assigned to the "Removal" work procedure to indicate the work item of the installation knowledge or precaution. The general tools required for "Installation" are listed as [1], [2], ..., without description of part number, part name, and quantity. Marks used in "Installation" section are explained below.
50-8
: This mark shows the weight of the part or equipment. : This mark shows a specific coating agent to be used. : This mark shows the specified tightening torque. : This mark shows the amount of oil or coolant to be added. q For details of oil or coolant to be added after installation, see Specification "Table of fuel, coolant and lubricants".
Disassembly and assembly of assembly Special tools q
q
q
The special tools required for disassembly and assembly work are described in the list as symbols such as A1, ..., X1. Part number, part name, quantity, and necessity are described. Mark used in the column of necessity are explained below. ■: Tools are not substituted, must always be equipped (used). q: Tools extremely useful if available or tools that can be substituted with commercially available tool. For details and the sketches of the special tools, see "Special tool list" and "Sketches of special tools."
Disassembly "Disassembly" describes the work procedure as well as the precautions, knowledge, and drain amounts of oil and coolant required for the work. q The general tools required for "Disassembly" are listed as [1], [2], ..., without description of part number, part name, and quantity. q Marks used in the section of "Disassembly" are explained below. k : This mark indicates safety-related precautions which must be followed when preforming the work. a : This mark gives knowledge or precautions when performing the work. q
6 4
: This mark shows the amount of oil or coolant to be drained. : This mark shows the weight of the part or equipment.
GD535-5 (01)
50 Disassembly and assembly
How to read this manual
Assembly The section of "Assembly" provides precautions and knowledge related to the work to be performed, and amount of oil or coolant to be refilled. q The general tools required for "Assembly" are listed as [1], [2], ..., without description of part number, part name, and quantity. q Marks used in the section of "Assembly" are explained below. k : This mark indicates safety-related precautions which must be followed when preforming the work. a : This mark gives knowledge or precautions when performing the work. q
4 2 3 5
: This mark shows the weight of the part or equipment. : This mark shows a specific coating agent to be used. : This mark shows the specified tightening torque. : This mark shows the amount of oil or coolant to be added. q For details of oil or coolant to be added after installation, see Specification "Table of fuel, coolant and lubricants".
GD535-5 (01)
50-9
Coating materials list
50 Disassembly and assembly
Coating materials list
1
a The coating materials such as adhesives, liquid gasket, and grease used for disassembly and assembly are listed below. a For coating materials not listed below, use the equivalent of products shown in this manual.
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50 Disassembly and assembly
Coating materials list
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