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KOMATSU HD325-7 HD405-7 DUMP TRUCK SHOP MANUAL SEN00486-17 – PDF
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KOMATSU HD325-7 HD405-7 DUMP TRUCK SHOP MANUAL SEN00486-17 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU HD325-7 HD405-7 DUMP TRUCK SHOP MANUAL SEN00486-17 – PDF DOWNLOAD
Language : English
Pages : 1504
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU HD325-7 HD405-7 DUMP TRUCK SHOP MANUAL SEN00486-17 – PDF DOWNLOAD
Cover........................................................................................................................................................ 1 00 Index and foreword........................................................................................................................................ 3 Index.................................................................................................................................................... 3 Composition of shop manual........................................................................................................................... 4 Table of contents.................................................................................................................................... 6 Foreword and general information......................................................................................................................... 19 Safety notice........................................................................................................................................ 20 How to read the shop manual.......................................................................................................................... 25 Explanation of terms for maintenance standard........................................................................................................ 27 Handling of electric equipment and hydraulic component............................................................................................... 29 How to read electric wire code....................................................................................................................... 41 Precautions when carrying out operation.............................................................................................................. 44 Method of disassembling and connecting push-pull type coupler........................................................................................ 47 Standard tightening torque table..................................................................................................................... 50 Conversion table..................................................................................................................................... 54 01 Specification............................................................................................................................................. 61 Specification and technical data......................................................................................................................... 61 Specification drawing................................................................................................................................ 62 Specifications....................................................................................................................................... 65 Weight table......................................................................................................................................... 77 Fuel, coolant and lubricants......................................................................................................................... 78 10 Structure, function and maintenance standard.............................................................................................................. 81 Engine and cooling system................................................................................................................................ 81 Radiator, oil cooler, aftercooler.................................................................................................................... 82 Output shaft......................................................................................................................................... 84 Power train, Part 1...................................................................................................................................... 87 Power train skeleton................................................................................................................................. 88 Drive shaft.......................................................................................................................................... 90 Torque converter and transmission hydraulic piping................................................................................................... 91 Power train charge pump.............................................................................................................................. 92 Retarder cooling pump................................................................................................................................ 93 Torque converter..................................................................................................................................... 94 Torque converter valve............................................................................................................................... 100 Transmission......................................................................................................................................... 101 Transmission control valve........................................................................................................................... 117 ECMV................................................................................................................................................. 118 Power train, Part 2...................................................................................................................................... 127 Axle................................................................................................................................................. 128 Differential......................................................................................................................................... 130 Final drive.......................................................................................................................................... 132 Wheel................................................................................................................................................ 134 Steering system.......................................................................................................................................... 137 Steering column...................................................................................................................................... 138 Steering linkage..................................................................................................................................... 139 Brake system............................................................................................................................................. 143 Brake piping......................................................................................................................................... 144 Brake valve.......................................................................................................................................... 146 Secondary brake valve................................................................................................................................ 149 Relay valve.......................................................................................................................................... 150 Front brake cut valve................................................................................................................................ 151 Accumulator charge valve............................................................................................................................. 152 Accumulator.......................................................................................................................................... 158 Slack adjuster....................................................................................................................................... 160 Brake................................................................................................................................................ 162 Proportional reducing valve.......................................................................................................................... 167 Parking brake........................................................................................................................................ 168 Parking brake solenoid............................................................................................................................... 170 Hand brake (retarder)................................................................................................................................ 171 Undercarriage and frame.................................................................................................................................. 173 Suspension........................................................................................................................................... 174 Suspension cylinder.................................................................................................................................. 176 Rear axle support.................................................................................................................................... 184 Hydraulic system......................................................................................................................................... 187 Steering, hoist oil pressure piping diagram.......................................................................................................... 188 Dump body control.................................................................................................................................... 190 Hydraulic tank....................................................................................................................................... 192 Steering valve....................................................................................................................................... 194 Cross-over relief valve.............................................................................................................................. 198 Steering control valve............................................................................................................................... 199 Hoist valve.......................................................................................................................................... 208 Dump control valve (EPC valve)....................................................................................................................... 214 Steering cylinder.................................................................................................................................... 218 Hoist cylinder....................................................................................................................................... 219 Work equipment and steering pump..................................................................................................................... 220 Cab and its attachments.................................................................................................................................. 223 ROPS cab............................................................................................................................................. 224 Air conditioner...................................................................................................................................... 225 Rear view monitor.................................................................................................................................... 231 Electrical system, Part 1................................................................................................................................ 241 Machine monitor system............................................................................................................................... 242 Electrical system, Part 2................................................................................................................................ 271 Automatic shift control system....................................................................................................................... 272 Transmission controller.............................................................................................................................. 276 External power supply heater......................................................................................................................... 290 Auto emergency steering system....................................................................................................................... 292 Retarder control system.............................................................................................................................. 296 Dump control lever................................................................................................................................... 310 Auto suspension system............................................................................................................................... 314 Battery disconnector switch.......................................................................................................................... 308 Electrical system, Part 3................................................................................................................................ 319 Payload meter (card type)............................................................................................................................ 320 Payload meter (PLM) controller related............................................................................................................... 350 Electrical system, Part 4................................................................................................................................ 375 Sensors, switches.................................................................................................................................... 376 KOMTRAX terminal system (If equipped)................................................................................................................ 390 20 Standard value table...................................................................................................................................... 395 Standard service value table............................................................................................................................. 395 Standard value table for engine...................................................................................................................... 396 Standard value table for machine..................................................................................................................... 398 30 Testing and adjusting..................................................................................................................................... 405 Testing and adjusting, Part 1............................................................................................................................ 405 Tools for testing, adjusting, and troubleshooting.................................................................................................... 407 Testing engine speed................................................................................................................................. 413 Testing intake air pressure (boost pressure)......................................................................................................... 414 Testing exhaust temperature.......................................................................................................................... 415 Testing exhaust gas color............................................................................................................................ 417 Adjusting valve clearance............................................................................................................................ 418 Testing compression pressure......................................................................................................................... 420 Testing blow-by pressure............................................................................................................................. 422 Testing engine oil pressure.......................................................................................................................... 423 Testing EGR valve and bypass valve drive oil pressure................................................................................................ 424 Handling of fuel system devices...................................................................................................................... 425 Releasing residual pressure from fuel system......................................................................................................... 425 Testing fuel pressure................................................................................................................................ 426 Testing fuel return rate and leakage................................................................................................................. 427 Bleeding air from fuel circuit....................................................................................................................... 430 Testing the fuel circuit for leakage................................................................................................................. 432 Testing and adjusting alternator belt tension........................................................................................................ 433 Testing and adjusting fan belt tension............................................................................................................... 434 Testing and adjusting air conditioner compressor belt tension........................................................................................ 436 Testing and adjusting, Part 2............................................................................................................................ 439 Testing torque converter stall speed................................................................................................................. 441 Testing power train oil pressure..................................................................................................................... 442 Adjusting transmission speed sensor.................................................................................................................. 449 Testing brake oil pressure........................................................................................................................... 450 Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas................................................ 452 Testing brake performance............................................................................................................................ 460 Adjusting parking brake.............................................................................................................................. 462 Releasing remaining pressure in brake circuit........................................................................................................ 463 Bleeding air from brake circuit...................................................................................................................... 464 Testing wear of rear brake disc...................................................................................................................... 465 Testing wear of front brake pad...................................................................................................................... 466 Method for emergency release of parking brake........................................................................................................ 467 Testing and adjusting front suspension cylinder...................................................................................................... 468 Testing and adjusting inverted type rear suspension cylinder......................................................................................... 473 Testing and adjusting front suspension cylinder (mode selector hydraulic cylnder).................................................................... 477 Testing and adjusting hydraulic pressure in steering, hoist circuit.................................................................................. 478 Testing and adjusting dump EPC circuit oil pressure.................................................................................................. 481 Air bleeding from steering cylinder.................................................................................................................. 482 Procedure for raising body in emergency.............................................................................................................. 483 Adjusting body positioner sensor..................................................................................................................... 484 Resetting method for dump body seating control....................................................................................................... 485 Adjustment of tilt lock lever of steering wheel...................................................................................................... 486 Handling of high voltage circuit of engine controller................................................................................................ 487 Adjusting transmission controller.................................................................................................................... 487 Method for emergency escape at electrical system failure............................................................................................. 488 Testing and adjusting, Part 3............................................................................................................................ 493 Setting and adjusting of devices..................................................................................................................... 494 Special functions of machine monitor (EMMS).......................................................................................................... 506 Testing and adjusting, Part 4............................................................................................................................ 565 How to start operation of KOMTRAX terminal........................................................................................................... 566 Lamp display of KOMTRAX terminal..................................................................................................................... 571 Pm Clinic check sheet................................................................................................................................ 574 Setting of card-type payload meter (PLM-) after installation or replacement.......................................................................... 576 Setting of payload meter............................................................................................................................. 582 40 Troubleshooting........................................................................................................................................... 591 General information on troubleshooting................................................................................................................... 591 Points to remember when performing troubleshooting................................................................................................... 592 How to proceed in troubleshooting.................................................................................................................... 594 Checks before troubleshooting........................................................................................................................ 596 Classification and procedures of troubleshooting..................................................................................................... 597 Information in troubleshooting table................................................................................................................. 601 Connection table for connector pin numbers........................................................................................................... 603 T- branch box and T- branch adapter table............................................................................................................ 639 Troubleshooting by failure code, General................................................................................................................. 643 Failure codes table.................................................................................................................................. 644 Before troubleshooting by failure codes.............................................................................................................. 654 Contents of troubleshooting table.................................................................................................................... 659 Troubleshooting by failure code, Part 1.................................................................................................................. 663 Failure code [1500L0] (Dual engagement).............................................................................................................. 665 Failure code [15B0NX] (Transmission oil filter: Clogging)............................................................................................ 666 Failure code [15F0KM] (R → F shifting abuse 1: Mistake in operation)................................................................................. 668 Failure code [15F0MB] (R → F shifting abuse 2: Mistake in operation)................................................................................. 668 Failure code [15F7KM] (Forward clutch disk abuse: Mistake in operation or setting)................................................................... 669 Failure code [15G0MW] (R clutch: Slipping)........................................................................................................... 670 Failure code [15G7KM] (Reverse clutch disk abuse: Mistake in operation or setting)................................................................... 672 Failure code [15H0MW] (Hi clutch: Slipping).......................................................................................................... 674 Failure code [15J0MW] ( Lo clutch: Slipping)......................................................................................................... 676 Failure code [15K0MW] (1st clutch: Slipping)......................................................................................................... 678 Failure code [15L0MW] (2nd clutch: Slipping)......................................................................................................... 680 Failure code [15M0MW] (3rd clutch: Slipping)......................................................................................................... 682 Failure code [15N0MW] (4th clutch: Slipping)......................................................................................................... 684 Failure code [15SBL1] (R clutch solenoid: Fill signal is ON when command current is OFF)............................................................. 686 Failure code [15SBMA] (R clutch solenoid: Malfunction)............................................................................................... 690 Failure code [15SCL1] (Hi clutch solenoid: Fill signal is ON when command current is OFF)............................................................ 692 Failure code [15SCMA] (Hi clutch solenoid: Malfunction).............................................................................................. 696 Failure code [15SDL1] (Lo clutch solenoid: Fill signal is ON when command current is OFF)............................................................ 698 Failure code [15SDMA] (Lo clutch solenoid: Malfunction).............................................................................................. 702 Failure code [15SEL1] (1st clutch solenoid: Fill signal is ON when command current is OFF)........................................................... 704 Failure code [15SEMA] (1st clutch solenoid: Malfunction)............................................................................................. 708 Failure code [15SFL1] (2nd clutch solenoid: Fill signal is ON when command current is OFF)........................................................... 710 Failure code [15SFMA] (2nd clutch solenoid: Malfunction)............................................................................................. 714 Failure code [15SGL1] (3rd clutch solenoid: Fill signal is ON when command current is OFF)........................................................... 716 Failure code [15SGMA] (3rd clutch solenoid: Malfunction)............................................................................................. 720 Failure code [15SHL1] (4th clutch solenoid: Command current is OFF and fill signal is ON)............................................................ 722 Failure code [15SHMA] (4th clutch solenoid: Malfunction)............................................................................................. 726 Failure code [15SJMA] (Lockup clutch solenoid: Malfunction).......................................................................................... 728 Failure code [989A00] (Engine over run prevention command signal: Operating)......................................................................... 730 Failure code [989D00] (Rear section tipping over alarm: Alarm is activated).......................................................................... 730 Failure code [2F00KM] (Parking brake: Mistake in operation or setting)............................................................................... 732 Failure code [2G42ZG] (Front accumulator: Lowering of oil pressure).................................................................................. 734 Failure code [2G43ZG] (Rear accumulator: Lowering of oil pressure)................................................................................... 734 Failure code [A570NX] (Engine oil filter: Clogging).................................................................................................. 735 Failure code [AA10NX] (Air cleaner element: Clogging)................................................................................................ 736 Failure code [AB00MA] (Alternator: Malfunction)...................................................................................................... 738 Failure code [B@BAZG] (Abnormal lowering of engine oil pressure: Lowering of oil pressure)........................................................... 740 Failure code [B@BAZK] (Engine oil: Level too low).................................................................................................... 742 Failure code [B@BCZK] (Lowering of radiator coolant: Lowering of level).............................................................................. 744 Failure code [B@BCNS] (Engine: Overheat)............................................................................................................. 746 Failure code [B@C7NS] (Rear brake oil: Overheat)..................................................................................................... 747 Failure code [B@CENS] (Torque converter oil: Overheat)............................................................................................... 747 Failure code [B@GAZK] (Battery electrolyte level: Lowering of level)................................................................................. 748 Failure code [B@JANS] (Steering oil: Overheat)....................................................................................................... 749 Troubleshooting by failure code, Part 2.................................................................................................................. 751 Failure code [CA111] Abnormality in engine controller................................................................................................ 754 Failure code [CA115] Engine Ne or Bkup speed sensor error............................................................................................ 756 Failure code [CA122] Charge (boost) pressure sensor high error....................................................................................... 758 Failure code [CA123] Charge (boost) pressure sensor low error........................................................................................ 760 Failure code [CA131] Throttle sensor high error...................................................................................................... 762 Failure code [CA132] Throttle sensor low error....................................................................................................... 765 Failure code [CA135] Engine oil pressure sensor high error........................................................................................... 768 Failure code [CA141] Engine oil pressure sensor low error............................................................................................ 770 Failure code [CA144] Coolant temperature sensor high error........................................................................................... 772 Failure code [CA145] Coolant temperature sensor low error............................................................................................ 774 Failure code [CA153] Charge (boost) temperature sensor high error.................................................................................... 776 Failure code [CA154] Charge (boost) temperature sensor low error..................................................................................... 778 Failure code [CA187] Sensor power supply 2 low error................................................................................................. 780 Failure code [CA221] Atmospheric pressure sensor high error.......................................................................................... 784 Failure code [CA222] Atmospheric pressure sensor low error........................................................................................... 786 Failure code [CA227] Sensor power supply 2 high error................................................................................................ 788 Failure code [CA234] Engine overspeed................................................................................................................ 789 Failure code [CA238] Ne speed sensor power supply error.............................................................................................. 790 Failure code [CA263] Fuel Temperature Sensor High Error.............................................................................................. 792 Failure code [CA265] Fuel Temperature Sensor Low Error............................................................................................... 794 Failure code [CA271] PCV1 Short circuit.............................................................................................................. 796 Failure code [CA272] PCV1 Disconnection.............................................................................................................. 797 Failure code [CA273] PCV2 Short circuit.............................................................................................................. 798 Failure code [CA274] PCV2 Disconnection.............................................................................................................. 799 Failure code [CA322] Injector #1 open/short error.................................................................................................... 800 Failure code [CA323] Injector #5 open/short error.................................................................................................... 802 Failure code [CA324] Injector #3 open/short error.................................................................................................... 804 Failure code [CA325] Injector #6 open/short error.................................................................................................... 806 Failure code [CA331] Injector #2 open/short error.................................................................................................... 808 Failure code [CA332] Injector #4 open/short error.................................................................................................... 810 Failure code [CA342] Calibration code inconsistency.................................................................................................. 812 Failure code [CA351] Injectors drive circuit error................................................................................................... 813 Failure code [CA352] Sensor power supply 1 low error................................................................................................. 814 Failure code [CA386] Sensor power supply 1 high error................................................................................................ 816 Failure code [CA431] Idle validation switch error.................................................................................................... 818 Failure code [CA432] Idle validation action error.................................................................................................... 821 Failure code [CA441] Battery voltage low error....................................................................................................... 824 Failure code [CA442] Battery voltage high error...................................................................................................... 825 Failure code [CA449] Common rail pressure high error 2............................................................................................... 826 Failure code [CA451] Common rail pressure sensor high error.......................................................................................... 828 Failure code [CA452] Common rail pressure sensor low error........................................................................................... 830 Failure code [CA553] Common rail pressure high error 1............................................................................................... 832 Failure code [CA554] Common rail pressure sensor in range error...................................................................................... 833 Failure code [CA559] Supply pump pressure very low error 1........................................................................................... 834 Failure code [CA689] Engine Ne speed sensor error.................................................................................................... 838 Failure code [CA731] Engine Bkup speed sensor phase error............................................................................................ 840 Failure code [CA757] All continuous data lost error.................................................................................................. 841 Failure code [CA778] Engine Bkup speed sensor error.................................................................................................. 842 Failure code [CA1228] EGR valve servo error 1........................................................................................................ 844 Failure code [CA1625] EGR valve servo error 2........................................................................................................ 845 Failure code [CA1626] Bypass valve solenoid current high error....................................................................................... 846 Failure code [CA1627] Bypass valve solenoid current low error........................................................................................ 848 Failure code [CA1628] Bypass Valve Servo Error 1..................................................................................................... 850 Failure code [CA1629] Bypass Valve Servo Error 2..................................................................................................... 851 Troubleshooting by failure code, Part 3.................................................................................................................. 853 Failure code [CA1631] Bypass valve lift sensor high error............................................................................................ 856 Failure code [CA1632] Bypass valve lift sensor low error............................................................................................. 858 Failure code [CA1633] KOMNET datalink timeout error.................................................................................................. 860 Failure code [CA1642] EGR inlet pressure sensor low error............................................................................................ 862 Failure code [CA1653] EGR inlet pressure sensor high error........................................................................................... 864 Failure code [CA2185] Throttle sensor power supply voltage high error................................................................................ 866 Failure code [CA2186] Throttle sensor power supply voltage low error................................................................................. 868 Failure code [CA2249] Supply pump pressure very low error 2.......................................................................................... 870 Failure code [CA2271] EGR valve lift sensor high error............................................................................................... 872 Failure code [CA2272] EGR valve lift sensor low error................................................................................................ 874 Failure code [CA2351] EGR valve solenoid operation short circuit..................................................................................... 876 Failure code [CA2352] EGR valve solenoid operation disconnect........................................................................................ 878 Failure code [CA2555] Intake air heater relay open circuit error..................................................................................... 880 Failure code [CA2556] Intake air heater relay short circuit error.................................................................................... 882 Failure code [D19HKB] (Stop lamp relay output system: Short circuit)................................................................................. 884 Failure code [D5ZKKZ] (Front brake cut-off solenoid valve: Disconnection or short circuit)........................................................... 886 Failure code [DAF9KM] Wrong connection of connector.................................................................................................. 888 Failure code [DAFRKR] Abnormal CAN communication (machine monitor): Abnormal communication........................................................... 890 Failure code [DAQ0KK] (Transmission controller direct power supply: Lowering of source voltage)...................................................... 892 Failure code [DAQ0KT] (Transmission controller nonvolatile memory: Abnormality in controller)........................................................ 894 Failure code [DAQ2KK] (Transmission controller solenoid power source: Power source voltage too low).................................................. 895 Failure code [DAQ9KQ] (Transmission controller: Disagreement of model selection)..................................................................... 896 Failure code [DAQRKR] Abnormal CAN communication (Transmission): Abnormal communication.............................................................. 897 Failure code [DAQRMA] (Transmission controller option setting: Malfunction).......................................................................... 902 Failure code [DB10KT] (Retarder controller nonvolatile memory: Abnormality in controller)............................................................ 903 Failure code [DB12KK] (Retarder controller solenoid power source: Power source voltage too low)...................................................... 904 Failure code [DB13KK] (Retarder controller direct power source: Power source voltage too low)........................................................ 906 Failure code [DB19KQ] Disagreement of model selection (Retarder controller).......................................................................... 908 Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled................................................................ 910 Failure code [DB1RMA] Disagreement of option setting (Retarder controller)........................................................................... 914 Failure code [DB1SKQ] (Model selection: Wrong information)........................................................................................... 915 Failure code [DB2RKR] CAN communication (engine controller): Communication disabled.................................................................. 916 Failure code [DBB0KK] PLM controller: Low source voltage (input) orPLM controller_LED display: "n9" → "01"........................................... 922 Failure code [DBB0KQ] PLM controller: Disagreement of model selection signals or PLM controller_LED display: "nF" → "11"............................. 924 Failure code [DBB3KK] PLM controller battery power supply: Lowsource voltage (input) or PLM controller_LED display: "n9" → "05"...................... 926 Failure code [DBB6KP] PLM controller 24V power supply output: Lowoutput voltage or PLM controller_LED display: "n9" → "02"........................... 928 Failure code [DBBQKR] PLM controller CAN communication: Defective communication or PLM controller_LED display: "n8" → "02"........................... 930 Failure code [DBBRKR] Abnormal CAN communication (PLM) : Defective communication..................................................................... 931 Failure code [DBC9KQ] Disagreement of model selection (ABS controller)............................................................................... 932 Failure code [DBCRMA] Disagreement of option setting (ABS controller)................................................................................ 933 Failure code [DDD7KX] (Trouble in travel speed setting switch system: Out of input signal range) (If equipped)....................................... 934 Failure code [DDD8KA] (ARSC system switch system: Disconnection)..................................................................................... 936 Failure code [DDD8KB] (ARSC system switch system: Short circuit)..................................................................................... 938 Failure code [DDDAKA] (ASR system switch: Disconnection) (If equipped)............................................................................... 940 Failure code [DDDAKB] (ASR system switch: Short circuit)............................................................................................. 942 Failure code [DDTHKA] (Hi clutch fill switch: Disconnection)......................................................................................... 944 Failure code [DDTJKA] (Lo clutch fill switch: Disconnection)......................................................................................... 946 Failure code [DDTKKA] (1st clutch fill switch: Disconnection)........................................................................................ 948 Failure code [DDTLKA] (2nd clutch fill switch: Disconnection)........................................................................................ 950 Failure code [DDTMKA] (3rd clutch fill switch: Disconnection)........................................................................................ 952 Failure code [DDTNKA] (R clutch fill switch: Disconnection).......................................................................................... 954 Failure code [DDTPKA] (4th clutch fill switch : Disconnection)....................................................................................... 956 Failure code [DF10KA] (Gear shift lever: Disconnection).............................................................................................. 958 Failure code [DF10KB] (Gear shift lever: Short circuit).............................................................................................. 961 Failure code [DGF1KX] (Transmission oil temperature sensor: Out of input signal range)............................................................... 964 Failure code [DGR2KZ] (Retarder oil temperature sensor : Disconnection or short circuit)............................................................. 966 Failure code [DGR6KX] (Steering oil temperature sensor: Input signal out of range)................................................................... 968 Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)........................................................... 970 Troubleshooting by failure code, Part 4.................................................................................................................. 973 Failure code [DHP4KY] Short circuit in suspension pressure sensor system (Front right) or PLM controller_LED display: "n5" → "44".................... 976 Failure code [DHP4KZ] Disconnection or ground fault in suspension pressure sensor system (Front right) or PLM controller_LED display: "n5" → "43".... 978 Failure code [DHP5KY] Short circuit in suspension pressure sensor system (Front left) or PLM controller_LED display: "n5" → "54"..................... 980 Failure code [DHP5KZ] Disconnection or ground fault in suspension pressure sensor system (Front left) or PLM controller_LED display: "n5" → "53"..... 982 Failure code [DHP6KA] (Suspension pressure sensor system (Rear right): Disconnection)................................................................ 984 Failure code [DHP6KX] (Failure in suspension pressure sensor system trouble (Rear right): Out of input signal range)................................. 986 Failure code [DHP6KY] Suspension pressure sensor system: Short circuit (Right rear) or PLM controller_LED display: "n5" → "64"....................... 988 Failure code [DHP6KZ] Suspension pressure sensor system: Disconnection or ground fault (Right rear) or PLM controller_LED display: "n5" → "63"....... 990 Failure code [DHP7KA] (Suspension pressure sensor system (Rear left): Disconnection)................................................................. 992 Failure code [DHP7KX] (Failure in suspension pressure sensor system trouble (Rear left): Out of input signal range).................................. 994 Failure code [DHP7KY] Suspension pressure sensor system: Short circuit (Left rear) or PLM controller_LED display: "n5" → "74"........................ 996 Failure code [DHP7KZ] Suspension pressure sensor system: Disconnection or ground fault (Left rear) or PLM controller_LED display: "n5" → "73"........ 998 Failure code [DHT5KX] (Torque converter oil pressure sensor: Out of input signal range)..............................................................1000 Failure code [DHT5L6] (Torque converter oil pressure sensor: Disagreement of run and stop condition with signal).....................................1002 Failure code [DHU2KX] (Front accumulator oil pressure sensor: Out of input signal range).............................................................1004 Failure code [DHU3KX] (Rear accumulator oil pressure sensor: Out of input signal range)..............................................................1006 Failure code [DJF1KA] (Fuel level sensor: Disconnection).............................................................................................1008 Failure code [DK30KX] Trouble in steering angle potentiometer........................................................................................1009 Failure code [DK51L5] (Retarder lever potentiometer: Potentiometer signal is inconsistent with switch signal)........................................1011 Failure code [DK52KX] (Failure in hoist lever potentiometer 1: Out of input signal range)............................................................1014 Failure code [DK53L8] (Failure in hoist lever potentiometer 2: Disagreement of analog signal)........................................................1016 Failure code [DK54KX] (Body positioner sensor: Out of input signal range)............................................................................1018 Failure code [DKD0L6] (Failure in steering speed sensor: Disagreement of run and stop condition with signal) (If equipped)...........................1020 Failure code [DKH0KX] (Pitch angle sensor: Out of input signal range) (If equipped)..................................................................1022 Failure code [DKH1KX] Abnormality in clinometer sensor or PLM controller_LED display: "n4" → "33"....................................................1024 Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection).........................................................................1026 Failure code [DLF1LC] (Transmission input shaft speed sensor: Disagreement of revolution speed signal)...............................................1028 Failure code [DLF2KA] (Transmission intermediate shaft speed sensor: Disconnection)..................................................................1030 Failure code [DLF2LC] (Transmission intermediate shaft speed sensor: Disagreement of revolution speed signal)........................................1032 Failure code [DLF8KA] Disconnection in wheel speed sensor (Right rear)...............................................................................1034 Failure code [DLF8LC] Trouble in wheel speed sensor system (Right rear)..............................................................................1035 Failure code [DLF9KA] Disconnection in wheel speed sensor (Left rear)................................................................................1036 Failure code [DLF9LC] Trouble in wheel speed sensor system (Left rear)...............................................................................1037 Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)........................................................................1038 Failure code [DLT3LC] (Transmission output shaft speed sensor: Disagreement of revolution speed signal) (If equipped)................................1040 Failure code [DLT4KA] (Transmission output shaft speed sensor: Disconnection) (If equipped)..........................................................1042 Failure code [DLT4LC] (Transmission output shaft speed sensor: Disagreement of revolution speed signal) (If equipped)................................1044 Failure code [DLT4MA] Disconnection in transmission output shaft speed sensor: Defective function (If equipped)......................................1046 Failure code [DV00KB] Short circuit in buzzer output.................................................................................................1048 Failure code [DW35KZ] (Failure in output system of auto suspension solenoid 1: Disconnection or short circuit) (If equipped).........................1050 Failure code [DW36KZ] (Failure in output system of auto suspension solenoid 2: Disconnection or short circuit) (If equipped).........................1052 Failure code [DW72KZ] (Failure in kick-out solenoid output system: Disconnection or short circuit)...................................................1054 Failure code [DW73KZ] (Failure in hoist select valve output system: Disconnection or short circuit)..................................................1056 Failure code [DW78KZ] (Failure in rear brake BCV command output system: Disconnection or short circuit)..............................................1058 Failure code [DWNBK4] Trouble in ASR shut-off valve (Valve keeps operating)..........................................................................1060 Failure code [DWNBKA] Disconnection in ASR shut-off valve output circuit.............................................................................1062 Failure code [DWNBKB] Ground fault in ASR shut-off valve output circuit..............................................................................1064 Failure code [DWNBKY] Short circuit in ASR shut-off valve output circuit.............................................................................1066 Failure code [DWNBMA] Trouble in ASR shut-off valve (Valve does not operate).........................................................................1067 Failure code [DX11K4] (Rear brake proportional pressure reducing solenoid valve: Out of control).....................................................1068 Failure code [DX11KA] (Rear brake proportional pressure reducing solenoid valve output circuit: Disconnection).......................................1070 Failure code [DX11KB] (Rear brake proportional pressure reducing solenoid valve: Short circuit)......................................................1071 Failure code [DX11KY] (Rear brake proportional pressure reducing solenoid valve: Short circuit to power source line).................................1072 Failure code [DX11MA] (Rear brake proportional pressure reducing solenoid valve: Malfunction)........................................................1074 Failure code [DX13KA] (Output circuit of hoist EPC valve: Disconnection).............................................................................1076 Failure code [DX13KB] (Output circuit of hoist EPC valve: Short circuit).............................................................................1078 Failure code [DX13KY] (Output circuit of hoist EPC valve: Short circuit with power source line)......................................................1080 Troubleshooting by failure code, Part 5..................................................................................................................1083 Failure code [DX17K4] Trouble in ASR proportional pressure reducing solenoid valve (right) (Valve keeps operating)...................................1086 Failure code [DX17KA] Disconnection in ASR proportional pressure reducing solenoid valve (right) output circuit......................................1088 Failure code [DX17KB] Ground fault in ASR proportional pressure reducing solenoid valve (right) output circuit.......................................1090 Failure code [DX17KY] Short circuit in ASR proportional pressure reducing solenoid valve (right) output circuit......................................1092 Failure code [DX17MA] Trouble in ASR proportional pressure reducing solenoid valve (right) (Valve does not operate)..................................1092 Failure code [DX18K4] Trouble in ASR proportional pressure reducing solenoid valve (left) (Valve keeps operating)....................................1094 Failure code [DX18KA] Disconnection in ASR proportional pressure reducing solenoid valve (left) output circuit.......................................1096 Failure code [DX18KB] Ground fault in ASR proportional pressure reducing solenoid valve (left) output circuit........................................1098 Failure code [DX18KY] Short circuit in ASR proportional pressure reducing solenoid valve (left) output circuit.......................................1100 Failure code [DX18MA] Trouble in ASR proportional pressure reducing solenoid valve (left) (Valve does not operate)...................................1100 Failure code [DXH1KA] (Lockup clutch solenoid output circuit: Disconnection).........................................................................1102 Failure code [DXH1KB] (Lock-up clutch solenoid output circuit: Short circuit)........................................................................1104 Failure code [DXH1KY] (Lockup clutch solenoid output circuit: Short circuit to power source line)....................................................1106 Failure code [DXH2KA] (Hi clutch solenoid output circuit: Disconnection).............................................................................1108 Failure code [DXH2KB] (Hi clutch solenoid output circuit: Short circuit).............................................................................1110 Failure code [DXH2KY] (Hi clutch solenoid output circuit: Short circuit to power source line)........................................................1112 Failure code [DXH3KA] (Lo clutch solenoid output circuit: Disconnection).............................................................................1116 Failure code [DXH3KB] (Lo clutch solenoid output circuit: Short circuit).............................................................................1118 Failure code [DXH3KY] (Lo clutch solenoid output circuit: Short circuit in power source line)........................................................1120 Failure code [DXH4KA] (1st clutch solenoid output circuit: Disconnection)............................................................................1124 Failure code [DXH4KB] (1st clutch solenoid output circuit: Short circuit)............................................................................1126 Failure code [DXH4KY] (1st clutch solenoid output circuit: Short circuit to power source line).......................................................1128 Failure code [DXH5KA] (2nd clutch solenoid output circuit: Disconnection)............................................................................1132 Failure code [DXH5KB] (2nd clutch solenoid output circuit: Short circuit)............................................................................1134 Failure code [DXH5KY] (2nd clutch solenoid output circuit: Short circuit in power source line).......................................................1136 Failure code [DXH6KA] (3rd clutch solenoid output circuit: Disconnection)............................................................................1140 Failure code [DXH6KB] (3rd clutch solenoid output circuit: Short circuit)............................................................................1142 Failure code [DXH6KY] (3rd clutch solenoid output circuit: Short circuit to power source line).......................................................1144 Failure code [DXH7KA] (R clutch solenoid output circuit: Disconnection)..............................................................................1148 Failure code [DXH7KB] (R clutch solenoid output circuit: Short circuit)..............................................................................1150 Failure code [DXH7KY] (R clutch solenoid output circuit: Short circuit to power source line).........................................................1152 Failure code [DXHHKA] (4th clutch solenoid output circuit: Disconnection)............................................................................1156 Failure code [DXHHKB] (4th clutch solenoid output circuit: Short circuit)............................................................................1158 Failure code [DXHHKY] (4th clutch solenoid output circuit: Short circuit to power source line).......................................................1160 Troubleshooting of electrical system (E-mode)............................................................................................................1165 Before troubleshooting of electric system............................................................................................................1167 Contents of troubleshooting table....................................................................................................................1173 E-1 Engine does not start............................................................................................................................1175 E-2 Automatic preheating does not operate............................................................................................................1178 E-3 Machine monitor does not display all, when starting switch is turned ON..........................................................................1182 E-4 Machine monitor does not operate when starting switch is OFF.....................................................................................1184 E-5 Alarm buzzer does not stop sounding..............................................................................................................1186 E-6 Gauges of machine monitor, caution lamps or character display section do not display properly....................................................1187 E-7 A selection of the display in character display section cannot be changed........................................................................1188 E-8 Power mode selecting function does not operate properly..........................................................................................1191 E-9 AISS function does not operate properly..........................................................................................................1192 E-10 Seat belt caution lamp does not display properly................................................................................................1193 E-11 Turn signal lamp or turning lamp (hazard lamp) do not work properly.............................................................................1194 E-12 Night illumination (lighting) does not work properly............................................................................................1197 E-13 Emergency steering does not operate.............................................................................................................1206 Troubleshooting of hydraulic and mechanical system (H-mode)..............................................................................................1211 Contents of troubleshooting table....................................................................................................................1213 H-1 Machine does not start...........................................................................................................................1214 H-2 Machine does not travel smoothly (hunting).......................................................................................................1216 H-3 Lockup cannot be cancelled.......................................................................................................................1216 H-4 Excessive shock when starting or shifting........................................................................................................1217 H-5 Transmission does not shift up...................................................................................................................1218 H-6 Machine lacks power or speed when traveling......................................................................................................1219 H-7 Time lag is excessive when starting or shifting gear.............................................................................................1221 H-8 Torque converter oil temperature is high.........................................................................................................1222 H-9 Torque converter oil pressure is low.............................................................................................................1223 H-10 Front brake is ineffective......................................................................................................................1224 H-11 Rear brake is ineffective.......................................................................................................................1225 H-12 Steering wheel is heavy.........................................................................................................................1226 H-13 Steering wheel does not work....................................................................................................................1227 H-14 Steering wheel vibrates.........................................................................................................................1228 H-15 Dump body lifting speed is slow.................................................................................................................1229 H-16 Dump body does not work.........................................................................................................................1230 H-17 Excessive hydraulic drift of dump body..........................................................................................................1231 Troubleshooting of mechanical system (S-mode)............................................................................................................1233 Method of using troubleshooting charts...............................................................................................................1236 S-1 Starting performance is poor.....................................................................................................................1240 S-2 Engine does not start............................................................................................................................1242 S-3 Engine does not pick up smoothly.................................................................................................................1246 S-4 Engine stops during operations...................................................................................................................1247 S-5 Engine does not rotate smoothly..................................................................................................................1248 S-6 Engine lacks output (or lacks power).............................................................................................................1249 S-7 Exhaust gas color is black (incomplete combustion)...............................................................................................1250 S-8 Oil consumption is excessive (or exhaust smoke is blue)..........................................................................................1252 S-9 Oil becomes contaminated quickly.................................................................................................................1253 S-10 Fuel consumption is excessive...................................................................................................................1254 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)...........................................................................1255 S-12 Oil pressure drops..............................................................................................................................1256 S-13 Oil level rises (Entry of coolant/fuel).........................................................................................................1258 S-14 Coolant temperature becomes too high (overheating)..............................................................................................1260 S-15 Abnormal noise is made..........................................................................................................................1261 S-16 Vibration is excessive..........................................................................................................................1262 50 Disassembly and assembly..................................................................................................................................1265 General information on disassembly and assembly..........................................................................................................1265 How to read this manual..............................................................................................................................1266 Coating materials list...............................................................................................................................1268 Special tool list....................................................................................................................................1271 Sketches of special tools............................................................................................................................1274 Engine and cooling system................................................................................................................................1279 Removal and installation of engine assembly..........................................................................................................1280 Removal and installation of radiator assembly........................................................................................................1286 Removal and installation of output shaft assembly....................................................................................................1294 Disassembly and assembly of output shaft assembly....................................................................................................1296 Removal and installation of fuel supply pump assembly................................................................................................1299 Removal and installation of cylinder head assembly...................................................................................................1303 Removal and installation of fuel injector assembly...................................................................................................1314 Removal and installation of engine front seal........................................................................................................1319 Removal and installation of engine rear seal.........................................................................................................1323 Power train, Part 1......................................................................................................................................1329 Removal and installation of torque converter and transmission assembly...............................................................................1330 Disassembly and assembly of torque converter and control valve assembly..............................................................................1337 Disassembly and assembly of torque converter assembly................................................................................................1338 Disassembly and assembly of PTO assembly.............................................................................................................1346 Disassembly and assembly of transmission assembly....................................................................................................1349 Removal and installation of transmission control valve assembly (ECMV assembly)......................................................................1374 Disassembly and assembly of transmission control valve assembly (ECMV assembly)......................................................................1375 Power train, Part 2......................................................................................................................................1381 Removal and installation of differential assembly....................................................................................................1382 Disassembly and assembly of differential assembly....................................................................................................1383 Removal and installation of rear final drive carrier assembly........................................................................................1396 Disassembly and assembly of rear final drive carrier assembly........................................................................................1398 Disassembly and assembly of rear final drive assembly................................................................................................1400 Disassembly and assembly of front wheel hub assembly.................................................................................................1406 Steering system..........................................................................................................................................1411 Disassembly and assembly of steering cylinder assembly...............................................................................................1412 Removal and installation of emergency steering motor pump assembly...................................................................................1415 Brake system.............................................................................................................................................1417 Removal and installation of front brake caliper pad..................................................................................................1418 Removal and installation of front brake caliper assembly.............................................................................................1419 Disassembly and assembly of front brake caliper assembly.............................................................................................1420 Removal and installation of parking brake pad........................................................................................................1422 Removal and installation of parking brake caliper assembly...........................................................................................1424 Disassembly and assembly of front brake caliper pad assembly.........................................................................................1425 Removal and installation of parking brake spring cylinder assembly...................................................................................1426 Removal and installation of slack adjuster assembly..................................................................................................1427 Disassembly and assembly of slack adjuster assembly..................................................................................................1428 Undercarriage and frame..................................................................................................................................1431 Removal and installation of front wheel assembly.....................................................................................................1432 Removal and installation of rear wheel assembly......................................................................................................1433 Removal and installation of front suspension cylinder assembly.......................................................................................1434 Disassembly and assembly of front suspension cylinder assembly.......................................................................................1436 Disassembly and assembly of variable damping selector valve assembly.................................................................................1438 Removal and installation of rear suspension cylinder assembly........................................................................................1440 Disassembly and assembly of rear suspension cylinder assembly........................................................................................1441 Hydraulic system.........................................................................................................................................1445 Disassembly and assembly of hoist cylinder assembly..................................................................................................1446 Body.....................................................................................................................................................1453 Removal and installation of body assembly............................................................................................................1454 Cab and its attachments..................................................................................................................................1459 Disassembly and assembly of operator's seat assembly.................................................................................................1460 Removal and installation of air conditioner unit assembly............................................................................................1469 Electrical system........................................................................................................................................1473 Removal and installation of engine controller assembly...............................................................................................1474 Removal and installation of transmission controller assembly.........................................................................................1475 Removal and installation of retarder controller assembly.............................................................................................1476 90 Diagrams and drawings.....................................................................................................................................1479 Hydraulic diagrams and drawings..........................................................................................................................1479 Power train hydraulic circuit diagram................................................................................................................1480 Steering and hoist hydraulic circuit diagram HD325-7 Serial No. 7001 - 7025, 7101 - 7523 HD405-7 Serial No. 3001 - 3035, 7101 - 7523.................1481 Steering and hoist hydraulic circuit diagram HD325-7 Serial No. 7524 and up HD405-7 Serial No. 7525 and up...........................................1482 Brake hydraulic circuit diagram......................................................................................................................1483 Electrical diagrams and drawings.........................................................................................................................1486 Electrical circuit diagram for inside cab (1/5) .....................................................................................................1488 Electrical circuit diagram for inside cab (2/5) HD325-7 Serial No. 7001 – 7025, 7101 – 7161 HD405-7 Serial No. 3001 – 3035, 7101 – 7157..............1489 Electrical circuit diagram for inside cab (2/5) HD325-7 Serial No. 7162 and up HD405-7 Serial No. 7158 and up........................................1490 Electrical circuit diagram for inside cab (3/5) HD325-7 Serial No. 7001 – 7025, 7101 – 7161 HD405-7 Serial No. 3001 – 3035, 7101 – 7157..............1491 Electrical circuit diagram for inside cab (3/5) HD325-7 Serial No. 7162 and up HD405-7 Serial No. 7158 and up........................................1492 Electrical circuit diagram for inside cab (4/5)......................................................................................................1493 Electrical circuit diagram for inside cab (5/5)......................................................................................................1494 Electrical circuit diagram for outside cab (1/3).....................................................................................................1495 Electrical circuit diagram for outside cab (2/3).....................................................................................................1496 Electrical circuit diagram for outside cab (3/3).....................................................................................................1497 Air conditioner electrical circuit diagram...........................................................................................................1498 Payload meter electrical circuit diagram.............................................................................................................1499 Electrical circuit diagram of external power supply heater...........................................................................................1500 Connectors table and arrangement drawing.............................................................................................................1502
DESCRIPTION:
KOMATSU HD325-7 HD405-7 DUMP TRUCK SHOP MANUAL SEN00486-17 – PDF DOWNLOAD
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 explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
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 judgement 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.
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 reproducing, repairing, and replacing parts.
S.S 12/12/24
