Komatsu DUMP TRUCK HD325-7 HD405-7 Shop Manual SEN00486-17 – PDF

Description

Komatsu DUMP TRUCK HD325-7 HD405-7 Shop Manual SEN00486-17 – PDF DOWNLOAD

FILE DETAILS:

Komatsu DUMP TRUCK HD325-7 HD405-7 Shop Manual SEN00486-17 – PDF DOWNLOAD

Language : English
Pages :1504
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu DUMP TRUCK HD325-7 HD405-7 Shop Manual SEN00486-17 – PDF DOWNLOAD

SERIAL NUMBERS
HD325- 7001-7025
HD325-7101 and up
HD405- 3001-3035
HD405-7101 and up

1. General precautions 

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.

TABLE OF CONTENTS:

Komatsu DUMP TRUCK HD325-7 HD405-7 Shop Manual SEN00486-17 – PDF DOWNLOAD

SERIAL NUMBERS
HD325- 7001-7025
HD325-7101 and up
HD405- 3001-3035
HD405-7101 and up

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 potentiometer1009
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 output1048
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 circuit1062
Failure code [DWNBKB] Ground fault in ASR shut-off valve output circuit1064
Failure code [DWNBKY] Short circuit in ASR shut-off valve output circuit1066
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 51083
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 circuit1088
Failure code [DX17KB] Ground fault in ASR proportional pressure reducing solenoid valve (right) output circuit1090
Failure code [DX17KY] Short circuit in ASR proportional pressure reducing solenoid valve (right) output circuit1092
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 circuit1096
Failure code [DX18KB] Ground fault in ASR proportional pressure reducing solenoid valve (left) output circuit1098
Failure code [DX18KY] Short circuit in ASR proportional pressure reducing solenoid valve (left) output circuit1100
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 system1167
Contents of troubleshooting table1173
E-1 Engine does not start1175
E-2 Automatic preheating does not operate1178
E-3 Machine monitor does not display all, when starting switch is turned ON1182
E-4 Machine monitor does not operate when starting switch is OFF1184
E-5 Alarm buzzer does not stop sounding1186
E-6 Gauges of machine monitor, caution lamps or character display section do not display properly1187
E-7 A selection of the display in character display section cannot be changed1188
E-8 Power mode selecting function does not operate properly1191
E-9 AISS function does not operate properly1192
E-10 Seat belt caution lamp does not display properly1193
E-11 Turn signal lamp or turning lamp (hazard lamp) do not work properly1194
E-12 Night illumination (lighting) does not work properly1197
E-13 Emergency steering does not operate1206
Troubleshooting of hydraulic and mechanical system (H-mode)1211
Contents of troubleshooting table1213
H-1 Machine does not start1214
H-2 Machine does not travel smoothly (hunting)1216
H-3 Lockup cannot be cancelled1216
H-4 Excessive shock when starting or shifting1217
H-5 Transmission does not shift up1218
H-6 Machine lacks power or speed when traveling1219
H-7 Time lag is excessive when starting or shifting gear1221
H-8 Torque converter oil temperature is high1222
H-9 Torque converter oil pressure is low1223
H-10 Front brake is ineffective1224
H-11 Rear brake is ineffective1225
H-12 Steering wheel is heavy1226
H-13 Steering wheel does not work1227
H-14 Steering wheel vibrates1228
H-15 Dump body lifting speed is slow1229
H-16 Dump body does not work1230
H-17 Excessive hydraulic drift of dump body1231
Troubleshooting of mechanical system (S-mode)1233
Method of using troubleshooting charts1236
S-1 Starting performance is poor1240
S-2 Engine does not start1242
S-3 Engine does not pick up smoothly1246
S-4 Engine stops during operations1247
S-5 Engine does not rotate smoothly1248
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 quickly1253
S-10 Fuel consumption is excessive1254
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1255
S-12 Oil pressure drops1256
S-13 Oil level rises (Entry of coolant/fuel)1258
S-14 Coolant temperature becomes too high (overheating)1260
S-15 Abnormal noise is made1261
S-16 Vibration is excessive1262
50 Disassembly and assembly1265
General information on disassembly and assembly1265
How to read this manual1266
Coating materials list1268
Special tool list1271
Sketches of special tools1274
Engine and cooling system1279
Removal and installation of engine assembly1280
Removal and installation of radiator assembly1286
Removal and installation of output shaft assembly1294
Disassembly and assembly of output shaft assembly1296
Removal and installation of fuel supply pump assembly1299
Removal and installation of cylinder head assembly1303
Removal and installation of fuel injector assembly1314
Removal and installation of engine front seal1319
Removal and installation of engine rear seal1323
Power train, Part 11329
Removal and installation of torque converter and transmission assembly1330
Disassembly and assembly of torque converter and control valve assembly1337
Disassembly and assembly of torque converter assembly1338
Disassembly and assembly of PTO assembly1346
Disassembly and assembly of transmission assembly1349
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 21381
Removal and installation of differential assembly1382
Disassembly and assembly of differential assembly1383
Removal and installation of rear final drive carrier assembly1396
Disassembly and assembly of rear final drive carrier assembly1398
Disassembly and assembly of rear final drive assembly1400
Disassembly and assembly of front wheel hub assembly1406
Steering system1411
Disassembly and assembly of steering cylinder assembly1412
Removal and installation of emergency steering motor pump assembly1415
Brake system1417
Removal and installation of front brake caliper pad1418
Removal and installation of front brake caliper assembly1419
Disassembly and assembly of front brake caliper assembly1420
Removal and installation of parking brake pad1422
Removal and installation of parking brake caliper assembly1424
Disassembly and assembly of front brake caliper pad assembly1425
Removal and installation of parking brake spring cylinder assembly1426
Removal and installation of slack adjuster assembly1427
Disassembly and assembly of slack adjuster assembly1428
Undercarriage and frame1431
Removal and installation of front wheel assembly1432
Removal and installation of rear wheel assembly1433
Removal and installation of front suspension cylinder assembly1434
Disassembly and assembly of front suspension cylinder assembly1436
Disassembly and assembly of variable damping selector valve assembly1438
Removal and installation of rear suspension cylinder assembly1440
Disassembly and assembly of rear suspension cylinder assembly1441
Hydraulic system1445
Disassembly and assembly of hoist cylinder assembly1446
Body1453
Removal and installation of body assembly1454
Cab and its attachments1459
Disassembly and assembly of operator’s seat assembly1460
Removal and installation of air conditioner unit assembly1469
Electrical system1473
Removal and installation of engine controller assembly1474
Removal and installation of transmission controller assembly1475
Removal and installation of retarder controller assembly1476
90 Diagrams and drawings1479
Hydraulic diagrams and drawings1479
Power train hydraulic circuit diagram1480
Steering and hoist hydraulic circuit diagram HD325-7 Serial No 7001 – 7025, 7101 – 7523 HD405-7 Serial No 3001 – 3035, 7101 – 75231481
Steering and hoist hydraulic circuit diagram HD325-7 Serial No 7524 and up HD405-7 Serial No 7525 and up1482
Brake hydraulic circuit diagram1483
Electrical diagrams and drawings1486
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 – 71571489
Electrical circuit diagram for inside cab (2/5) HD325-7 Serial No 7162 and up HD405-7 Serial No 7158 and up1490
Electrical circuit diagram for inside cab (3/5) HD325-7 Serial No 7001 – 7025, 7101 – 7161 HD405-7 Serial No 3001 – 3035, 7101 – 71571491
Electrical circuit diagram for inside cab (3/5) HD325-7 Serial No 7162 and up HD405-7 Serial No 7158 and up1492
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 diagram1498
Payload meter electrical circuit diagram1499
Electrical circuit diagram of external power supply heater1500
Connectors table and arrangement drawing1502

IMAGES PREVIEW OF THE MANUAL:

S.M 26/12/24