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Komatsu HD325-6, HD405-6 Dump Truck Service Manual – PDF DOWNLOAD
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Komatsu HD325-6, HD405-6 Dump Truck Service Manual
MACHINE MODEL SERIAL NUMBER
- HD325-6 (2WD) 5680 and up
- HD325-6W (4W|D) 5706 and up
- HD405-6 1055 and up
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Description
Komatsu HD325-6, HD405-6 Dump Truck Service Manual
FILE DETAILS:
Komatsu HD325-6, HD405-6 Dump Truck Service Manual
Brands: Komatsu
Equipment Type: Dump Truck
Manuals Type: Shop Manual
Machine Model:HD325-6, HD405-6
Serial Number: 20001 and up
Book Code: SEBM015115
Language: English
Pages: 598
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu HD325-6, HD405-6 Dump Truck Service Manual
FOREWORD:
General :
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accu- rate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service work- shop. For ease of understanding. the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
Structure and function:
This section explains the structure and function of each component It serves not only to give an under- standing of the structure, but also serves as reference material for troubleshooting. in addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
Testing and adjusting:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems‘ with “Causes‘ are also included in this section.
Disassembly and assembly:
This section explains the procedures for removing, installing, disassembling and assembling each compo- nent, as well as precautions for them.
Maintenance standard:
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in “Structure and function.
Others:
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. in addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
Komatsu HD325-6, HD405-6 Dump Truck Service Manual
MAIN MENU............................................................................................................................................ 0 COVER................................................................................................................................................ 1 CONTENTS............................................................................................................................................. 2 SAFETY............................................................................................................................................... 9 FOREWARD............................................................................................................................................. 11 GENERAL.......................................................................................................................................... 11 HOW TO READ THE SHOP MANUAL...................................................................................................................... 12 HOISTING INSTRUCTIONS............................................................................................................................ 13 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER....................................................................................... 14 COATING MATERIALS................................................................................................................................ 16 STANDARD TIGHTENING TORQUE....................................................................................................................... 18 ELECTRIC WIRE CODE............................................................................................................................... 21 CONVERSION TABLE................................................................................................................................. 22 UNITS............................................................................................................................................ 28 01 GENERAL........................................................................................................................................... 29 GENERAL ASSEMBLY DRAWING......................................................................................................................... 30 SPECIFICATIONS................................................................................................................................... 32 WEIGHT TABLE..................................................................................................................................... 39 LIST OF LUBRICANT AND WATER...................................................................................................................... 42 10 STRUCTURE AND FUNCTION............................................................................................................................ 44 RADIATOR, TORQUE CONVERTER, OIL COOLER, AFTER COOLER............................................................................................. 46 POWER TRAIN SKELETON............................................................................................................................. 47 OUTPUT SHAFT..................................................................................................................................... 51 DRIVE SHAFT...................................................................................................................................... 52 TORQUE CONVERTER, TRANSMISSION AND BRAKE COOLING HYDRAULIC PIPING................................................................................ 53 HYDRAULIC CIRCUIT DIAGRAM FOR TORQUE CONVERTER, TRANSMISSION AND BRAKE COOLING................................................................... 56 TORQUE CONVERTER, TRANSMISSION AND BRAKE COOLING HYRDAULIC CIRCUIT SCHEMATICS.................................................................... 57 TORQUE CONVERTER................................................................................................................................. 58 TORQUE CONVERTER VALVE........................................................................................................................... 62 LOCKUP SOLENOID VALVE............................................................................................................................ 67 TRANSMISSION..................................................................................................................................... 68 TRANSMISSION VALVE............................................................................................................................... 73 ECMV (ELECTRONIC CONTROL MODULATION VALVE)....................................................................................................... 75 FRONT AXLE....................................................................................................................................... 80 REAR AXLE........................................................................................................................................ 84 DIFFERENTIAL..................................................................................................................................... 85 FINAL DRIVE...................................................................................................................................... 87 FRONT BRAKE...................................................................................................................................... 88 REAR BRAKE....................................................................................................................................... 89 PARKING BRAKE.................................................................................................................................... 90 WHEELS........................................................................................................................................... 91 REAR AXLE SUPPORT................................................................................................................................ 92 STEERING SYSTEM.................................................................................................................................. 93 STEERING WHEEL................................................................................................................................... 94 STEERING LINKAGE................................................................................................................................. 95 SUSPENSION SYSTEM................................................................................................................................ 97 SUSPENSION CYLINDER.............................................................................................................................. 99 AIR PIPING....................................................................................................................................... 104 AIR CIRCUIT DIAGRAM.............................................................................................................................. 106 AIR GOVERNOR..................................................................................................................................... 108 AIR DRYER........................................................................................................................................ 110 SAFETY VALVE..................................................................................................................................... 113 CHECK VALVE...................................................................................................................................... 113 DOUBLE CHECK VALVE............................................................................................................................... 114 HAND BRAKE VALVE................................................................................................................................. 115 BRAKE VALVE...................................................................................................................................... 117 EMERGENCY BRAKE CONTROL VALVE.................................................................................................................... 120 PARKING BRAKE CONTROL VALVE...................................................................................................................... 123 RELAY VALVE...................................................................................................................................... 125 PARKING BRAKE RELAY VALVE........................................................................................................................ 128 FRONT BRAKE CHAMBER.............................................................................................................................. 130 REAR BRAKE CHAMBER............................................................................................................................... 131 PARKING BRAKE CHAMBER............................................................................................................................ 134 SLACK ADJUSTER................................................................................................................................... 135 FRONT DRIVE HYDRAULIC CIRCUIT DIAGRAM............................................................................................................ 138 FRONT DRIVE PISTON PUMP.......................................................................................................................... 141 FRONT DRIVE PISTON MOTOR......................................................................................................................... 143 CHARGE PUMP OIL FILTER........................................................................................................................... 145 HYDRAULIC PIPING................................................................................................................................. 147 HYDRAULIC CIRCUIT DIAGRAM........................................................................................................................ 150 HYDRAULIC CIRCUIT SCHEMATICS..................................................................................................................... 151 DUMP BODY CONTROL................................................................................................................................ 152 HYDRAULIC TANK, FILTER........................................................................................................................... 155 DEMAND VALVE..................................................................................................................................... 158 STEERING CONTROL VALVE........................................................................................................................... 162 CROSS-OVER RELIEF VALVE.......................................................................................................................... 166 HOIST VALVE...................................................................................................................................... 167 DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB........................................................................................................ 168 DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB....................................................................................................... 169 FRONT BRAKE CUT-OFF VALVE........................................................................................................................ 170 OVERRUN PREVENTION VALVE ........................................................................................................................ 171 EXHAUST BRAKE VALVE.............................................................................................................................. 171 HORN VALVE....................................................................................................................................... 172 WIPER SWITCH..................................................................................................................................... 172 WIPER RELAY...................................................................................................................................... 173 AIR CONDITIONER.................................................................................................................................. 174 PIPING DIAGRAM............................................................................................................................... 174 ELECTRICAL CIRCUIT DIAGRAM................................................................................................................... 176 REFRIGERANT CIRCUIT DIAGRAM.................................................................................................................. 178 UNIT......................................................................................................................................... 179 RECEIVER DRYER............................................................................................................................... 179 CONDENSER.................................................................................................................................... 180 COMPRESSOR................................................................................................................................... 180 ENGINE CONTROL SYSTEM............................................................................................................................ 181 EXHAUST BRAKE.................................................................................................................................... 184 SYSTEM DIAGRAM............................................................................................................................... 184 AUTOMATIC RETARD SPEED CONTROL SYSTEM (OP)....................................................................................................... 187 SYSTEM DRAWING............................................................................................................................... 187 STRUCTURE OF SYSTEM.......................................................................................................................... 188 ELECTRICAL CIRCUIT DIAGRAM................................................................................................................... 189 AIR CIRCUIT DIAGRAM.......................................................................................................................... 190 AUTOMATIC RETARD SPEED CONTROL............................................................................................................... 191 AUTOMATIC RETARD SPEED CONTROLLER............................................................................................................ 192 AUTOMATIC SHIFT CONTROL SYSTEM................................................................................................................... 193 SYSTEM DIAGRAM............................................................................................................................... 193 ELECTRICAL CIRCUIT DIAGRAM................................................................................................................... 195 TRANSMISSION CONTROLLER...................................................................................................................... 196 CONNECTOR SIGNALS............................................................................................................................ 198 SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES..................................................................................... 199 AUTOMATIC GEAR SHIFT LINE GRAPH.............................................................................................................. 200 SHIFT LEVER SWITCH........................................................................................................................... 202 SENSORS, SWITCHES............................................................................................................................ 203 ENGINE SPEED SENSOR...................................................................................................................... 203 TRANSMISSION SPEED SENSOR................................................................................................................ 203 TRANSMISSION OIL TEMPERATURE SENSORS..................................................................................................... 203 FILL SWITCH.............................................................................................................................. 204 ACCELERATOR SENSOR....................................................................................................................... 204 MODE SELECTOR SWITCH..................................................................................................................... 205 SELF-DIAGNOSTIC FUNCTION................................................................................................................. 205 AUTOMATIC EMERGENCY STEERING SYTEM............................................................................................................... 206 SYSTEM DIAGRAM............................................................................................................................... 206 ELECTRICAL CIRCUIT DIAGRAM................................................................................................................... 207 FLOW SWITCH.................................................................................................................................. 208 RELAY TIMER.................................................................................................................................. 210 AUTOMATIC SUSPENSION SYSTEM...................................................................................................................... 211 STRUCTURE OF SYSTEM.......................................................................................................................... 212 SYSTEM CIRCUIT DIAGRAM....................................................................................................................... 213 AUTOMATIC SUSPENSION MODE SELECTION CONTROL.................................................................................................. 214 SUSPENSION CONTROLLER........................................................................................................................ 215 SENSORS, SWITCHES............................................................................................................................ 216 STEERING ANGLE SENSOR.................................................................................................................... 216 PRESSURE SENSOR.......................................................................................................................... 216 SELF-DIAGNOSTIC FUNCTION................................................................................................................. 217 PAYLOAD METER (PRINTER TYPE)..................................................................................................................... 218 STRUCTURE OF SYSTEM.......................................................................................................................... 218 ELECTRICAL CIRCUIT DIAGRAM....................................................................................................................... 219 PRINCIPLE OF CALCULATION......................................................................................................................... 220 FEATURES OF EQUIPMENT............................................................................................................................ 222 1. PAYLOAD METER............................................................................................................................. 222 2. PRESSURE SENSOR........................................................................................................................... 225 3. CLINOMETER................................................................................................................................ 226 4. LAMP DRIVE RELAY.......................................................................................................................... 226 SELF-DIAGNOSTIC FUNCTION..................................................................................................................... 227 PAYLOAD METER II (CARD TYPE)..................................................................................................................... 228 STRUCTURE OF SYSTEM.......................................................................................................................... 228 ELECTRICAL CIRCUIT DIAGRAM................................................................................................................... 229 PAYLOAD METER BLOCK DIAGRAM.................................................................................................................. 229 PRINCIPLE OF MEASUREMENT..................................................................................................................... 230 FEATURES OF EACH DEVICE.................................................................................................................. 231 1. PAYLOAD METER II...................................................................................................................... 231 LEFT FACE............................................................................................................................ 232 2. PRESSURE SENSOR....................................................................................................................... 259 3. CLINOMETER............................................................................................................................ 260 4. LAMP DRIVE RELAY...................................................................................................................... 260 5. SELF-DIAGNOSTIC FUNCTION.............................................................................................................. 262 MACHINE MONITOR SYSTEM........................................................................................................................... 268 SYSTEM DRAWING............................................................................................................................... 268 MONITOR PANEL DIAGRAM........................................................................................................................ 270 MACHINE MONITOR NORMAL DISPLAY FUNCTIONS..................................................................................................... 271 SELF-DIAGNOSTIC FUNCTION WHEN STARTING SWITCH IS OPERATED.................................................................................... 278 TRAVEL SPEED COMPENSATION ROTARY SWITCH...................................................................................................... 278 ENGINE OIL PRESSURE.......................................................................................................................... 279 ENGINE WATER TEMPERATURE SENSOR.............................................................................................................. 280 RETARDER OIL TEMPERATURE SENSOR.............................................................................................................. 280 TORQUE CONVERTER OIL TEMPERATURE SENSOR...................................................................................................... 280 AIR PRESSURE SENSOR.......................................................................................................................... 280 FUEL LEVEL SENSOR............................................................................................................................ 281 TILT SWITCH.................................................................................................................................. 282 TRANSMISSION OIL FILTER SENSOR............................................................................................................... 283 RADIATOR WATER LEVEL SENSOR.................................................................................................................. 283 BODY SEATED SWITCH........................................................................................................................... 284 STEERING OIL TEMPERATURE SENSOR.............................................................................................................. 285 BRAKE STROKE SENSOR.......................................................................................................................... 285 OIL FILTER CAUTION SYSTEM (IF EQUIPPED).......................................................................................................... 286 SYSTEM DIAGRAM............................................................................................................................... 286 MONITOR PANEL................................................................................................................................ 287 CIRCUIT DIAGRAM OF OIL FILTER CAUTION MONITOR................................................................................................ 288 ITEMS DISPLAYED BY MONITOR AND FUNCTIONS..................................................................................................... 289 FUNCTIONS OF SWITCHES........................................................................................................................ 291 HYDRAULIC OIL FILTER SENSOR.................................................................................................................. 293 FRONT DRIVE SYSTEM............................................................................................................................... 295 SYSTEM DIAGRAM............................................................................................................................... 295 4-WHEEL DRIVE CONTROLLER......................................................................................................................... 298 ECMV............................................................................................................................................. 299 SENSORS, SWITCHES................................................................................................................................ 300 STEERING ANGLE SENSOR (POTENTIOMETER)........................................................................................................ 300 HIGH-PRESSURE OIL PRESSURE SENSOR............................................................................................................ 303 CLUTCH OIL PRESSURE SENSOR................................................................................................................... 304 WHEEL SPEED SENSOR........................................................................................................................... 305 20 TESTING AND ADJUSTING............................................................................................................................. 307 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS.................................................................................................... 310 STANDARD VALUE TABLE FOR CHASSIS................................................................................................................. 312 STANDARD VALUE TABLE FOR ELECTRICAL PARTS........................................................................................................ 317 TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING....................................................................................... 335 ADJUSTING VALVE CLEARANCE........................................................................................................................ 339 MEASURING COMPRESSION PRESSURE................................................................................................................... 342 MEASURING BLOW-BY................................................................................................................................ 343 ADJUSTING ALTERNATOR BELT TENSION................................................................................................................ 344 ADJUSTING FAN BELT TENSION....................................................................................................................... 345 MEASURING ENGINE SPEED........................................................................................................................... 347 MEASURING ENGINE OIL PRESSURE.................................................................................................................... 348 MEASURING BOOST PRESSURE......................................................................................................................... 349 MEASURING EXHAUST TEMPERATURE.................................................................................................................... 350 MEASURING EXHAUST GAS COLOR...................................................................................................................... 351 TESTING AND ADJUSTING FUEL INJECTION TIMING...................................................................................................... 352 AIR BLEEDING FROM FUEL SYSTEM.................................................................................................................... 356 CHECKING FOR LEAKAGE IN FUEL SYSTEM.............................................................................................................. 359 MEASURING FUEL PRESSURE.......................................................................................................................... 360 REALEASING REMAINING PRESSURE IN FUEL SYSTEM..................................................................................................... 360 HANDLING EQUIPMENT IN FUEL CIRCUIT............................................................................................................... 361 REDUCED CYLINDER MODE OPERATION.................................................................................................................. 362 HANDLING OF ENGINE CONTROLLER HIGH CONTROLLER HIGH TENSION CIRCUIT............................................................................... 363 ADJUSTING ENGINE STOP MOTOR CABLE................................................................................................................ 365 ADJUSTING ACCELERATOR PEDAL...................................................................................................................... 366 ADJUSTING ENGINE SPEED SENSOR.................................................................................................................... 367 ADJUSTING TRANSMISSION SPEED SENSOR.............................................................................................................. 367 TESTING HYDRAULIC PRESSURE OF TORQUE CONVERTER VALVE............................................................................................. 368 TESTING ECMV OIL PRESSURE........................................................................................................................ 369 TESTING TORQUE CONVERTER STALL SPEED............................................................................................................. 371 TESTING BRAKE PRESSURE........................................................................................................................... 372 BLEEDING AIR FROM BRAKE CIRCUIT.................................................................................................................. 373 TESTING AND ADJUSTING PARKING BRAKE PERFORMANCE.................................................................................................. 374 TESTING WEAR OF FRONT BRAKE PAD.................................................................................................................. 375 TESTING WEAR OF FRONT BRAKE DISC................................................................................................................. 375 TESTING WEAR OF REAR BRAKE DISC.................................................................................................................. 376 TESTING REAR BRAKE CAUTION SYSTEM................................................................................................................ 377 TESTING AND ADJUSTING SUSPENSION CYLINDER........................................................................................................ 379 TESTING AND ADJUSTING SET PRESSURE OF AIR GOVERNOR............................................................................................... 385 ADJUSTING HOIST LEVER LINKAGE.................................................................................................................... 386 ADJUSTING BODY POSITIONER........................................................................................................................ 389 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING, HOIST CIRCUIT.............................................................................. 390 AIR BLEEDING FROM STEERING CYLINDER.............................................................................................................. 392 BLEEDING AIR FROM FRONT DRIVE HYDAULIC CIRCUIT................................................................................................... 393 ADJUSTING ELECTRONIC MONITOR .................................................................................................................... 395 SETTING ROTARY SWITCH............................................................................................................................ 396 METHOD OF DELETING DATA FROM TRANSMISSION CONTROLLER MEMORY...................................................................................... 397 METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM........................................................................... 400 PM CLINIC CHECK SHEET............................................................................................................................ 407 TROUBLESHOOTING.................................................................................................................................. 411 POINTS TO REMEMBER WHEN TROUBLESHOOTING...................................................................................................... 412 SEQUENCE OF EVENTS IN TROUBLESHOOTING........................................................................................................ 413 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE............................................................................................. 414 CHECKS BEFORE TROUBLESHOOTING................................................................................................................ 422 TYPE OF CONNECTOR AND POSITION OF INSTALLATION............................................................................................... 424 (HD325-6 SERIAL NO. 5680-6000, HD325-6W SERIAL NO. 5706-6000,HD405-6 SERIAL NO. 1055-2000)............................................... 424 CONNECTOR PIN ALLOCATION CHART............................................................................................................... 430 (HD325-6 SERIAL NO. 5680-6000, HD325-6W SERIAL NO. 5706-6000,HD405-6 SERIAL NO. 1055-2000)............................................... 430 TYPE OF CONNECTOR AND POSITION OF INSTALLATION............................................................................................... 437 (HD325-6 SERIAL NO. 6001 AND UP, HD325-6W SERIAL NO. 6001 AND UP,HD405-6 SERIAL NO. 2001 AND UP)......................................... 437 CONNECTOR PIN ALLOCATION CHART............................................................................................................... 444 (HD325-6 SERIAL NO. 6001 AND UP, HD325-6W SERIAL NO. 6001 AND UP,HD405-6 SERIAL NO. 2001 AND UP)......................................... 444 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS................................................................................................... 450 EXPLANATIONS OF FUNCTIONS (CONTROL MECHANISM)OF ELECTRICAL SYSTEM............................................................................ 472 MONITOR PANEL USER CODES AND SERVICE MODE FUNCTION........................................................................................... 478 SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL AND CONTROLLERS............................................................................. 498 TABLE OF SERVICE CODES AND USER CODES........................................................................................................ 505 METHOD OF USING JUDGEMENT TABLES............................................................................................................. 517 METHOD OF USING TROUBLESHOOTING CHARTS....................................................................................................... 518 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE).................................................................................................... 521 METHOD OF USING TROUBLESHOOTING CHARTS................................................................................................... 522 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)............................................................................ 526 S-2 ENGINE DOES NOT START................................................................................................................ 528 (1) ENGINE DOES NOT TURN............................................................................................................. 528 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)......................................................... 529 (3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)....................................................... 530 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)................................................................................. 531 S-4 ENGINE STOPS DURING OPERATIONS....................................................................................................... 532 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)............................................................................................ 533 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)................................................................................................. 534 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)....................................................................................... 535 S-8 OIL CONSUMPTION IS EXCESSIV (OR EXHAUST SMOKE IS BLUE)............................................................................... 536 S-9 OIL BECOMES CONTAMINATED QUICKLY..................................................................................................... 537 S-10 FUEL CONSUMPTION IS EXCESSIVE....................................................................................................... 538 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN............................................................. 539 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE).......................................................................... 540 S-13 OIL LEVEL RISES..................................................................................................................... 541 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING).................................................................................... 542 S-15 ABNORMAL NOISE IS MADE.............................................................................................................. 543 S-16 VIBRATION IS EXCESSIVE.............................................................................................................. 544 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A MODE)................................................................................... 545 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM................................................... 548 ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE........................................................................... 550 JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS.................................................................. 570 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM............................................................................ 572 ABNORMALITY IN POWER SOURCE.............................................................................................................. 573 A-1 ................................................................................................................................. 573 A) [OFF] CONTROLLER SELF-DIAGNOSTIC DISPLAY LED DOES NOT LIGHT UP................................................................ 573 B) DROP IN VOLTAGE OF CONTROLLER POWER SOURCE IS DISPLAYED....................................................................... 574 C) DROP IN VOLTAGE OF BATTERY DIRECT POWER SOURCE IS DISPLAYED................................................................... 575 D) DROP IN VOLTAGE OF MAIN POWER SOURCE IS DISPLAYED............................................................................. 576 E) ABNORMALITY IN TRANSMISSION CUT RELAY POWER SOURCE IS DISPLAYED............................................................... 577 A-2 A) ABNORMALITY IN NEUTRAL SAFETY SYSTEM IS DISPLAYED............................................................................ 578 ABNORMALITY IN CONTROLLER SYSTEM......................................................................................................... 579 A-3 DOUBLE ENGAGEMENT FOR CLUTCH IS DISPLAYED........................................................................................ 579 A-4 ABNORMALITY IN TRANSMISSION [CUT RELAY] SYSTEM IS DISPLAYED...................................................................... 580 A-5 ABNORMALITY IN REAR BRAKE SOLENOID SYSTEM IS DISPLAYED........................................................................... 581 A-6 ABNORMALTIY IN EXHAUST BRAKE SOLENOID SYSTEM IS DISPLAYED........................................................................ 582 ABNORMALITY IN SPEED SENSOR SYSTEM....................................................................................................... 583 A-7 ................................................................................................................................. 583 A) DISCONNECTION IN ENGINE SPEED SENSOR [B]SYSTEM IS DISPLAYED OR FAILURE IN ENGINE SPEED SENSOR IS DISPLAYED.................... 583 B) DISCONNECTION IN INPUT SHAFT SPEED SENSOR SYSTEM IS DISPLAYED OR FAILURE OF INPUT SHAFT SPEED SENSOR IS DISPLAYED............. 584 C) DISCONNECTION IN INTERMEDIATE SHAFT-SPEED SENSOR SYSTEM IS DISPLAYED OR FAILURE OF INTERMEDIATE SHAFT SPEED SENSOR IS DISP.... 585 D) DISCONNECTION IN TRAVEL SPEED SENSOR (TRANSMISSION OUTPUT SHAFT SPEED SENSOR) SYSTEM IS DISPLAYED OR FAILURE OF OUTPUT SHA.... 586 SPEED SENSOR SYSTEM, CLUTCH SLIPPING..................................................................................................... 587 A-8.................................................................................................................................. 587 A) INPUT SHAFT SPEED SENSOR OR H, L CLUTCH SYSTEM IS DISPLAYED................................................................... 587 B) TRAVEL SPEED SENSOR SYSTEM OR SPEED CLUTCH (1,2,3,4,R) SYSTEM IS DISPLAYED.................................................... 588 ABNORMALITY IN MODEL SELECTION SYSTEM.................................................................................................... 589 A-9.................................................................................................................................. 589 A) ABNORMALITY IN MODEL SELECTION (WIRING HARNESS) IS DISPLAYED.................................................................. 589 B) ABNORMALITY IN MODEL SELECTION (ROTARY SWITCH) IS DISPLAYED................................................................... 590 ABNORMALITY IN SHIFT LEVER SYSTEM........................................................................................................ 591 A-10 ................................................................................................................................ 591 A) SHORT CIRCUIT IN SHIFT LEVER ASSEMBLY POWER SOURCE IS DISPLAYED............................................................... 591 B) SHIFT LEVER POSITION SIGNAL INPUT FOR 2 OR MORE SYSTEMS IS DISPLAYED.......................................................... 592 C) SHIFT LEVER POSITION IN NOT INPUT............................................................................................. 594 A-11 ABNORMALITY IN ACCELERATOR SIGNAL IS DISPLAYED.................................................................................. 596 A-12 ABNORMALITY IN TRANSMISSION OIL TEMPERATURE SENSOR IS DISPLAYED................................................................. 597 ABNORMALITY IN PRESSURE CONTROL VALVEDE418-1098.......................................................................................... 598 A-13 ................................................................................................................................ 598 A) FILL SIGNAL (CLUTCH ON) IS DISPLAYED REGARDLESS OF COMMAND.................................................................... 598 B) FILL SIGNAL IS NOT INPUT AND CLUTCH SLIPPING IS DISPLAYED..................................................................... 600 B-1) INSPECTING FILL SIGNAL SYSTEM........................................................................................... 600 B-2) INSPECTING TRANMISSION INPUT SHAFT SPEED SIGNAL SYSTEM, H, L CLUTCH SYSTEM (INSPECTING CLUTCH SLIPPAGE)................. 601 B-3) INSPECTING TRANSMISSION OUTPUT SHAFT SPEED SIGNAL SYSTEM, 1-4, R CLUTCH SYSTEM (INSPECTING CLUTCH SLIPPAGE)............. 601 A-14 WHEN FILL SIGNAL IS NOT INPUT (FLOW DETECTOR VALVE SYSTEM)...................................................................... 602 A-15 SHORT CIRCUIT IN PRESSURE CONTROL VALVE SOLENOID SYSTEM IS DISPLAYED............................................................ 603 DISCONNECTION IN PRESSURE CONTROL VLAVE SOLENOID SYSTEM IS DISPLAYED............................................................. 603 ABNORMALITY IN SENSOR SYSTEM............................................................................................................. 605 A-16 ................................................................................................................................ 605 A) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM IS DISPLAYED.................................................... 605 B) ABNORMALITY IN FUEL LEVEL SENSOR SYSTEM IS DISPLAYED.......................................................................... 606 C) ABNORMALITY IN COOLING WATER TEMPERATURE SENSOR SYTEM IS DISPLAYED............................................................ 607 D) ABNORMALITY IN AIR PRESSURE SENSOR SYSTEM IS DISPLAYED........................................................................ 608 E) ABNORMALITIY IN RETARD BRAKE OIL TEMPERATURE SENSOR SYSTEM IS DISPLAYED....................................................... 609 WARNING DISPLAY.......................................................................................................................... 610 A-17................................................................................................................................. 610 A) TRANSMISSION FILTER CLOGGED WARNING IS DISPLAYED.............................................................................. 610 B) TILT WARNING IS DISPLAYED..................................................................................................... 611 C) DROP IN RADIATOR WATER LEVEL WARNING IS DISPLAYED............................................................................. 612 D) BATTERY CHARGE LEVEL WARNING IS DISPLAYED..................................................................................... 613 E) STEERING OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED........................................................................ 614 F) DROP IN ENGINE OIL PRESSURE WARNING IS DISPLAYED.............................................................................. 615 G) REAR BRAKE OIL PRESSURE WARNING IS DISPLAYED.................................................................................. 616 A-18 ABNORMALITY IN ENGINE OIL PRESSURE SENSOR SYSTEM IS DISPLAYED................................................................... 617 A-19 ABNORMALITY IN CONNECTOR CONNECTION IS DISPLAYED................................................................................ 618 A-20 ................................................................................................................................ 619 A) TORQUE CONVERTER OIL TEMPERATUER OVERHEAT WARNING IS DISPLAYED................................................................ 619 B) ENGINE WATER TEMPERATURE OVERHEAT WARNING IS DISPLAYED........................................................................ 619 C) AIR PRESSURE DROP WARNING IS DISPLAYED........................................................................................ 619 D) RETARDER BRAKE OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED.................................................................. 619 E) ENGINE OVERRUN ACUTATED IS DISPLAYED.......................................................................................... 620 F) ENGINE OVERSHOOTI ACTUATED IS DISPLAYED....................................................................................... 620 TROUBLESHOOTING OF SUSPENSION CONTROLLER SYSTEM (SP MODE).................................................................................... 621 JUDGEMENT TABLE FOR SUSPENSION CONTROLLER, SUSPENSION RELATED PARTS...................................................................... 622 ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE........................................................................... 624 ELECTRICAL CIRCUIT DIAGRAM OF SUSPENSION CONTROLLER SYSTEM............................................................................... 628 SP-1 ABNORMALITY IN POWER SOURCE IS DISPLAYED............................................................................................ 632 SP-2 ABNORMALITY IN PRESSURE SENSOR [RIGHT] SYSTEM IS DISPLAYED.......................................................................... 633 SP-3 ABNORMALITY IN PRESSURE SENSOR [LEFT] SYSTEM IS DISPLAYED........................................................................... 635 SP-4 ABNORMALITY IN TRAVEL SPEED SENSOR SYSTEM IS DISPLAYED.............................................................................. 637 SP-5 ABNORMALITY IN STEERING SENSOR SYSTEM IS DISPLAYED.................................................................................. 638 SP-6 DEFECTIVE MODEL SELECTION DATA IS DISPLAYED......................................................................................... 639 SP-7 ABNORMALITY IN SOLENOID [1] SYSTEM IS DISPLAYED..................................................................................... 640 SP-8 ABNORMALITY IN SOLENOID [2] SYSTEM IS DISPLAYED..................................................................................... 641 SP-9 ABNORMALITY IN SOLENOID............................................................................................................. 642 SP-10 DISCONNECTION IN NETWORK IS DISPLAYED.............................................................................................. 643 SP-11 DEFECTIVE TRAVEL SPEED COMPENSATION DATA IS DISPLAYED.............................................................................. 644 TROUBLESHOOTING OF PAYLOAD METER (PRINTER TYPE) SYSTEM (LP MODE)............................................................................. 645 (HD325-6 SERIAL NO. 5680-6000, HD325-6W SERIAL NO. 5706-6000, HD405-6 SERIAL NO. 1055-2000).............................................. 645 SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER (PRINTER TYPE)......................................................................... 646 ELECTRICAL CIRCUIT DIAGRAM FOR PAYLOAD METER (PRINTER TYPE) SYSTEM....................................................................... 648 LP-1 NO DISPLAY APPEARS WHEN STARTING SWITCH IS TURNED ON ............................................................................... 650 LP-2 CALIBRATION DEMAND (CAL FLASHES) IS SHOWN CONTINUOUSLY AFTER STARTING SWITCH IS TURNED ON........................................... 651 LP-3 CALIBRATION CANNOT BE CARRIED OUT................................................................................................... 652 LP-4 AFTER STARTING SWITCH IS TURNED ON, ALL EXTERNAL DISPLAY LAMPS DO NOT LIGHT UP..................................................... 655 LP-5 CONDITION DOES NOT EXIST FOR LAMPS TO LIGHT UP, BUT EXTERNAL DISPLAY LAMPS LIGHT UP................................................. 657 LP-6 LEVEL OF LIGHTING UP OF EXTERNAL DISPLAY LAMPS IS NOT CORRECT....................................................................... 658 LP-7 ABNORMALITY IN DISPLAY LOGIC........................................................................................................ 660 LP-8 E01-E04 IS DISPLAYED................................................................................................................ 665 LP-9 E11-E14 IS DISPLAYED................................................................................................................ 666 LP-10 E21-E28 IS DISPLAYED BY SENSOR CHECK............................................................................................... 667 LP-11 E31 IS DISPLAYED................................................................................................................... 668 LP-12 E32 IS DISPLAYED................................................................................................................... 670 LP-13 E41 IS DISPLAYED................................................................................................................... 672 LP-14 E42 IS DISPLAYED................................................................................................................... 673 LP-15 PRINTER DOES NOT PRINT ANYTHING (BLANK PAPER COMES OUT)............................................................................ 674 LP-16 PRINTER PRINTS ONLY "NO DATA"...................................................................................................... 674 LP-17 PRINTER DOES NOT PRINT OUT WHE PRT SWITCH IS PRESSED............................................................................... 674 LP-18 "PAPE" FLASHES..................................................................................................................... 675 LP-19 TIME IS WRONG...................................................................................................................... 675 LP-20 E33 IS DISPLAYED................................................................................................................... 675 TROUBLESHOOTING OF PAYLOAD METER (PRINTER TYPE) SYSTEM (LP MODE)............................................................................. 677 (HD325-6 SERIAL NO. 6001 AND UP, HD325-6W SERIAL NO. 6001 AND UP, HD405-6 SERIAL NO. 2001 AND UP)........................................ 677 SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER (PRINTER TYPE)......................................................................... 678 ELECTRICAL CIRCUIT DIAGRAM FOR PAYLOAD METER (PRINTER TYPE) SYSTEM....................................................................... 680 LP-1 NO DISPLAY APPEARS WHEN STARTING SWITCH IS TURNED ON ............................................................................... 682 LP-2 CALIBRATION DEMAND (CAL FLASHES) IS SHOWN CONTINUOUSLY AFTER STARTING SWITCH IS TURNED ON........................................... 683 LP-3 CALIBRATION CANNOT BE CARRIED OUT................................................................................................... 684 LP-4 AFTER STARTING SWITCH IS TURNED ON, ALL EXTERNAL DISPLAY LAMPS DO NOT LIGHT UP..................................................... 687 LP-5 CONDITION DOES NOT EXIST FOR LAMPS TO LIGHT UP, BUT EXTERNAL DISPLAY LAMPS LIGHT UP................................................. 689 LP-6 LEVEL OF LIGHTING UP OF EXTERNAL DISPLAY LAMPS IS NOT CORRECT....................................................................... 690 LP-7 ABNORMALITY IN DISPLAY LOGIC........................................................................................................ 692 A) EVEN WHEN DUMP BODY IS OPERATED, DISPLAY DOES NOT SHOW 0 TON...................................................................... 692 B) DISPLAY STAYS AT 0 TON AND DOES NOT CHANGE........................................................................................ 693 C) WHEN TRANSMISSION IS AT N, WEIGHT DISPLAY IS NOT GIVEN (STAYS AT TIME DISPLAY).................................................... 694 D) WHEN TRANSMISSION LEVER IS AT POSITION OTHER THAN N, DISPLAY DOES NOT CHANGE TIME DISPLAY......................................... 696 LP-8 E01-E04 IS DISPLAYED................................................................................................................ 697 LP-9 E11-E14 IS DISPLAYED................................................................................................................ 698 LP-10 E21-E28 IS DISPLAYED BY SENSOR CHECK............................................................................................... 699 LP-11 E31 IS DISPLAYED................................................................................................................... 700 LP-12 E32 IS DISPLAYED................................................................................................................... 702 LP-13 E41 IS DISPLAYED................................................................................................................... 704 LP-14 E42 IS DISPLAYED................................................................................................................... 705 LP-15 PRINTER DOES NOT PRINT ANYTHING (BLANK PAPER COMES OUT)............................................................................ 706 LP-16 PRINTER PRINTS ONLY "NO DATA"...................................................................................................... 706 LP-17 PRINTER DOES NOT PRINT OUT WHE PRT SWITCH IS PRESSED............................................................................... 706 LP-18 "PAPE" FLASHES..................................................................................................................... 707 LP-19 TIME IS WRONG...................................................................................................................... 707 LP-20 E33 IS DISPLAYED................................................................................................................... 707 TROUBLESHOOTING OF PAYLOAD METER II (CARD TYPE) SYSTEM (LC MODE)............................................................................. 709 SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER II (CARD TYPE)......................................................................... 710 ELECTRICAL CIRCUIT DIAGRAM FOR PAYLOAD METER II (CARD TYPE) SYSTEM....................................................................... 714 LC-1 NO DISPLAY APPEARS WHEN STARTING SWITCH IS TURNED ON................................................................................ 718 LC-2 AFTER STARTING SWITCH IS TURNED ON, ALL EXTERNAL DISPLAY LAMPS DO NOT LIGHT UP...................................................... 720 LC-3 CONDITION DOES NOT EXIST FOR LAMPS TO LIGHT UP, BUT EXTERNAL DISPLAY LAMPS LIGHT UP................................................. 722 LC-4 LEVEL OF LIGHTING UP OF EXTERNAL DISPLAY LAMPS IS NOT CORRECT....................................................................... 725 LC-5 CYCLE DATA IS NOT RECORDED, ON/OFF DATA IS NOT RECORDED: BATTERY CHARGE SIGNAL SYSTEM: ENGINE NOT STARTED IS DETECTED.............. 729 LC-6 CALIBRATION CANNOT BE CARRIED OUT, TIME DISPLAY DOES NOT MATCH CONDITIONS: SHIFT LEVER N POSITION SIGNAL SYSTEM.................... 730 LC-7 ABNORMAITY IN DISPLAY LOGIC......................................................................................................... 733 LC-8 B-FL REMAINS DISPLAYED AND DOES NOT CHANGE: BODY FLOAT RELAY SYSTEMS: WHEN NOT DUMPING AND WHEN DUMP LEVER IS NOT AT ............ 735 LC-9 F-09 IS DISPLAYED: DROP IN VOLTAGE OF BACK-UP BATTERY BUILT INTO PAYLOAD METER..................................................... 736 LC-10 FULL DISPLAY APPEARS............................................................................................................... 736 LC-11 F-20 IS DISPLAYED: SENSOR POWER SOURCE VOLTAGE SYSTEM ............................................................................. 737 LC-12 F-21-F-24 IS DISPLAYED: DISCONNECTION, SHORT CIRCUIT WITH GROUND IN SUSPENSION PRESSURE SENSOR SYSTEM............................. 740 LC-13 F-25-F-28 IS DISPLAYED: SHORT CIRCUIT IN SUSPENSION PRESSURE SENSOR SYSTEM POWER SOURCE........................................... 742 LC-14 ECAL IS DISPLAYED: CALIBRATION NOT CARRIED OUT, DAMAGED DATA INSIDE PAYLOAD METER................................................. 744 LC-15 F-41 - F-45 IS DISPLAYED: SHORT CIRCUIT IN EXTERNAL DISPLAY LAMP SYSTEM POWER SOURCE.............................................. 744 LC-16 L-BAD IS DISPLAYED: CYCLE DATA SAVED WHEN MACHINE WAS SWAYING..................................................................... 748 LC-17 MACHINE IS NOT LOADING BUT EXTERNAL DISPLAY LAMPS GIVE LOAD ESTIMATE DISPLAY. AFTER LOADING, DISPLAY SWITCHES TO TIME............ 750 LC-18 F-31 IS DISPLAYED: DISCONNECTION, SHORT CIRCUIT WITH GROUND IN CLINOMETER SYSTEM.................................................. 750 LC-19 F-32 IS DISPLAYED: SHORT CIRCUIT WITH CLINOMETER SYSTEM POWER SOURCE.............................................................. 753 LC-20 F-18 IS DISPLAYED: DISCONNECTION IN BATTERY CHARGE SIGNAL......................................................................... 756 TROUBLESHOOTING OF ARSC (AUTOMATIC RETARDER SPEED CONTROLLER) SYSTEM (R MODE)................................................................ 757 OUTLINE.................................................................................................................................. 758 ELECTRICAL CIRCUIT DIAGRAM FOR ARSC (AUTOMATIC RETARDER SPEED CONTROLLER) SYSTEM......................................................... 762 R-1 0.1 (ABNORMALITY IN POWER SOURCE VOLTAGE) IS DISPLAYED............................................................................... 764 R-2 1.0 (DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED....................................................................... 765 R-3 1.3 (DISCONNECTION IN TRANSMISSION OUTPUT SHAFT SPEED SENSOR SYSTEM) IS DISPLAYED.................................................... 766 R-4 1.5 (FAILURE IN RETARDER OIL TEMPERATURE SENSOR SYSTEM) IS DISPLAYED................................................................ 767 R-5 1.7 (FAILURE IN ACCELERATOR SIGNAL SYSTEM) IS DISPLAYED.............................................................................. 768 R-6 1.8 (FAILURE IN SUSPENSION PRESSURE SENSOR "LEFT" SYSTEM) IS DISPLAYED............................................................... 769 R-7 1.9 (FAILURE IN SUSPENSION PRESSURE SENSOR "RIGHT" SYSTEM) IS DISPLAYED.............................................................. 770 R-8 4.2 (DISCONNECTION IN EXHAUST BRAKE SELECTOR SIGNAL SYSTEM) IS DISPLAYED............................................................. 771 R-9 4.3 (DISCONNECTION IN ARSC CAUTION LAMP SYSTEM) IS DISPLAYED......................................................................... 772 R-10 4.4 (DISCONNECTION IN READY LAMP SYSTEM) IS DISPLAYED............................................................................... 773 R-11 4.5 (DISCONNECTION IN PANEL CAUTION AND BUZZER SYSTEM) IS DISPLAYED................................................................. 774 R-12 5.2 (SHORT CIRCUIT WITH GROUND IN EXHAUST BRAKE SELECTOR SIGNAL OUTPUT SYSTEM) IS DISPLAYED......................................... 775 R-13 5.3 (SHORT CIRCUIT WITH GROUND IN ARSC CAUTION LAMP SYSTEM) IS DISPLAYED............................................................ 776 R-14 5.4 (SHORT CIRCUIT WITH GROUND IN READY OUTPUT CIRCUIT SYSTEM) IS DISPLAYED......................................................... 777 R-15 5.5 (SHORT CIRCUIT WITH GROUND IN PANEL CAUTION LAMP AND BUZZER OUTPUT SYSTEM) IS DISPLAYED......................................... 778 R-16 6.0 (FAILURE IN ENGINE SPEED SYSTEM) IS DISPLAYED................................................................................... 779 R-17 7.0 (DISCONNECTION IN TRAVEL SPEED DISPLAY UP OUTPUT SYSTEM) IS DISPLAYED........................................................... 780 R-18 7.1 (DISCONNECTION IN TRAVEL SPEED DISPLAY DOWN OUTPUT SYSTEM) IS DISPLAYED......................................................... 781 R-19 7.2 (DISCONNECTION IN TRAVEL SPEED DISPLAY CLEAR OUTPUT SYSTEM) IS DISPLAYED........................................................ 782 R-20 7.3 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY UP OUTPUT SYSTEM) IS DISPLAYED............................................... 783 R-21 7.4 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY DOWN OUTPUT SYSTEM) IS DISPLAYED............................................. 784 R-22 7.5 (SHORT CIRCUIT WITH GROUD IN TRAVEL SPEED DISPLAY CLEAR OUTPUT SYSTEM) IS DISPLAYED............................................. 785 R-23 8.1 (SHORT CIRCUIT WITH GROUND IN PRESSURE CONTROL VALVE SYSTEM) IS DISPLAYED....................................................... 786 R-24 8.3 (DISCONNECTION IN PRESSURE CONTROL VALVE SYSTEM) IS DISPLAYED................................................................... 787 R-25 8.5 (FAILURE IN PRESSURE CONTROL VALVE (PRESSURE CONTROL VALVE REMAINS OPEN) IS DISPLAYED........................................... 788 R-26 8.7 (FAILURE IN PRESSURE CONTROL VALVE (PRESSURE CONTROL VALVE DOES NOT OPEN) IS DISPLAYED.......................................... 789 R-27 8.9 (SHORT CIRCUIT WITH GROUND IN PRESSURE SWITCH VALVE SYSTEM) IS DISPLAYED........................................................ 790 R-28 9.0 (DISCONNECTION IN PRESSURE SWITCH VALVE SYSTEM) IS DISPLAYED.................................................................... 791 R-29 9.1 (FAILURE IN PRESSURE SWITCH VALVE SYSTEM (REMAINS OPEN)) IS DISPLAYED........................................................... 792 R-30 9.2 (FAILURE IN PRESSURE SWITCH VALVE SYSTEM (DOES NOT OPEN)) IS DISPLAYED.......................................................... 793 R-31 9.3 (DISCONNECTION IN SYSTEM SWITCH SYSTEM) IS DISPLAYED............................................................................ 794 R-32 9.4 (SHORT CIRCUIT WITH GROUND IN SYSTEM SWITCH SYSTEM) IS DISPLAYED................................................................ 795 R-33 9.5 (DISCONNECTION, SHORT CIRCUIT WTH GROUND IN TRAVEL SPEED SETTING SWITCH SYSTEM) IS DISPLAYED.................................... 796 R-101 SET SPEED CANNOT BE SET............................................................................................................ 797 R-102 FAILURE CODE IS ALWAYS CLEARED (CONTROLLER DISPLAY WINDOW ALWAYS SHOWS '--") OR FAILURE CODE CANNOT BE CLEARED..................... 800 R-103 EFFECT OF RETARDER IS TOO STRONG WHEN MACHINE IS EMPTY, OR TOO WEAK WHEN MACHINE IS LOADED (DOES NOT JUDGE LOADED/UNLOA............ 801 R-104 ABNORMALITY APPEARS IN OTHER CONTROLLER............................................................................................ 801 R-105 WHEN TRAVELING DOWNHILL, EVEN WHEN SET SPEED IS EXCEEDED, NO CONTROL IS CARRIED OUT................................................ 802 R-106 MONITOR LAMP (BUZZER) STAY ON (OR OFF)............................................................................................. 803 R-107 READY LAMP DOES NOT LIGHT UP (OR STAY LIT UP)...................................................................................... 804 R-108 EXHAUST BRAKE DOES NOT WORK PROPERLY .............................................................................................. 806 [EXHAUST BRAKE IS ACTUATED WHEN EXHAUST BRAKE SWITCH IS OFF; OR EXHAUST BRAKE IS NOT ACTUATED WHEN EXHAUST BRAKE SWITCH IS ON........ 806 R-109 THERE IS DIFFERENCE BETWEEN TRAVEL SPEED ROD VALUE AND ACTUAL MACHINE VALUE........................................................ 808 R-110 RETARDER LAMP DOES NOT LIGHT UP, OR STAY LIT UP.................................................................................... 810 R-111 TRAVEL SPEED DISPLAY ALWAYS GIVES DISPLAY (OR DOES NOT GIVE ANY DISPLAY)........................................................... 811 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)................................................................................. 813 H-1 MACHINE DOES NOT START............................................................................................................... 814 H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE JERKS)..................................................................................... 816 H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED (ENGINE STALLS).................................................................................. 816 H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING............................................................................................ 817 H-5 TRANSMISSION DOES NOT SHIFT UP....................................................................................................... 817 H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING.......................................................................................... 818 H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR................................................................................. 822 H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH............................................................................................. 824 H-9 TORQUE CONVERTER OIL PRESSURE IS LOW................................................................................................. 825 H-10 FRONT BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE........................................................................... 826 H-11 REAR BRAKE IS INEFFECTIVE, OR EFFECTIVE ON ONE SIDE................................................................................. 829 H-12 STEERING WHEEL IS HEAVY............................................................................................................. 830 H-13 STEERING WHEEL DOES NOT WORK........................................................................................................ 831 H-14 STEERING WHEEL VIBRATES............................................................................................................. 831 H-15 HOIST CYLINDER LACKS LIFTING FORCE (LIFTING SPEED).................................................................................. 832 H-16 HOIST CYLINDER DOES NOT WORK........................................................................................................ 833 H-17 EXCESSIVE HYRDRAULIC DRIFT OF DUMP BODY............................................................................................. 834 H-18 AIR PRESSURE DOES NOT RISE ......................................................................................................... 835 TROUBLESHOOTING OF MONITOR PANEL SYSTEM (P MODE)............................................................................................. 837 METHOD OF SELF-DIAGNOSTIC DISPLAY FOR MONITOR PANEL AND CONTROLLERS...................................................................... 839 ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE (MONITOR PANEL SYSTEM).................................................... 840 ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR PANEL SYSTEM...................................................................................... 844 P-1 CHECK PATTERN FOR WIRING HARNESSES BETWEEN MODULES................................................................................... 846 P-2 NOTHING ON MONITOR PANEL WORKS....................................................................................................... 850 P-3 LH, RH MODULE AND FUEL GAUGE DO NOT WORK............................................................................................. 851 P-4 LH, RH MODULE AND FUEL GAUGE DO NOT WORK............................................................................................. 852 P-5 RH MODULE DOES NOT WORK.............................................................................................................. 853 P-6 LH MODULE DOES NOT WORK.............................................................................................................. 854 P-7 TRAVEL CALCULATOR DOES NOT WORK...................................................................................................... 855 P-8 SERVICE METER DISPLAY DOES NOT WORK CORRECTLY........................................................................................ 856 P-9 CENTRAL WARNING LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS FAILURE CODE (MONITOR PANEL DISPLAY)[A002].............................. 857 P-10 CENTRAL WARNING LAMP STAYS LIT UP................................................................................................... 858 P-11 ALARM BUZZER DOES NOT WORK, OR MONITOR PANEL DETECTS FAILURE CODE [A003]............................................................ 859 P-12 ALARM BUZZER CONTINUES TO SOUND..................................................................................................... 860 P-13 ALL DATA FROM SHIFT CONTROLLER (SPPEDOMETER, TACHOMETER, SHIFT INDICATOR, ETC.) ARE ABNORMAL (NOTHING IS DISPLAYED, OR D............ 861 P-14 SUSPENSION MODE, POWER/ECONOMY MODE DISPLAYS ARE ABNORMAL (NOTHIND IS DISPLAYED, OR DISPLAY DOES NOT CHANGE), OR MONITOR............ 862 P-15 GAUGE DISPLAYS ARE ABNORMAL (NOTHING IS DISPLAYED, OR DISPLAY DOES NOT CHANGE)...................................................... 863 P-16 COOLING WATER LEVEL DROP CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]................................... 864 P-17 COOLING WATER LEVEL DROP CAUTION LAMP STAY LIT UP................................................................................... 865 P-18 EMERGENCY STEERING PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]........................................... 866 P-19 EMERGENCY STEERING PILOT LAMP STAYS LIT UP.......................................................................................... 867 P-20 ENGINE OIL PRESSURE DROP CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]................................... 868 P-21 ENGINE OIL PRESSURE DROP CAUTION LAMP STAYS LIT UP.................................................................................. 869 P-22 EXHAUST BRAKE PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]................................................ 870 P-23 EXHAUST BRAKE PILOT LAMP STAYS LIT UP............................................................................................... 871 P-24 CHARGING CIRCUIT ABNORMALITY CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]............................... 872 P-25 CHARGING CIRCUIT ABNORMALTIY CAUTION LAMP STAY LIT UP............................................................................... 873 P-26 TRANSMISSION FILTER CLOGGING CAUTION LAMP DOES NOT WORK OR MONITOR PANEL DETECTS SERVICE CODE [A001]................................ 874 P-27 TRANSMISSION FILTER CLOGGING CAUTION LAMP STAYS LIT UP.............................................................................. 875 P-28 BRAKE STROKE CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]............................................... 876 P-29 BRAKE STROKE CAUTION LAMP STAY LIT UP............................................................................................... 877 P-30 PREHEATING SWITCH PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]............................................ 878 P-31 PREHEATING SWITCH PILOT LAMP STAYS LIT UP........................................................................................... 879 P-32 TILT WARNING LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]....................................................... 880 P-33 TILT WARNING LAMP STAYS LIT UP...................................................................................................... 881 P-34 BODY FLOAT (EXCEPT FLOAT) PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001].................................... 882 P-35 BODY FLOAT (EXCEPT FLOAT) PILOT LAMP STAYS LIGHTED UP............................................................................... 883 P-36 REAR BRAKE PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE............................................................... 884 P-37 REAR BRAKE PILOT LAMP STAYS LIT UP.................................................................................................. 885 P-38 PARKING BRAKE PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]................................................ 886 P-39 PARKING BRAKE PILOT LAMP STAYS LIT UP............................................................................................... 887 P-40 MAINTENANCE CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]................................................ 888 P-41 MAINTENANCE CAUTION LAMP STAYS LIT UP .............................................................................................. 889 P-42 STEERING OIL TEMPERATURE CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]................................... 890 P-43 STEERING OIL TEMPERATURE CAUTION LAMP STAYS LIT UP.................................................................................. 891 P-44 DIFFERENTIAL LOCK PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]............................................ 892 P-45 DIFFERENTIAL LOCK PILOT LAMP STAYS LIT UP........................................................................................... 893 P-46 HIGH BEAM DISPLAY DOES NOT LIGHT UP................................................................................................. 894 P-47 TURN SIGNAL LAMP (RIGHT) DOES NOT LIGHT UP.......................................................................................... 896 P-48 TURN SIGNAL LAMP (LEFT) DOES NOT LIGHT UP........................................................................................... 897 P-49 LAMP CHEK SWITCH DOES NOT WORK...................................................................................................... 898 P-50 EXHAUST BRAKE SWITCH DOES NOT WORK................................................................................................. 899 P-51 MODE CHANGE SWITCH (1) DOES NOT WORK................................................................................................ 900 P-52 MODE CHANGE SWITCH (2) DOES NOT WORK................................................................................................ 901 P-53 KPH/MPH SPEEDOMETER UNIT SELECTOR DOES NOT WORK..................................................................................... 902 P-54 DEFECTIVE OPERATION OF ALL SWITCH INPUTS............................................................................................ 903 P-55 MONITOR PANEL DETECTS SERVICE CODES [A014] OR [A019]................................................................................ 904 P-56 MONITOR PANEL DETECTS SERVICE CODE [A015]........................................................................................... 905 P-57 MONITOR PANEL DETECTS SERVICE CODE [A011]........................................................................................... 906 P-58 MONITOR PANEL DETECTS SERVICE CODE [A012]........................................................................................... 906 P-59 MONITOR PANEL DETECTS SERVICE CODE [A000]........................................................................................... 906 TROUBLESHOOTING OF ABS/ASR SYSTEM (OP)....................................................................................................... 907 TROUBLESHOOTING FLOWCHART................................................................................................................ 908 FOR MACHINES WITH ABS INSTALLED INDEPENDENTLY........................................................................................ 908 FOR MACHINES WITH ABS/ASR INSTALLED.................................................................................................. 909 METHOD OF DELETING ECU TROUBLE DATA FROM MEMORY.......................................................................................... 910 PROCEDURE FOR DELETING TROUBLE DATA FROM MEMORY...................................................................................... 910 METHOD OF TROUBLESHOOTING USING SELF-DIAGNOSTIC FUNCTION OF ECU.......................................................................... 911 INDEX (TROUBLESHOOTING CODE)......................................................................................................... 912 SYSTEM CHECK SHEET FOR USING SYSTEM CHECKER.............................................................................................. 914 TROUBLESHOOTING.......................................................................................................................... 922 W-1 WARNING LAMP DOES NOT LIGHT UP................................................................................................... 922 I-1 ASR INFORMATION SWITCH DOES NOT GO OUT........................................................................................... 923 ASR-1 FAILURE IN ASR CONTROL VALVE (ONLY MACHINES WITH ABS/ASR INSTALLED)............................................................ 924 ASR-2................................................................................................................................ 925 ABS-1 FAILURE INSIDE ECU............................................................................................................. 926 ABS-2 FAILURE IN FRONT RIGHT PRESSURE CONTROL VALVE.................................................................................. 927 ABS-3 FAILURE IN FRONT LEFT PRESSURE CONTROL VALVE................................................................................... 928 ABS-4 FAILURE IN REAR LEFT PRESSURE CONTROL VALVE.................................................................................... 929 ABS-5 FAILURE IN REAR RIGHT PRESSURE CONTROL VALVE................................................................................... 930 ABS-6 FAILURE IN FRONT RIGHT WHEEL SPEED SENSOR...................................................................................... 931 ABS-10 ABNORMALITY IN FRONT RIGHT WHEEL SPEED SENSOR OUTPUT.......................................................................... 931 ABS-7 FAILURE IN FRONT LEFT WHEEL SPEED SENSOR....................................................................................... 932 ABS-11 ABNORMALITY IN FRONT LEFT WHEEL SPEED SENSOR OUTPUT........................................................................... 932 ABS-8 FAILURE IN REAR LEFT WHEEL SPEED SENSOR........................................................................................ 933 ABS-12 ABNORMALITY IN REAR LEFT WHEEL SPEED SENSOR OUTPUT............................................................................ 933 ABS-9 FAILURE IN REAR RIGHT WHEEL SPEED SENSOR....................................................................................... 934 ABS-13 ABNORMALITY IN REAR RIGHT WHEEL SPEED SENSOR OUTPUT........................................................................... 934 ABS-14 FAILURE IN VALVE RELAY (VR2).................................................................................................. 935 ABS-15 FAILURE IN VALVE RELAY (VR1).................................................................................................. 936 ABS-16 FAILURE IN VALVE RELAY (VR2).................................................................................................. 937 ABS-17 FAILURE IN VALVE RELAY (VR1).................................................................................................. 938 ABS-18 ABNORMALITY IN POWER SOURCE VOLTAGE........................................................................................... 939 TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (G MODE)......................................................................................... 941 (HD325-6 SERIAL NO. 6001 AND UP, HD325-6W SERIAL NO. 6001 AND UP, HD405-6 SERIAL NO. 2001 AND UP)........................................ 941 ERROR CODE DISPLAYS AND POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................... 943 ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED......................................................... 946 ENGINE CONTROLLER RELATED JUDGEMENT TABLE................................................................................................ 954 ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE CONTROLLER SYSTEM.................................................................................. 956 G-1 ERROR CODE [C01B] [ABNORMALITY IN NE REVOLUTION SENSOR SYSTEM]....................................................................... 958 G-2 ERROR CODE [C01C] [ABNORMALITY IN G REVOLUTION SENSOR SYSTEM]........................................................................ 959 G-3 ERROR CODE [C020] [ABNORMALITY IN MODEL SELECTION SYSTEM]............................................................................ 960 G-4 ERROR CODE [C022] [OVERRUN].......................................................................................................... 961 G-5 ERROR CODE [C022] [OVERHEAT]......................................................................................................... 961 G-6 ERROR CODE [C024] [DROP IN OIL PRESSURE]............................................................................................. 962 G-7 ERROR CODE [C030] [ABNORMALITY IN IDLING VALIDATION SIGNAL SYSTEM]................................................................... 963 G-8 ERROR CODE [C031] [ABNORMALITY IN ACCELERATOR SENSOR SYSTEM]......................................................................... 965 G-9 ERROR CODE [C034] [ABNORMALITY IN HIGH WATER TEMPERATURE SENSOR SYSTEM].............................................................. 967 G-10 ERROR CODE [C036] [ABNORMALITY IN OIL PRESSURESWITCH SYSTEM] ....................................................................... 968 G-11 ERROR CODE [C03C] [ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM]..................................................................... 970 G-12 ERROR CODE [C03D] [ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM.................................................................... 971 G-13 ERROR CODE [C050] [ABNORMALITY IN PREHEATING RELAY CONNECTING POINT SYSTEM.......................................................... 972 G-14 ERROR CODE [C051] [ABNORMALITY IN PREHEATING RELAY COIL SYSTEM]..................................................................... 973 G-15 ERROR CODE [C054] [SHORT CIRCUIT IN STARTING SWITCH C SYSTEM]....................................................................... 974 G-16 ERROR CODE [C055] [ABNORMALITY IN NETWORK].......................................................................................... 975 G-17 ERROR CODE [C056] [POWER SOURCE SYSTEM ABNORMALITY 1]............................................................................... 976 G-18 ERROR CODE [C057] [POWER SOURCE SYSTEM ABNORMALITY 2]............................................................................... 978 G-19 ERROR CODE [C06A] [ABNORMALITY IN FUEL INJECTION QUANITY CONTROL SWITCH SYSTEM]..................................................... 979 G-20 ERROR CODE [ABNORMALITY IN HIGH ENGINE WATER TEMPERATURE SENSOR SYSTEM]............................................................. 979 G-21 ERROR CODE [C070] EXCESS CURRENT IN FUEL SUPPLY PUMP PCV1 SYSTEM]................................................................... 980 G-22 ERROR CODE [C071] EXCESS CURRENT IN FUEL SUPPLY PUMP PCV2 SYSTEM]................................................................... 981 G-23 ERROR CODE [C074] [DISCONNECTION IN FUEL SUPPLY PUMP PCV1 SYSTEM]................................................................... 982 G-24 ERROR CODE [C075] [DISCONNECTION IN FUEL SUPPLY PUMP PCV2 SYSTEM]................................................................... 983 G-25 ERROR CODE [C077] ABNORMALITY IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM]........................................................... 984 G-26 ERROR CODE [C079] [COMMON RAIL HIGH FUEL PRESSURE ABNORMALITY 1].................................................................... 985 ERROR CODE [E-7A] [COMMON RAIL HIGH FUEL PRESSURE ABNORMALITY 2]..................................................................... 985 G-27 ERROR CODE [C07B] [FUEL SUPPLY PUMP NON-FORCE FEED 1] .............................................................................. 986 ERROR CODE [C07C] [FUEL SUPPLY PUMP NON-FORCE FEED 2] ............................................................................... 986 G-28 ERROR CODE [C07D] [ABNORMALITY IN COMMON RAIL FUEL PRESSURE]........................................................................ 988 G-29 ERROR CODE [CO80] [DEFECTIVE CONTROLLER]............................................................................................ 988 G-30 ERROR CODE [C081] [DISCONNECTION IN N0. FUEL INJECTOR <A> SYSTEM]................................................................... 989 G-31 ERROR CODE [C082] [DISCONNECTION IN N0.2 FUEL INJECTOR <E> SYSTEM].................................................................. 990 G-32 ERROR CODE [C083] [DISCONNECTION IN N0.3 FUEL INJECTOR <C> SYSTEM].................................................................. 991 G-33 ERROR CODE [C084] [DISCONNECTION IN N0.4 FUEL INJECTOR <F> SYSTEM].................................................................. 992 G-34 ERROR CODE [C085] [DISCONNECTION IN N0.5 FUEL INJECTOR <B> SYSTEM].................................................................. 993 G-35 ERROR CODE [C086] [DISCONNECTION IN N0.6 FUEL INJECTOR <D> SYSTEM].................................................................. 994 G-36 ERROR CODE [CO8A] [SHORT CIRCUIT IN NO. 1 ,<A>, NO. 2 <E>, NO.3 <C> FUEL INJECTOR SYSTEM]........................................... 995 G-37 ERROR CODE [CO8A] [SHORT CIRCUIT IN NO. 4 ,<F>, NO. 5 <B>, NO.6 <D> FUEL INJECTOR SYSTEM]........................................... 998 TROUBLESHOOTING OF FRONT DRIVE SYSTEM (W MODE) SERIAL NO. 5706-6000..........................................................................1001 ELECTRICAL CIRCUIT DIAGRAM FOR FRONT DRIVE SYSTEM........................................................................................1002 W-1 SELF-DIAGNOSTIC DISPLAY UNIT OF CONTROLLER DOES NOT LIGHT UP.........................................................................1004 W-2 E-0.1 (DROP IN CONTROLLER POWER SUPPLY VOLTAGE) IS DISPLAYED.........................................................................1005 W-3 E-0.4 (ABNORMALITY IN ANALOG POWER SOURCE RELAY) IS DISPLAYED........................................................................1006 W-4 E-1.1 (DISCONNECTION IN CLUTCH CONTROL VALVE OUTPUT WIRING) IS DISPLAYED.............................................................1007 W-4 E-1.2 (SHORT CIRCUIT IN CLUTCH CONTROL VALVE OUTPUT WIRING) IS DIPLAYED..............................................................1007 W-5 E-1.3 (DEFECTIVE CLUTCH CONTROL VALVE SYSTEM) IS DISPLAYED...........................................................................1008 W-5 E-1.4 (DEFECTIVE FILL SIGNAL INPUT SYSTEM) IS DISPLAYED..............................................................................1008 W-6 E-2.0 (DISCONNECTION IN PUMP OUTPUT WIRING) IS DISPLAYED.............................................................................1009 W-6 E-2.1 (SHORT CIRCUIT IN PUMP OUTPUT WIRING) IS DISPLAYED.............................................................................1009 W-7 E-2.2 (DISCONNECTION IN LEFT MOTOR OUPUT WIRING) IS DISPLAYED........................................................................1010 W-7 E-2.3 (SHORT CIRCUIT IN LEFT MOTOR OUTPUT WIRING) IS DISPLAYED.......................................................................1010 W-8 E-2.4 (DISCONNECTION IN RIGHT MOTOR OUTPUT WIRING) IS DISPLAYED......................................................................1011 W-8 E-2.5 (SHORT CIRCUIT IN RIGHT MOTOR OUTPUT WIRING) IS DISPLAYED......................................................................1011 W-9 E-5.0 (ABNORMALITY (DISCONNECTION) IN PRESSURE SENSOR [A] IS DISPLAYED...............................................................1012 W-9 E-5.2 (ABNORMALITY (DISCONNECTION) IN PRESSURE SENSOR [B]) IS DISPLAYED..............................................................1012 W-10 E-5.1 (SHORT CIRCUIT IN PRESSOR SENSOR [A]) IS DISPLAYED............................................................................1013 W-10 E-5.3 (SHORT CIRCUIT IN PRESSURE SENSOR [B]) IS DISPLAYED...........................................................................1013 W-11 E-5.4, E-5.5, E-5.6 (ABNORMALITY IN HST HYDRAULIC SYSTEM) IS DISPLAYED..............................................................1014 W-12 E-6.1 (DISCONNECTION IN STEERING ANGLE SENSOR) IS DISPLAYED.........................................................................1015 W-12 E-6.2 (SHORT CIRCUIT IN STEERING ANGLE SENSOR) IS DISPLAYED.........................................................................1015 W-12 E-6.3 (DEFECTIVE MOUNT OF STEERING ANGLE SENSOR) IS DISPLAYED.......................................................................1015 W-13 E-7.1 (DISCONNECTION IN ENGINE SPEED SENSOR) IS DISPLAYED...........................................................................1016 W-14 E-7.2 (DISCONNECTION IN TRANSMISSION INPUT SHAFT SPEED SENSOR) IS DISPLAYED.........................................................1017 W-15 E-7.3 (ABNORMALITY IN LEFT FRONT WHEEL SPEED SENSOR SYSTEM) IS DISPLAYED............................................................1018 W-15 E-7.4 (ABNORMALITY IN RIGHT FRONT WHEEL SPEED SENSOR SYSTEM) IS DISPLAYED...........................................................1018 W-16 E-7.5 (ABNORMALITY IN FRONT WHEEL SPEED SENSOR SYSTEM) IS DISPLAYED.................................................................1018 W-17 E-8.2 (SHORT CIRCUIT IN 4-WHEEL DRIVE LAMP RELAY) IS DISPLAYED......................................................................1019 W-18 E-9.0 (CLOGGING OF FRONT DRIVE OIL FILTER) IS DISPLAYED.............................................................................1020 W-19 E-9.1 (RISE IN TEMPERATURE OF FRONT DRIVE OIL) IS DISPLAYED.........................................................................1021 W-20 E-9.3 (ABNORMALITY IN CLUTCH OIL PRESSURE SYSTEM) IS DISPLAYED......................................................................1022 TROUBLESHOOTING OF FRONT DRIVE SYSTEM (W MODE) SERIAL NO. 6001 AND UP........................................................................1023 ELECTRICAL CIRCUIT DIAGRAM FOR FRONT DRIVE SYSTEM........................................................................................1024 W-1 SELF-DIAGNOSTIC DISPLAY UNIT OF CONTROLLER DOES NOT LIGHT UP.........................................................................1026 W-2 E-0.1 (DROP IN CONTROLLER POWER SUPPLY VOLTAGE) IS DISPLAYED.........................................................................1027 W-3 E-0.4 (ABNORMALITY IN CLUTCH POWER SUPPLY CUT RELAY) IS DISPLAYED....................................................................1028 W-4 E-1.1 (DISCONNECTION IN CLUTCH CONTROL VALVE OUTPUT WIRING) IS DISPLAYED.............................................................1029 W-4 E-1.2 (SHORT CIRCUIT IN CLUTCH VALVE OUTPUT WIRING) IS DISPLAYED.....................................................................1029 W-5 E-1.3 (DEFECTIVE CLUTCH CONTROL VALVE SYSTEM) IS DISPLAYED...........................................................................1030 W-5 E-1.4 (DEFECTIVE FILL SIGNAL INPUT SYSTEM) IS DISPLAYED..............................................................................1030 W-6 E-2.0 (DISCONNECTION IN PUMP OUTPUT WIRING) IS DISPLAYED.............................................................................1031 W-6 E-2.1 (SHORT CIRCUIT IN PUMP OUTPUT WIRING) IS DISPLAYED.............................................................................1031 W-7 E-2.2 (DISCONNECTION IN LEFT MOTOR OUTPUT WIRING) IS DISPLAYED.......................................................................1032 W-7 E-2.3 (SHORT CIRCUIT IN LEFT MOTOR OUTPUT WIRING) IS DISPLAYED.......................................................................1032 W-8 E-2.4 (DISCONNECTION IN RIGHT MOTOR OUTPUT WIRING) IS DISPLAYED......................................................................1033 W-8 E-2.5 (SHORT CIRCUIT IN RIGHT MOTOR OUTPUT WIRING) IS DISPLAYED......................................................................1033 W-9 E-5.0 (ABNORMALITY (DISCONNECTION) IN PRESSURE SENSOR [A]) IS DISPLAYED..............................................................1034 W-9 E-5.2 (ABNORMALITY (DISCONNECTION) IN PRESSURE SENSOR [B]) IS DISPLAYED..............................................................1034 W-10 E-5.1 (SHORT CIRCUIT IN PRESSURE SENSOR [A]) IS DISPLAYED...........................................................................1035 W-10 E-5.3 (SHORT CIRCUIT IN PRESSURE SENSOR [B]) IS DISPLAYED...........................................................................1035 W-11 E-5.4, E-5.5, E-5.6 (ABNORMALITY IN HST HYDRAULIC SYSTEM) IS DISPLAYED..............................................................1036 W-12 E-6.1 (DISCONNECTION IN STEERING ANGLE SENSOR) IS DISPLAYED.........................................................................1037 W-12 E-6.2 (SHORT CIRCUIT IN STEERING ANGLE SENSOR) IS DISPLAYED.........................................................................1037 W-12 E-6.3 (DEFECTIVE MOUNT OF STEERING ANGLE SENSOR) IS DISPLAYED.......................................................................1037 W-13 E-7.1 (DISCONNECTION IN ENGINE SPEED SENSOR) IS DISPLAYED...........................................................................1038 W-14 E-7.2 (DISCONNECTION IN TRANSMISSION INPUT SHAFT SPEED SENSOR) IS DISPLAYED.........................................................1039 W-15 E-7.3 (ABNORMALITY IN LEFT FRONT WHEEL SPEED SENSOR SYSTEM) IS DISPLAYED............................................................1040 W-15 E-7.4 (ABNORMALITY IN RIGHT FRONT WHEEL SPEED SENSOR SYSTEM) IS DISPLAYED...........................................................1040 W-16 E-7.5 (ABNORMALITY IN FRONT WHEEL SPEED SENSOR SYSTEM) IS DISPLAYED.................................................................1040 W-17 E-8.2 (SHORT CIRCUIT IN 4-WHEEL DRIVE LAMP RELAY) IS DISPLAYED......................................................................1041 W-18 E-9.0 (CLOGGING OF FRONT DRIVE OIL FILTER) IS DISPLAYED.............................................................................1042 W-19 E-9.1 (RISE IN TEMPERATURE OF FRONT DRIVE OIL) IS DISPLAYED ........................................................................1043 W-20 E-9.3 (ABNORMALITY IN CLUTCH OIL PRESSURE SYSTEM) IS DISPLAYED......................................................................1044 30 DISASSEMBLY AND ASSEMBLY..........................................................................................................................1045 METHOD OF USING MANUAL...........................................................................................................................1049 PRECAUTIONS WHEN CARRYING OUT OPERATION..........................................................................................................1050 SPECIAL TOOL LIST................................................................................................................................1053 SKETCHES OF SPECIAL TOOLS........................................................................................................................1056 STARTING MOTOR...................................................................................................................................1064 REMOVAL AND INSTALLATION.....................................................................................................................1064 ALTERNATOR ......................................................................................................................................1065 REMOVAL AND INSTALLATION.....................................................................................................................1065 ENGINE OIL COOLER ...............................................................................................................................1066 REMOVAL .....................................................................................................................................1066 INSTALLATION.................................................................................................................................1067 FUEL INJECTION PUMP ASSEMBLY.....................................................................................................................1069 REMOVAL .....................................................................................................................................1069 INSTALLATION.................................................................................................................................1070 FUEL SUPPLY PUMP.................................................................................................................................1071 REMOVAL......................................................................................................................................1071 INSTALLATION.................................................................................................................................1073 AIR COMPRESSOR...................................................................................................................................1074 REMOVAL......................................................................................................................................1074 INSTALLATION.................................................................................................................................1075 AIR CONDITIONER COMPRESSOR ......................................................................................................................1077 REMOVAL......................................................................................................................................1077 INSTALLATION.................................................................................................................................1078 AIR CONDITIONER CONDENSER .......................................................................................................................1079 REMOVAL AND INSTALLATION.....................................................................................................................1079 WATER PUMP.......................................................................................................................................1080 REMOVAL......................................................................................................................................1080 INSTALLATION.................................................................................................................................1081 AFTERCOOLER......................................................................................................................................1083 REMOVAL......................................................................................................................................1083 INSTALLATION.................................................................................................................................1085 EXHAUST BRAKE CYLINDER ..........................................................................................................................1086 REMOVAL AND INSTALLATION.....................................................................................................................1086 TURBOCHARGER ....................................................................................................................................1087 REMOVAL .....................................................................................................................................1087 INSTALLATION.................................................................................................................................1088 NOZZLE HOLDER....................................................................................................................................1090 REMOVAL AND INSTALLATION.....................................................................................................................1090 FUEL INJECTOR....................................................................................................................................1091 REMOVAL .....................................................................................................................................1091 INSTALLATION.................................................................................................................................1092 CYLINDER HEAD....................................................................................................................................1095 REMOVAL......................................................................................................................................1095 INSTALLATION.................................................................................................................................1103 ENGINE ..........................................................................................................................................1110 REMOVAL......................................................................................................................................1110 INSTALLATION.................................................................................................................................1118 RADIATOR, TORQUE CONVERTER OIL COOLER............................................................................................................1121 REMOVAL......................................................................................................................................1121 INSTALLATION.................................................................................................................................1128 RADIATOR, FRONT DRIVE COOLER (HD325-6W)..........................................................................................................1131 REMOVAL......................................................................................................................................1131 INSTALLATION.................................................................................................................................1132 FRONT DRIVE OIL COOLER (HD325-6W)................................................................................................................1133 REMOVAL AND INSTALLATION.....................................................................................................................1133 OUTPUT SHAFT.....................................................................................................................................1135 REMOVAL......................................................................................................................................1135 INSTALLATION.................................................................................................................................1138 DISASSEMBLY..................................................................................................................................1139 ASSEMBLY.....................................................................................................................................1140 TORQUE CONVERTER, TRANSMISSION (HD325-6, 405-6)..................................................................................................1142 REMOVAL......................................................................................................................................1142 INSTALLATION.................................................................................................................................1144 TORQUE CONVERTER, TRANSMISSION (HD325-6W)........................................................................................................1146 REMOVAL......................................................................................................................................1146 INSTALLATION.................................................................................................................................1148 TORQUE CONVERTER VALVE...........................................................................................................................1150 REMOVAL AND ASSEMBLY.........................................................................................................................1150 DISASSEMBLY AND ASSEMBLY.....................................................................................................................1151 TORQUE CONVERTER, TRANSMISSION...................................................................................................................1152 DISCONNECTION................................................................................................................................1152 CONNECTION...................................................................................................................................1153 TORQUE CONVERTER.................................................................................................................................1154 DISASSEMBLY..................................................................................................................................1154 ASSEMBLY.....................................................................................................................................1159 PTO (HD325, 405-6)...............................................................................................................................1164 DISASSEMBLY..................................................................................................................................1164 ASSEMBLY.....................................................................................................................................1165 PTO (HD325-6W)...................................................................................................................................1167 DISASSEMBLY..................................................................................................................................1167 ASSEMBLY.....................................................................................................................................1168 TRANSMISSION.....................................................................................................................................1169 DISASSEMBLY..................................................................................................................................1169 ASSEMBLY.....................................................................................................................................1187 TRANSMISSION CONTROL VALVE (ECMV ASSEMBLY).......................................................................................................1205 REMOVAL AND INSTALLATION.....................................................................................................................1205 DISASSEMBLY..................................................................................................................................1206 ASSEMBLY.....................................................................................................................................1207 DIFFERENTIAL.....................................................................................................................................1208 REMOVAL AND INSTALLATION.....................................................................................................................1208 DISASSEMBLY (STANDARD).......................................................................................................................1209 DISASSEMBLY (WITH DIFFERENTIAL LOCK).........................................................................................................1214 DIFFERENTIAL GEAR................................................................................................................................1219 ASSEMBLY (STANDARD)..........................................................................................................................1219 ASSEMBLY (WITH DIFFERENTIAL LOCK)............................................................................................................1229 FRONT WHEEL (HD325, 405-6).......................................................................................................................1241 REMOVAL AND INSTALLATION.....................................................................................................................1241 FRONT WHEEL (HD325-6W)...........................................................................................................................1242 REMOVAL AND INSTALLATION.....................................................................................................................1242 REAR WHEEL.......................................................................................................................................1244 REMOVAL......................................................................................................................................1244 INSTALLATION.................................................................................................................................1245 FRONT BRAKE CALIPER PAD..........................................................................................................................1246 REMOVAL AND INSTALLATION.....................................................................................................................1246 FRONT BRAKE CALIPER .............................................................................................................................1247 REMOVAL AND INSTALLATION.....................................................................................................................1247 DISASSEMBLY..................................................................................................................................1248 ASSEMBLY....................................................................................................................................1249 FRONT WHEEL HUB..................................................................................................................................1251 DISASSEMBLY..................................................................................................................................1251 ASSEMBLY.....................................................................................................................................1253 FRONT FINAL DRIVE CLUTCH, CARRIER (HD325-6W).....................................................................................................1256 DISASSEMBLY..................................................................................................................................1256 ASSEMBLY.....................................................................................................................................1260 FRONT FINAL DRIVE, BRAKE (HD325-6W)..............................................................................................................1265 DISASSEMBLY..................................................................................................................................1265 ASSEMBLY.....................................................................................................................................1270 FRONT DRIVE SHAFT (HD325-6W).....................................................................................................................1277 DISASSEMBLY..................................................................................................................................1277 ASSEMBLY.....................................................................................................................................1281 REAR FINAL DRIVE CARRIER.........................................................................................................................1288 REMOVAL......................................................................................................................................1288 INSTALLATION.................................................................................................................................1289 DISASSEMBLY..................................................................................................................................1290 ASSEMBLY.....................................................................................................................................1291 REAR FINAL DRIVE.................................................................................................................................1292 DISASSEMBLY..................................................................................................................................1292 ASSEMBLY.....................................................................................................................................1294 REAR BRAKE ......................................................................................................................................1296 REMOVAL AND INSTALLATION.....................................................................................................................1296 DISASSEMBLY..................................................................................................................................1297 ASSEMBLY.....................................................................................................................................1298 PARKING BRAKE PAD................................................................................................................................1300 REMOVAL......................................................................................................................................1300 INSTALLATION.................................................................................................................................1301 PARKING BRAKE CALIPER............................................................................................................................1302 REMOVAL AND INSTALLATION.....................................................................................................................1302 DISASSEMBLY AND ASSEMBLY.....................................................................................................................1303 FRONT SUSPENSION CYLINDER (HD325, 405-6)........................................................................................................1304 REMOVAL......................................................................................................................................1304 INSTALLATION.................................................................................................................................1305 FRONT SUSPENSION CYLINDER (HD325-6W)............................................................................................................1306 REMOVAL......................................................................................................................................1306 INSTALLATION.................................................................................................................................1307 DISASSEMBLY..................................................................................................................................1308 ASSEMBLY.....................................................................................................................................1309 VARIABLE DAMPING SELECTOR VALVE..................................................................................................................1312 DISASSEMBLY..................................................................................................................................1312 ASSEMBLY.....................................................................................................................................1313 REAR SUSPENSION..................................................................................................................................1314 REMOVAL AND INSTALLATION.....................................................................................................................1314 DISASSEMBLY..................................................................................................................................1315 ASSEMBLY.....................................................................................................................................1316 AIR GOVERNOR.....................................................................................................................................1317 REMOVAL AND INSTALLATION.....................................................................................................................1317 DISASSEMBLY AND ASSEMBLY.....................................................................................................................1318 BRAKE VALVE......................................................................................................................................1319 REMOVAL AND INSTALLATION.....................................................................................................................1319 DISASSEMBLY..................................................................................................................................1320 ASSEMBLY.....................................................................................................................................1322 PARKING BRAKE CHAMBER............................................................................................................................1324 REMOVAL AND INSTALLATION.....................................................................................................................1324 DISASSEMBLY..................................................................................................................................1325 ASSEMBLY.....................................................................................................................................1326 FRONT BRAKE CHAMBER (HD325, 405-60...............................................................................................................1328 REMOVAL AND INSTALLATION.....................................................................................................................1328 REAR BRAKE CHAMBER...............................................................................................................................1329 REMOVAL AND INSTALLATION.....................................................................................................................1329 FRONT BRAKE CHAMBER .............................................................................................................................1330 DISASSEMBLY..................................................................................................................................1330 ASSEMBLY.....................................................................................................................................1332 REAR BRAKE CHAMBER...............................................................................................................................1334 DISASSEMBLY..................................................................................................................................1334 ASSEMBLY.....................................................................................................................................1338 SLACK ADJUSTER...................................................................................................................................1341 REMOVAL AND INSTALLATION.....................................................................................................................1341 DISASSEMBLY AND ASSEMBLY.....................................................................................................................1342 TRANSMISSION LUBRICATION, RETARDER BRAKE PUMP (HD325, 405-6) ....................................................................................1343 TRANSMISSION LUBRICATION, RETARDER BRAKE PUMP (HD325-6W).........................................................................................1344 REMOVAL AND INSTALLATION.....................................................................................................................1344 BRAKE COOLING PUMP (HD325, HD405-6)..............................................................................................................1345 REMOVAL AND INSTALLATION.....................................................................................................................1345 BRAKE COOLING PUMP (HD325-6W)....................................................................................................................1346 REMOVAL AND INSTALLATION.....................................................................................................................1346 HOIST, STEERING PUMP.............................................................................................................................1347 REMOVAL AND INSTALLATION.....................................................................................................................1347 FRONT DRIVE PUMP (HD325-6W)......................................................................................................................1348 REMOVAL......................................................................................................................................1348 INSTALLATION.................................................................................................................................1349 EMERGENCY STEERING MOTOR PUMP....................................................................................................................1350 REMOVAL AND INSTALLATION....................................................................................................................1350 TRAVEL DRIVE MOTOR (HD325-6W)....................................................................................................................1351 REMOVAL......................................................................................................................................1351 INSTALLATION.................................................................................................................................1352 TRAVEL MOTOR (HD325-6W)..........................................................................................................................1353 DISASSEMBLY AND ASSEMBLY.....................................................................................................................1353 STEERING VALVE...................................................................................................................................1357 REMOVAL AND INSTALLATION.....................................................................................................................1357 DISASSEMBLY..................................................................................................................................1358 ASSEMBLY.....................................................................................................................................1362 DEMAND VALVE.....................................................................................................................................1368 REMOVAL AND INSTALLATION.....................................................................................................................1368 DISASSEMBLY AND ASSEMBLY.....................................................................................................................1369 RELIEF VALVE.....................................................................................................................................1370 HOIST VALVE......................................................................................................................................1371 REMOVAL AND INSTALLATION.....................................................................................................................1371 DISASSEMBLY..................................................................................................................................1372 ASSSEMBLY....................................................................................................................................1373 STEERING CYLINDER................................................................................................................................1374 REMOVAL AND INSTALLATION.....................................................................................................................1374 DISASSEMBLY..................................................................................................................................1375 ASSEMBLY.....................................................................................................................................1377 HOIST CYLINDER...................................................................................................................................1379 REMOVAL AND INSTALLATION.....................................................................................................................1379 DISASSEMBLY..................................................................................................................................1380 ASSEMBLY.....................................................................................................................................1382 BODY ASSEMBLY....................................................................................................................................1386 REMOVAL .....................................................................................................................................1386 INSTALLATION.................................................................................................................................1387 TRANSMISSION CONTROLLER..........................................................................................................................1388 REMOVAL AND INSTALLATION.....................................................................................................................1388 SUSPENSION CONTROLLER............................................................................................................................1388 REMOVAL AND INSTALLATION.....................................................................................................................1388 FRONT DRIVE CONTROLLER...........................................................................................................................1388 REMOVAL AND INSTALLATION.....................................................................................................................1388 40 MAINTENANCE STANDARD..............................................................................................................................1389 OUTPUT SHAFT.....................................................................................................................................1390 TORQUE CONVERTER VALVE...........................................................................................................................1391 TORQUE CONVERTER.................................................................................................................................1392 TRANSMISSION.....................................................................................................................................1394 ECMV (ELECTRONIC CONTROL MODULATION VALVE).......................................................................................................1398 FRONT AXLE.......................................................................................................................................1399 DIFFERENTIAL.....................................................................................................................................1400 FINAL DRIVE (REAR)...............................................................................................................................1402 FINAL DRIVE (FRONT) HD325-6W.....................................................................................................................1403 FRONT BRAKE (HD325-6, 405-6).....................................................................................................................1405 FRONT BRAKE (HD325-6W)...........................................................................................................................1406 REAR BRAKE.......................................................................................................................................1408 PARKING BRAKE....................................................................................................................................1409 REAR AXLE SUPPORT................................................................................................................................1410 STEERING LINKAGE.................................................................................................................................1411 FRONT SUSPENSION CYLINDER........................................................................................................................1413 REAR SUSPENSION CYLINDER.........................................................................................................................1414 PARKING BRAKE CHAMBER............................................................................................................................1415 SLACK ADJUSTER...................................................................................................................................1416 HYDRAULIC PUMP...................................................................................................................................1417 DEMAND VALVE.....................................................................................................................................1420 CROSS-OVER RELIEF VALVE..........................................................................................................................1420 HOIST VALVE......................................................................................................................................1421 STEERING CYLINDER................................................................................................................................1422 HOIST CYLINDER...................................................................................................................................1423 90 OTHER.............................................................................................................................................1425 AIR PIPING DIAGRAM (HD325-6, 6W: 6001 AND UP, HD405-6: 2001 AND UP)..............................................................................1427 AIR PIPING DIAGRAM (HD325-6W: 5485 - 6000).......................................................................................................1428 AIR PIPING DIAGRAM (HD325-6W: 6001 AND UP).......................................................................................................1429 AIR CIRCUIT DIAGRAM (HD325-6W: 5485 - 6000)......................................................................................................1430 AIR CIRCUIT DIAGRAM (HD325-6, 6W: 6001 AND UP, HD405-6: 2001 AND UP).............................................................................1431 DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (1/3 - 3/3) (HD325-6: 5680-6000, HD325-6W: 5706-6000, HD405-6: 1055-2000)..............................1432 DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (1/4-4/4) (HD325-6, 6W: 6001 AND UP, HD405-6: 2001 AND UP).............................................1435 DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (1/2-2/2) (HD325-6: 5680-6000, HD325-6W: 5706-6000, HD405-6: 1055-2000)...............................1439 DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (1/2-2/2) (HD325-6, 6W: 6001-6613, HD405-6: 2001 -2229)...............................................1441 DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (1/2-2/2) (HD325-6, 6W: 6614 AND UP, HD405-6: 2230 AND UP)............................................1443 AUTOMATIC RETARD SPEED CONTROL SYSTEM ELECTRICAL CIRCUIT DIAGRAM.................................................................................1445 AUTOMATIC SHIFT CONTROLLER (HD325-6: 5680-6000, HD325-6W: 5706-6000, HD405-6: 1055-2000).........................................................1446 AUTOMATIC SHIFT CONTROLLER (HD325-6, 6W: 6001 AND UP, HD405-6: 2001 AND UP)......................................................................1447 AUTOMATIC SUSPENSION SYSTEM......................................................................................................................1448 SYSTEM CIRCUIT DIAGRAM (1/2-2/2) (HD325-6: 5680-6000, HD325-6W: 5706-6000, HD405-6: 1055-2000)...............................................1448 SYSTEM CIRCUIT DIAGRAM (HD325-6, 6W: 6001 AND UP, HD405-6: 2001 AND UP)......................................................................1450 PAYLOAD METER (PRINTER TYPE).....................................................................................................................1451 ELECTRICAL CIRCUIT DIAGRAM (HD325-6: 5680-6000, HD325-6W: 5706-6000, HD405-6: 1055-2000).....................................................1451 PAYLOAD METER II (CARD TYPE).....................................................................................................................1453 ELECTRICAL CIRCUIT DIAGRAM (HD325-6: 5680-6000, HD325-6W: 5706-6000, HD405-6: 1055-2000).....................................................1453 PAYLOAD METER II (PRINTER - CARD TYPE)........................................................................................................... 0 ELECTRICAL CIRCUIT DIAGRAM (HD325-6, 6W: 6001 AND UP, HD405-6: 2001 AND UP)..................................................................1452 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM (HD325-6, 6W: 6001 AND UP, HD405-6: 2001 AND UP)...................................1454 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM (1/2-2/2) (HD325-6, 6W: 6001 AND UP, HD405-6: 2001 AND UP).........................1455 OIL FILTER CAUTION SYSTEM........................................................................................................................1457 FRONT DRIVE SYSTEM- ELECTRICAL COMPONENT LAYOUT..................................................................................................1458
KOMATSU HD325-6, HD405-6 DUMP TRUCK SERVICE MANUAL – PDF DOWNLOAD:
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