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KOMATSU HD325-7 HD405-7 DUMP TRUCK SHOP MANUAL SEN00486-22 – PDF DOWNLOAD
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Description
KOMATSU HD325-7 HD405-7 DUMP TRUCK SHOP MANUAL SEN00486-22 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU HD325-7 HD405-7 DUMP TRUCK SHOP MANUAL SEN00486-22 – PDF DOWNLOAD
Language : English
Pages : 1554
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU HD325-7 HD405-7 DUMP TRUCK SHOP MANUAL SEN00486-22 – PDF DOWNLOAD
Cover............................................................................................................................................................ 1 00 Index and foreword........................................................................................................................................ 3 Index.................................................................................................................................................... 3 Composition of shop manual........................................................................................................................... 4 Table of contents.................................................................................................................................... 6 Foreword and general information......................................................................................................................... 19 Safety notice........................................................................................................................................ 20 How to read the shop manual.......................................................................................................................... 26 Explanation of terms for maintenance standard........................................................................................................ 28 Handling of electric equipment and hydraulic component............................................................................................... 30 Handling of connectors newly used for engines........................................................................................................ 39 How to read electric wire code....................................................................................................................... 42 Precautions when carrying out operation.............................................................................................................. 45 Method of disassembling and connecting push-pull type coupler........................................................................................ 48 Standard tightening torque table..................................................................................................................... 51 Conversion table..................................................................................................................................... 55 01 Specification............................................................................................................................................. 61 Specification and technical data......................................................................................................................... 61 Specification drawing................................................................................................................................ 62 Specifications....................................................................................................................................... 65 Weight table......................................................................................................................................... 77 Fuel, coolant and lubricants......................................................................................................................... 78 10 Structure, function and maintenance standard.............................................................................................................. 81 Engine and cooling system................................................................................................................................ 81 Radiator, oil cooler, aftercooler.................................................................................................................... 82 Output shaft......................................................................................................................................... 84 Power train, Part 1...................................................................................................................................... 87 Power train skeleton................................................................................................................................. 88 Drive shaft.......................................................................................................................................... 90 Torque converter and transmission hydraulic piping................................................................................................... 91 Power train charge pump.............................................................................................................................. 92 Retarder cooling pump................................................................................................................................ 93 Torque converter..................................................................................................................................... 94 Torque converter valve............................................................................................................................... 100 Transmission......................................................................................................................................... 101 Transmission control valve........................................................................................................................... 117 ECMV................................................................................................................................................. 118 Power train, Part 2...................................................................................................................................... 127 Axle................................................................................................................................................. 128 Differential......................................................................................................................................... 130 Final drive.......................................................................................................................................... 132 Wheel................................................................................................................................................ 134 Steering system.......................................................................................................................................... 137 Steering column...................................................................................................................................... 138 Steering linkage..................................................................................................................................... 139 Brake system............................................................................................................................................. 143 Brake piping......................................................................................................................................... 144 Brake valve.......................................................................................................................................... 146 Secondary brake valve................................................................................................................................ 149 Relay valve.......................................................................................................................................... 150 Front brake cut valve................................................................................................................................ 151 Accumulator charge valve............................................................................................................................. 152 Accumulator.......................................................................................................................................... 158 Slack adjuster....................................................................................................................................... 160 Brake................................................................................................................................................ 162 Proportional reducing valve.......................................................................................................................... 167 Parking brake........................................................................................................................................ 168 Parking brake solenoid............................................................................................................................... 170 Hand brake (retarder)................................................................................................................................ 171 Undercarriage and frame.................................................................................................................................. 173 Suspension........................................................................................................................................... 174 Suspension cylinder.................................................................................................................................. 176 Rear axle support.................................................................................................................................... 184 Hydraulic system......................................................................................................................................... 187 Steering, hoist oil pressure piping diagram.......................................................................................................... 188 Dump body control.................................................................................................................................... 190 Hydraulic tank....................................................................................................................................... 192 Steering valve....................................................................................................................................... 194 Cross-over relief valve.............................................................................................................................. 198 Steering control valve............................................................................................................................... 199 Hoist valve.......................................................................................................................................... 208 Dump control valve (EPC valve)....................................................................................................................... 214 Steering cylinder.................................................................................................................................... 218 Hoist cylinder....................................................................................................................................... 219 Work equipment and steering pump..................................................................................................................... 220 Cab and its attachments.................................................................................................................................. 223 ROPS cab............................................................................................................................................. 224 Air conditioner...................................................................................................................................... 225 Rear view monitor.................................................................................................................................... 231 Electrical system, Part 1................................................................................................................................ 241 Machine monitor system............................................................................................................................... 242 Electrical system, Part 2................................................................................................................................ 271 Automatic shift control system....................................................................................................................... 272 Transmission controller.............................................................................................................................. 276 External power supply heater......................................................................................................................... 290 Auto emergency steering system....................................................................................................................... 292 Retarder control system.............................................................................................................................. 296 Dump control lever................................................................................................................................... 310 Auto suspension system............................................................................................................................... 314 Battery disconnector switch.......................................................................................................................... 308 Electrical system, Part 3................................................................................................................................ 319 Payload meter II (card type)......................................................................................................................... 320 Payload meter (PLM) controller related............................................................................................................... 350 Electrical system, Part 4................................................................................................................................ 375 Sensors, switches.................................................................................................................................... 376 KOMTRAX terminal system (If equipped)................................................................................................................ 390 20 Standard value table...................................................................................................................................... 395 Standard service value table............................................................................................................................. 395 Standard value table for engine...................................................................................................................... 396 Standard value table for machine..................................................................................................................... 398 30 Testing and adjusting..................................................................................................................................... 405 Testing and adjusting, Part 1............................................................................................................................ 405 Precautions before work.............................................................................................................................. 407 Tools for testing, adjusting, and troubleshooting.................................................................................................... 408 Testing engine speed................................................................................................................................. 414 Testing intake air pressure (boost pressure)......................................................................................................... 415 Testing exhaust temperature.......................................................................................................................... 416 Testing exhaust gas color............................................................................................................................ 418 Adjusting valve clearance............................................................................................................................ 419 Testing compression pressure......................................................................................................................... 421 Testing blow-by pressure............................................................................................................................. 423 Testing engine oil pressure.......................................................................................................................... 424 Testing EGR valve and bypass valve drive oil pressure................................................................................................ 425 Handling of fuel system devices...................................................................................................................... 426 Releasing residual pressure from fuel system......................................................................................................... 426 Testing fuel pressure................................................................................................................................ 427 Testing fuel return rate and leakage................................................................................................................. 428 Bleeding air from fuel circuit....................................................................................................................... 431 Testing the fuel circuit for leakage................................................................................................................. 433 Testing and adjusting alternator belt tension........................................................................................................ 434 Testing and adjusting fan belt tension............................................................................................................... 435 Testing and adjusting air conditioner compressor belt tension........................................................................................ 437 Testing and adjusting, Part 2............................................................................................................................ 439 Testing torque converter stall speed................................................................................................................. 441 Testing power train oil pressure..................................................................................................................... 442 Adjusting transmission speed sensor.................................................................................................................. 449 Testing brake oil pressure........................................................................................................................... 450 Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas................................................ 452 Testing brake performance............................................................................................................................ 460 Adjusting parking brake.............................................................................................................................. 462 Releasing remaining pressure in brake circuit........................................................................................................ 463 Bleeding air from brake circuit...................................................................................................................... 464 Testing wear of rear brake disc...................................................................................................................... 465 Testing wear of front brake pad...................................................................................................................... 466 Method for emergency release of parking brake........................................................................................................ 467 Testing and adjusting front suspension cylinder...................................................................................................... 468 Testing and adjusting inverted type rear suspension cylinder......................................................................................... 473 Testing and adjusting front suspension cylinder (mode selector hydraulic cylnder).................................................................... 477 Testing and adjusting hydraulic pressure in steering, hoist circuit.................................................................................. 478 Testing and adjusting dump EPC circuit oil pressure.................................................................................................. 481 Air bleeding from steering cylinder.................................................................................................................. 482 Procedure for raising body in emergency.............................................................................................................. 483 Adjusting body positioner sensor..................................................................................................................... 484 Resetting method for dump body seating control....................................................................................................... 485 Adjustment of tilt lock lever of steering wheel...................................................................................................... 486 Handling of high voltage circuit of engine controller................................................................................................ 487 Adjusting transmission controller.................................................................................................................... 487 Method for emergency escape at electrical system failure............................................................................................. 488 Testing and adjusting, Part 3............................................................................................................................ 493 Setting and adjusting of devices..................................................................................................................... 494 Special functions of machine monitor (EMMS).......................................................................................................... 506 Testing and adjusting, Part 4............................................................................................................................ 565 How to start operation of KOMTRAX terminal........................................................................................................... 566 Lamp display of KOMTRAX terminal..................................................................................................................... 571 Pm Clinic check sheet................................................................................................................................ 574 Setting of card-type payload meter (PLM-II) after installation or replacement........................................................................ 576 Setting of payload meter............................................................................................................................. 582 40 Troubleshooting........................................................................................................................................... 591 General information on troubleshooting................................................................................................................... 591 Precautions before work.............................................................................................................................. 592 Points to remember when performing troubleshooting................................................................................................... 593 How to proceed in troubleshooting.................................................................................................................... 595 Checks before troubleshooting........................................................................................................................ 597 Classification and procedures of troubleshooting..................................................................................................... 598 Information in troubleshooting table................................................................................................................. 602 Connection table for connector pin numbers........................................................................................................... 604 T- branch box and T- branch adapter table............................................................................................................ 640 Troubleshooting by failure code, General................................................................................................................. 645 Failure codes table.................................................................................................................................. 646 Before troubleshooting by failure codes.............................................................................................................. 656 Contents of troubleshooting table.................................................................................................................... 661 Troubleshooting by failure code, Part 1.................................................................................................................. 665 Failure code [1500L0] Dual engagement................................................................................................................ 667 Failure code [15B0NX] Transmission oil filter: Clogging.............................................................................................. 668 Failure code [15F0KM] R → F shifting abuse 1: Mistake in operation................................................................................... 670 Failure code [15F0MB] R → F shifting abuse 2: Mistake in operation................................................................................... 670 Failure code [15F7KM] Forward clutch disk abuse: Mistake in operation or setting..................................................................... 671 Failure code [15G0MW] R clutch: Slipping............................................................................................................. 672 Failure code [15G7KM] Reverse clutch disk abuse: Mistake in operation or setting..................................................................... 674 Failure code [15H0MW] Hi clutch: Slipping............................................................................................................ 676 Failure code [15J0MW] Lo clutch: Slipping............................................................................................................ 678 Failure code [15K0MW] 1st clutch: Slipping........................................................................................................... 680 Failure code [15L0MW] 2nd clutch: Slipping........................................................................................................... 682 Failure code [15M0MW] 3rd clutch: Slipping........................................................................................................... 684 Failure code [15N0MW] 4th clutch: Slipping........................................................................................................... 686 Failure code [15SBL1] R clutch solenoid: Fill signal is ON when command current is OFF............................................................... 688 Failure code [15SBMA] R clutch solenoid: Malfunction................................................................................................. 690 Failure code [15SCL1] Hi clutch solenoid: Fill signal is ON when command current is OFF.............................................................. 691 Failure code [15SCMA] Hi clutch solenoid: Malfunction................................................................................................ 694 Failure code [15SDL1] Lo clutch solenoid: Fill signal is ON when command current is OFF.............................................................. 695 Failure code [15SDMA] Lo clutch solenoid: Malfunction................................................................................................ 698 Failure code [15SEL1] 1st clutch solenoid: Fill signal is ON when command current is OFF............................................................. 699 Failure code [15SEMA] 1st clutch solenoid: Malfunction............................................................................................... 702 Failure code [15SFL1] 2nd clutch solenoid: Fill signal is ON when command current is OFF............................................................. 703 Failure code [15SFMA] 2nd clutch solenoid: Malfunction............................................................................................... 706 Failure code [15SGL1] 3rd clutch solenoid: Fill signal is ON when command current is OFF............................................................. 707 Failure code [15SGMA] 3rd clutch solenoid: Malfunction............................................................................................... 710 Failure code [15SHL1] 4th clutch solenoid: Command current is OFF and fill signal is ON.............................................................. 711 Failure code [15SHMA] 4th clutch solenoid: Malfunction............................................................................................... 714 Failure code [15SJMA] Lockup clutch solenoid: Malfunction............................................................................................ 716 Failure code [989A00] Engine over run prevention command signal: Operating........................................................................... 718 Failure code [989D00] Rear section tipping over alarm: Alarm is activated............................................................................ 719 Failure code [2F00KM] Parking brake: Mistake in operation or setting................................................................................. 720 Failure code [2G42ZG] Front accumulator: Lowering of oil pressure.................................................................................... 722 Failure code [2G43ZG] Rear accumulator: Lowering of oil pressure..................................................................................... 722 Failure code [A570NX] Engine oil filter: Clogging.................................................................................................... 723 Failure code [AA10NX] Air cleaner element: Clogging.................................................................................................. 724 Failure code [AB00MA] Alternator: Malfunction........................................................................................................ 726 Failure code [B@BAZG] Abnormal lowering of engine oil pressure: Lowering of oil pressure............................................................. 728 Failure code [B@BAZK] Engine oil: Level too low...................................................................................................... 729 Failure code [B@BCZK] Lowering of radiator coolant: Lowering of level................................................................................ 730 Failure code [B@BCNS] Engine: Overheat............................................................................................................... 732 Failure code [B@C7NS] Rear brake oil: Overheat....................................................................................................... 732 Failure code [B@CENS] Torque converter oil: Overheat................................................................................................. 733 Failure code [B@GAZK] Battery electrolyte level: Lowering of level................................................................................... 734 Failure code [B@JANS] Steering oil: Overheat......................................................................................................... 735 Troubleshooting by failure code, Part 2.................................................................................................................. 737 Failure code [CA111] Abnormality in engine controller................................................................................................ 740 Failure code [CA115] Engine Ne or Bkup speed sensor error............................................................................................ 742 Failure code [CA122] Charge (boost) pressure sensor high error....................................................................................... 744 Failure code [CA123] Charge (boost) pressure sensor low error........................................................................................ 746 Failure code [CA131] Throttle sensor high error...................................................................................................... 748 Failure code [CA132] Throttle sensor low error....................................................................................................... 751 Failure code [CA135] Engine oil pressure sensor high error........................................................................................... 754 Failure code [CA141] Engine oil pressure sensor low error............................................................................................ 756 Failure code [CA144] Coolant temperature sensor high error........................................................................................... 758 Failure code [CA145] Coolant temperature sensor low error............................................................................................ 760 Failure code [CA153] Charge (boost) temperature sensor high error.................................................................................... 762 Failure code [CA154] Charge (boost) temperature sensor low error..................................................................................... 764 Failure code [CA187] Sensor power supply 2 low error................................................................................................. 766 Failure code [CA221] Atmospheric pressure sensor high error.......................................................................................... 770 Failure code [CA222] Atmospheric pressure sensor low error........................................................................................... 772 Failure code [CA227] Sensor power supply 2 high error................................................................................................ 774 Failure code [CA234] Engine overspeed................................................................................................................ 775 Failure code [CA238] Ne speed sensor power supply error.............................................................................................. 776 Failure code [CA263] Fuel Temperature Sensor High Error.............................................................................................. 778 Failure code [CA265] Fuel Temperature Sensor Low Error............................................................................................... 780 Failure code [CA271] PCV1 Short circuit.............................................................................................................. 782 Failure code [CA272] PCV1 Disconnection.............................................................................................................. 783 Failure code [CA273] PCV2 Short circuit.............................................................................................................. 784 Failure code [CA274] PCV2 Disconnection.............................................................................................................. 785 Failure code [CA322] Injector #1 open/short error.................................................................................................... 786 Failure code [CA323] Injector #5 open/short error.................................................................................................... 788 Failure code [CA324] Injector #3 open/short error.................................................................................................... 790 Failure code [CA325] Injector #6 open/short error.................................................................................................... 792 Failure code [CA331] Injector #2 open/short error.................................................................................................... 794 Failure code [CA332] Injector #4 open/short error.................................................................................................... 796 Failure code [CA342] Calibration code inconsistency.................................................................................................. 798 Failure code [CA351] Injectors drive circuit error................................................................................................... 799 Failure code [CA352] Sensor power supply 1 low error................................................................................................. 800 Failure code [CA386] Sensor power supply 1 high error................................................................................................ 802 Failure code [CA431] Idle validation switch error.................................................................................................... 804 Failure code [CA432] Idle validation action error.................................................................................................... 807 Failure code [CA441] Battery voltage low error....................................................................................................... 810 Failure code [CA442] Battery voltage high error...................................................................................................... 811 Failure code [CA449] Common rail pressure high error 2............................................................................................... 812 Failure code [CA451] Common rail pressure sensor high error.......................................................................................... 814 Failure code [CA452] Common rail pressure sensor low error........................................................................................... 816 Failure code [CA553] Common rail pressure high error 1............................................................................................... 818 Failure code [CA554] Common rail pressure sensor in range error...................................................................................... 819 Failure code [CA559] Supply pump pressure very low error 1........................................................................................... 820 Failure code [CA689] Engine Ne speed sensor error.................................................................................................... 824 Failure code [CA731] Engine Bkup speed sensor phase error............................................................................................ 826 Failure code [CA757] All continuous data lost error.................................................................................................. 827 Failure code [CA778] Engine Bkup speed sensor error.................................................................................................. 828 Failure code [CA1228] EGR valve servo error 1........................................................................................................ 830 Failure code [CA1625] EGR valve servo error 2........................................................................................................ 831 Failure code [CA1626] Bypass valve solenoid current high error....................................................................................... 832 Failure code [CA1627] Bypass valve solenoid current low error........................................................................................ 834 Failure code [CA1628] Bypass Valve Servo Error 1..................................................................................................... 836 Failure code [CA1629] Bypass Valve Servo Error 2..................................................................................................... 837 Troubleshooting by failure code, Part 3.................................................................................................................. 839 Failure code [CA1631] Bypass valve lift sensor high error............................................................................................ 842 Failure code [CA1632] Bypass valve lift sensor low error............................................................................................. 844 Failure code [CA1633] KOMNET datalink timeout error.................................................................................................. 846 Failure code [CA1642] EGR inlet pressure sensor low error............................................................................................ 848 Failure code [CA1653] EGR inlet pressure sensor high error........................................................................................... 850 Failure code [CA2185] Throttle sensor power supply voltage high error................................................................................ 852 Failure code [CA2186] Throttle sensor power supply voltage low error................................................................................. 854 Failure code [CA2249] Supply pump pressure very low error 2.......................................................................................... 856 Failure code [CA2271] EGR valve lift sensor high error............................................................................................... 858 Failure code [CA2272] EGR valve lift sensor low error................................................................................................ 860 Failure code [CA2351] EGR valve solenoid operation short circuit..................................................................................... 862 Failure code [CA2352] EGR valve solenoid operation disconnect........................................................................................ 864 Failure code [CA2555] Intake air heater relay open circuit error..................................................................................... 866 Failure code [CA2556] Intake air heater relay short circuit error.................................................................................... 868 Failure code [D19HKB] Stop lamp relay output system: Short circuit................................................................................... 870 Failure code [D5ZKKZ] Front brake cut-off solenoid valve: Disconnection or short circuit............................................................. 872 Failure code [DAF9KM] Wrong connection of connector.................................................................................................. 874 Failure code [DAFRKR] Abnormal CAN communication (machine monitor): Abnormal communication........................................................... 876 Failure code [DAQ0KK] Transmission controller direct power supply: Lowering of source voltage........................................................ 878 Failure code [DAQ0KT] Transmission controller nonvolatile memory: Abnormality in controller.......................................................... 880 Failure code [DAQ2KK] Transmission controller solenoid power source: Power source voltage too low.................................................... 881 Failure code [DAQ9KQ] Transmission controller: Disagreement of model selection....................................................................... 882 Failure code [DAQRKR] Abnormal CAN communication (Transmission): Abnormal communication.............................................................. 883 Failure code [DAQRMA] Transmission controller option setting: Malfunction............................................................................ 888 Failure code [DB10KT] Retarder controller nonvolatile memory: Abnormality in controller.............................................................. 889 Failure code [DB12KK] Retarder controller solenoid power source: Power source voltage too low........................................................ 890 Failure code [DB13KK] Retarder controller direct power source: Power source voltage too low.......................................................... 892 Failure code [DB19KQ] Disagreement of model selection (Retarder controller).......................................................................... 894 Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled................................................................ 896 Failure code [DB1RMA] Disagreement of option setting (Retarder controller)........................................................................... 900 Failure code [DB1SKQ] Model selection: Wrong information............................................................................................. 901 Failure code [DB2RKR] CAN communication (engine controller): Communication disabled.................................................................. 902 Failure code [DBB0KK] PLM controller: Low source voltage (input) or PLM controller_LED display: "n9" → "01".......................................... 908 Failure code [DBB0KQ] PLM controller: Disagreement of model selection signals or PLM controller_LED display: "nF" → "11"............................. 910 Failure code [DBB3KK] PLM controller battery power supply: Low source voltage (input) or PLM controller_LED display: "n9" → "05"..................... 912 Failure code [DBB6KP] PLM controller 24V power supply output: Low output voltage or PLM controller_LED display: "n9" → "02".......................... 914 Failure code [DBBQKR] PLM controller CAN communication: Defective communication or PLM controller_LED display: "n8" → "02"........................... 916 Failure code [DBBRKR] Abnormal CAN communication (PLM) : Defective communication..................................................................... 917 Failure code [DBC9KQ] Disagreement of model selection (ABS controller)............................................................................... 918 Failure code [DBCRMA] Disagreement of option setting (ABS controller)................................................................................ 919 Failure code [DDD7KX] Trouble in travel speed setting switch system: Out of input signal range (If equipped)......................................... 920 Failure code [DDD8KA] ARSC system switch system: Disconnection....................................................................................... 922 Failure code [DDD8KB] ARSC system switch system: Short circuit....................................................................................... 924 Failure code [DDDAKA] ASR system switch: Disconnection (If equipped)................................................................................. 926 Failure code [DDDAKB] ASR system switch: Short circuit............................................................................................... 928 Failure code [DDTHKA] Hi clutch fill switch: Disconnection........................................................................................... 930 Failure code [DDTJKA] Lo clutch fill switch: Disconnection........................................................................................... 932 Failure code [DDTKKA] 1st clutch fill switch: Disconnection.......................................................................................... 933 Failure code [DDTLKA] 2nd clutch fill switch: Disconnection.......................................................................................... 934 Failure code [DDTMKA] 3rd clutch fill switch: Disconnection.......................................................................................... 935 Failure code [DDTNKA] R clutch fill switch: Disconnection............................................................................................ 936 Failure code [DDTPKA] 4th clutch fill switch : Disconnection......................................................................................... 937 Failure code [DF10KA] Gear shift lever: Disconnection................................................................................................ 938 Failure code [DF10KB] Gear shift lever: Short circuit................................................................................................ 941 Failure code [DGF1KX] Transmission oil temperature sensor: Out of input signal range................................................................. 944 Failure code [DGR2KZ] Retarder oil temperature sensor : Disconnection or short circuit............................................................... 946 Failure code [DGR6KX] Steering oil temperature sensor: Input signal out of range..................................................................... 948 Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range............................................................. 950 Troubleshooting by failure code, Part 4.................................................................................................................. 953 Failure code [DHP4KY] Short circuit in suspension pressure sensor system (Front right) or PLM controller_LED display: "n5" → "44".................... 956 Failure code [DHP4KZ] Disconnection or ground fault in suspension pressure sensor system (Front right) or PLM controller_LED display: "n5" → "43".... 958 Failure code [DHP5KY] Short circuit in suspension pressure sensor system (Front left) or PLM controller_LED display: "n5" → "54"..................... 960 Failure code [DHP5KZ] Disconnection or ground fault in suspension pressure sensor system (Front left) or PLM controller_LED display: "n5" → "53"..... 962 Failure code [DHP6KA] (Suspension pressure sensor system (Rear right): Disconnection)................................................................ 964 Failure code [DHP6KX] (Failure in suspension pressure sensor system trouble (Rear right): Out of input signal range)................................. 966 Failure code [DHP6KY] Suspension pressure sensor system: Short circuit (Right rear) or PLM controller_LED display: "n5" → "64"....................... 968 Failure code [DHP6KZ] Suspension pressure sensor system: Disconnection or ground fault (Right rear) or PLM controller_LED display: "n5" → "63"....... 970 Failure code [DHP7KA] (Suspension pressure sensor system (Rear left): Disconnection)................................................................. 972 Failure code [DHP7KX] (Failure in suspension pressure sensor system trouble (Rear left): Out of input signal range).................................. 974 Failure code [DHP7KY] Suspension pressure sensor system: Short circuit (Left rear) or PLM controller_LED display: "n5" → "74"........................ 976 Failure code [DHP7KZ] Suspension pressure sensor system: Disconnection or ground fault (Left rear) or PLM controller_LED display: "n5" → "73"........ 978 Failure code [DHT5KX] (Torque converter oil pressure sensor: Out of input signal range).............................................................. 980 Failure code [DHT5L6] (Torque converter oil pressure sensor: Disagreement of run and stop condition with signal)..................................... 982 Failure code [DHU2KX] (Front accumulator oil pressure sensor: Out of input signal range)............................................................. 984 Failure code [DHU3KX] (Rear accumulator oil pressure sensor: Out of input signal range).............................................................. 986 Failure code [DJF1KA] (Fuel level sensor: Disconnection)............................................................................................. 988 Failure code [DK30KX] Trouble in steering angle potentiometer........................................................................................ 989 Failure code [DK51L5] (Retarder lever potentiometer: Potentiometer signal is inconsistent with switch signal)........................................ 991 Failure code [DK52KX] (Failure in hoist lever potentiometer 1: Out of input signal range)............................................................ 994 Failure code [DK53L8] (Failure in hoist lever potentiometer 2: Disagreement of analog signal)........................................................ 996 Failure code [DK54KX] (Body positioner sensor: Out of input signal range)............................................................................ 998 Failure code [DKD0L6] (Failure in steering speed sensor: Disagreement of run and stop condition with signal) (If equipped)...........................1000 Failure code [DKH0KX] (Pitch angle sensor: Out of input signal range) (If equipped)..................................................................1002 Failure code [DKH1KX] Abnormality in clinometer sensor or PLM controller_LED display: "n4" → "33"....................................................1004 Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection).........................................................................1006 Failure code [DLF1LC] (Transmission input shaft speed sensor: Disagreement of revolution speed signal)...............................................1008 Failure code [DLF2KA] (Transmission intermediate shaft speed sensor: Disconnection)..................................................................1010 Failure code [DLF2LC] (Transmission intermediate shaft speed sensor: Disagreement of revolution speed signal)........................................1012 Failure code [DLF8KA] Disconnection in wheel speed sensor (Right rear)...............................................................................1014 Failure code [DLF8LC] Trouble in wheel speed sensor system (Right rear)..............................................................................1015 Failure code [DLF9KA] Disconnection in wheel speed sensor (Left rear)................................................................................1016 Failure code [DLF9LC] Trouble in wheel speed sensor system (Left rear)...............................................................................1017 Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)........................................................................1018 Failure code [DLT3LC] (Transmission output shaft speed sensor: Disagreement of revolution speed signal) (If equipped)................................1020 Failure code [DLT4KA] (Transmission output shaft speed sensor: Disconnection) (If equipped)..........................................................1022 Failure code [DLT4LC] (Transmission output shaft speed sensor: Disagreement of revolution speed signal) (If equipped)................................1024 Failure code [DLT4MA] Disconnection in transmission output shaft speed sensor: Defective function (If equipped)......................................1026 Failure code [DV00KB] Short circuit in buzzer output.................................................................................................1028 Failure code [DW35KZ] (Failure in output system of auto suspension solenoid 1: Disconnection or short circuit) (If equipped).........................1030 Failure code [DW36KZ] (Failure in output system of auto suspension solenoid 2: Disconnection or short circuit) (If equipped).........................1032 Failure code [DW72KZ] (Failure in kick-out solenoid output system: Disconnection or short circuit)...................................................1034 Failure code [DW73KZ] (Failure in hoist select valve output system: Disconnection or short circuit)..................................................1036 Failure code [DW78KZ] (Failure in rear brake BCV command output system: Disconnection or short circuit)..............................................1038 Failure code [DWNBK4] Trouble in ASR shut-off valve (Valve keeps operating)..........................................................................1040 Failure code [DWNBKA] Disconnection in ASR shut-off valve output circuit.............................................................................1042 Failure code [DWNBKB] Ground fault in ASR shut-off valve output circuit..............................................................................1044 Failure code [DWNBKY] Short circuit in ASR shut-off valve output circuit.............................................................................1046 Failure code [DWNBMA] Trouble in ASR shut-off valve (Valve does not operate).........................................................................1047 Failure code [DX11K4] (Rear brake proportional pressure reducing solenoid valve: Out of control).....................................................1048 Failure code [DX11KA] (Rear brake proportional pressure reducing solenoid valve output circuit: Disconnection).......................................1050 Failure code [DX11KB] (Rear brake proportional pressure reducing solenoid valve: Short circuit)......................................................1051 Failure code [DX11KY] (Rear brake proportional pressure reducing solenoid valve: Short circuit to power source line).................................1052 Failure code [DX11MA] (Rear brake proportional pressure reducing solenoid valve: Malfunction)........................................................1054 Failure code [DX13KA] (Output circuit of hoist EPC valve: Disconnection).............................................................................1056 Failure code [DX13KB] (Output circuit of hoist EPC valve: Short circuit).............................................................................1058 Failure code [DX13KY] (Output circuit of hoist EPC valve: Short circuit with power source line)......................................................1060 Troubleshooting by failure code, Part 5..................................................................................................................1063 Failure code [DX17K4] Trouble in ASR proportional pressure reducing solenoid valve (right) (Valve keeps operating)...................................1066 Failure code [DX17KA] Disconnection in ASR proportional pressure reducing solenoid valve (right) output circuit......................................1068 Failure code [DX17KB] Ground fault in ASR proportional pressure reducing solenoid valve (right) output circuit.......................................1070 Failure code [DX17KY] Short circuit in ASR proportional pressure reducing solenoid valve (right) output circuit......................................1072 Failure code [DX17MA] Trouble in ASR proportional pressure reducing solenoid valve (right) (Valve does not operate)..................................1073 Failure code [DX18K4] Trouble in ASR proportional pressure reducing solenoid valve (left) (Valve keeps operating)....................................1074 Failure code [DX18KA] Disconnection in ASR proportional pressure reducing solenoid valve (left) output circuit.......................................1076 Failure code [DX18KB] Ground fault in ASR proportional pressure reducing solenoid valve (left) output circuit........................................1078 Failure code [DX18KY] Short circuit in ASR proportional pressure reducing solenoid valve (left) output circuit.......................................1080 Failure code [DX18MA] Trouble in ASR proportional pressure reducing solenoid valve (left) (Valve does not operate)...................................1081 Failure code [DXH1KA] Lockup clutch solenoid output circuit: Disconnection...........................................................................1082 Failure code [DXH1KB] Lock-up clutch solenoid output circuit: Short circuit..........................................................................1084 Failure code [DXH1KY] Lockup clutch solenoid output circuit: Short circuit to power source line......................................................1085 Failure code [DXH2KA] Hi clutch solenoid output circuit: Disconnection...............................................................................1086 Failure code [DXH2KB] Hi clutch solenoid output circuit: Short circuit...............................................................................1088 Failure code [DXH2KY] Hi clutch solenoid output circuit: Short circuit to power source line..........................................................1090 Failure code [DXH3KA] Lo clutch solenoid output circuit: Disconnection...............................................................................1092 Failure code [DXH3KB] Lo clutch solenoid output circuit: Short circuit...............................................................................1094 Failure code [DXH3KY] Lo clutch solenoid output circuit: Short circuit in power source line..........................................................1096 Failure code [DXH4KA] 1st clutch solenoid output circuit: Disconnection..............................................................................1098 Failure code [DXH4KB] 1st clutch solenoid output circuit: Short circuit..............................................................................1100 Failure code [DXH4KY] 1st clutch solenoid output circuit: Short circuit to power source line.........................................................1102 Failure code [DXH5KA] 2nd clutch solenoid output circuit: Disconnection..............................................................................1104 Failure code [DXH5KB] 2nd clutch solenoid output circuit: Short circuit..............................................................................1106 Failure code [DXH5KY] 2nd clutch solenoid output circuit: Short circuit in power source line.........................................................1108 Failure code [DXH6KA] 3rd clutch solenoid output circuit: Disconnection..............................................................................1110 Failure code [DXH6KB] 3rd clutch solenoid output circuit: Short circuit..............................................................................1112 Failure code [DXH6KY] 3rd clutch solenoid output circuit: Short circuit to power source line.........................................................1114 Failure code [DXH7KA] R clutch solenoid output circuit: Disconnection................................................................................1116 Failure code [DXH7KB] R clutch solenoid output circuit: Short circuit................................................................................1118 Failure code [DXH7KY] R clutch solenoid output circuit: Short circuit to power source line...........................................................1119 Failure code [DXHHKA] 4th clutch solenoid output circuit: Disconnection..............................................................................1120 Failure code [DXHHKB] 4th clutch solenoid output circuit: Short circuit..............................................................................1122 Failure code [DXHHKY] 4th clutch solenoid output circuit: Short circuit to power source line.........................................................1124 Troubleshooting of electrical system (E-mode)............................................................................................................1127 Before troubleshooting of electric system............................................................................................................1129 Contents of troubleshooting table....................................................................................................................1135 E-1 Engine does not start............................................................................................................................1137 E-2 Automatic preheating does not operate............................................................................................................1140 E-3 Machine monitor does not display all, when starting switch is turned ON..........................................................................1144 E-4 Machine monitor does not operate when starting switch is OFF.....................................................................................1146 E-5 Alarm buzzer does not stop sounding..............................................................................................................1148 E-6 Gauges of machine monitor, caution lamps or character display section do not display properly....................................................1149 E-7 A selection of the display in character display section cannot be changed........................................................................1150 E-8 Power mode selecting function does not operate properly..........................................................................................1153 E-9 AISS function does not operate properly..........................................................................................................1154 E-10 Seat belt caution lamp does not display properly................................................................................................1155 E-11 Turn signal lamp or turning lamp (hazard lamp) do not work properly.............................................................................1156 E-12 Night illumination (lighting) does not work properly............................................................................................1159 E-13 Emergency steering does not operate.............................................................................................................1168 Troubleshooting of hydraulic and mechanical system (H-mode)..............................................................................................1173 Contents of troubleshooting table....................................................................................................................1175 H-1 Machine does not start...........................................................................................................................1176 H-2 Machine does not travel smoothly (hunting).......................................................................................................1178 H-3 Lockup cannot be cancelled.......................................................................................................................1178 H-4 Excessive shock when starting or shifting........................................................................................................1179 H-5 Transmission does not shift up...................................................................................................................1180 H-6 Machine lacks power or speed when traveling......................................................................................................1181 H-7 Time lag is excessive when starting or shifting gear.............................................................................................1183 H-8 Torque converter oil temperature is high.........................................................................................................1184 H-9 Torque converter oil pressure is low.............................................................................................................1185 H-10 Front brake is ineffective......................................................................................................................1186 H-11 Rear brake is ineffective.......................................................................................................................1187 H-12 Steering wheel is heavy.........................................................................................................................1188 H-13 Steering wheel does not work....................................................................................................................1189 H-14 Steering wheel vibrates.........................................................................................................................1190 H-15 Dump body lifting speed is slow.................................................................................................................1191 H-16 Dump body does not work.........................................................................................................................1192 H-17 Excessive hydraulic drift of dump body..........................................................................................................1193 Troubleshooting of mechanical system (S-mode)............................................................................................................1195 Method of using troubleshooting charts...............................................................................................................1198 S-1 Starting performance is poor.....................................................................................................................1202 S-2 Engine does not start............................................................................................................................1204 S-3 Engine does not pick up smoothly.................................................................................................................1208 S-4 Engine stops during operations...................................................................................................................1209 S-5 Engine does not rotate smoothly..................................................................................................................1210 S-6 Engine lacks output (or lacks power).............................................................................................................1211 S-7 Exhaust gas color is black (incomplete combustion)...............................................................................................1212 S-8 Oil consumption is excessive (or exhaust smoke is blue)..........................................................................................1214 S-9 Oil becomes contaminated quickly.................................................................................................................1215 S-10 Fuel consumption is excessive...................................................................................................................1216 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)...........................................................................1217 S-12 Oil pressure drops..............................................................................................................................1218 S-13 Oil level rises (Entry of coolant/fuel).........................................................................................................1220 S-14 Coolant temperature becomes too high (overheating)..............................................................................................1222 S-15 Abnormal noise is made..........................................................................................................................1223 S-16 Vibration is excessive..........................................................................................................................1224 50 Disassembly and assembly..................................................................................................................................1227 General information on disassembly and assembly..........................................................................................................1227 Precautions before work..............................................................................................................................1228 How to read this manual..............................................................................................................................1229 Coating materials list...............................................................................................................................1231 Special tool list....................................................................................................................................1234 Sketches of special tools............................................................................................................................1242 Engine and cooling system................................................................................................................................1247 Removal and installation of engine assembly..........................................................................................................1248 Removal and installation of radiator assembly........................................................................................................1258 Removal and installation of output shaft assembly....................................................................................................1270 Disassembly and assembly of output shaft assembly....................................................................................................1274 Removal and installation of fuel supply pump assembly................................................................................................1277 Removal and installation of cylinder head assembly...................................................................................................1283 Removal and installation of fuel injector assembly...................................................................................................1298 Removal and installation of engine front seal........................................................................................................1304 Removal and installation of engine rear seal.........................................................................................................1308 Power train, Part 1......................................................................................................................................1315 Removal and installation of torque converter and transmission assembly...............................................................................1316 Disassembly and assembly of torque converter and control valve assembly..............................................................................1328 Disassembly and assembly of torque converter assembly................................................................................................1330 Disassembly and assembly of PTO assembly.............................................................................................................1341 Disassembly and assembly of transmission assembly....................................................................................................1345 Removal and installation of transmission control valve assembly (ECMV assembly)......................................................................1382 Disassembly and assembly of transmission control valve assembly (ECMV assembly)......................................................................1383 Power train, Part 2......................................................................................................................................1389 Removal and installation of differential assembly....................................................................................................1390 Disassembly and assembly of differential assembly....................................................................................................1393 Removal and installation of rear final drive carrier assembly........................................................................................1410 Disassembly and assembly of rear final drive carrier assembly........................................................................................1413 Disassembly and assembly of rear final drive assembly................................................................................................1415 Disassembly and assembly of front wheel hub assembly.................................................................................................1423 Steering system..........................................................................................................................................1429 Disassembly and assembly of steering cylinder assembly...............................................................................................1430 Removal and installation of emergency steering motor pump assembly...................................................................................1434 Brake system.............................................................................................................................................1437 Removal and installation of front brake caliper pad..................................................................................................1438 Removal and installation of front brake caliper assembly.............................................................................................1439 Disassembly and assembly of front brake caliper assembly.............................................................................................1441 Removal and installation of parking brake pad........................................................................................................1443 Removal and installation of parking brake caliper assembly...........................................................................................1446 Disassembly and assembly of front brake caliper pad assembly.........................................................................................1447 Removal and installation of parking brake spring cylinder assembly...................................................................................1448 Removal and installation of slack adjuster assembly..................................................................................................1450 Disassembly and assembly of slack adjuster assembly..................................................................................................1451 Undercarriage and frame..................................................................................................................................1453 Removal and installation of front wheel assembly.....................................................................................................1454 Removal and installation of rear wheel assembly......................................................................................................1456 Removal and installation of front suspension cylinder assembly.......................................................................................1458 Disassembly and assembly of front suspension cylinder assembly.......................................................................................1461 Disassembly and assembly of variable damping selector valve assembly.................................................................................1464 Removal and installation of rear suspension cylinder assembly........................................................................................1467 Disassembly and assembly of rear suspension cylinder assembly........................................................................................1469 Hydraulic system.........................................................................................................................................1473 Disassembly and assembly of hoist cylinder assembly..................................................................................................1474 Body.....................................................................................................................................................1483 Removal and installation of body assembly............................................................................................................1484 Cab and its attachments..................................................................................................................................1489 Disassembly and assembly of operator's seat assembly.................................................................................................1490 Removal and installation of air conditioner unit assembly............................................................................................1503 Electrical system........................................................................................................................................1507 Removal and installation of engine controller assembly...............................................................................................1508 Removal and installation of transmission controller assembly.........................................................................................1509 Removal and installation of retarder controller assembly.............................................................................................1510 90 Diagrams and drawings.....................................................................................................................................1513 Hydraulic diagrams and drawings..........................................................................................................................1513 Power train hydraulic circuit diagram................................................................................................................1514 Steering and hoist hydraulic circuit diagram HD325-7 Serial No. 7001 - 7025, 7101 - 7523 HD405-7 Serial No. 3001 - 3035, 7101 - 7523.................1515 Steering and hoist hydraulic circuit diagram HD325-7 Serial No. 7524 and up HD405-7 Serial No. 7525 and up...........................................1517 Brake hydraulic circuit diagram......................................................................................................................1519 Electrical diagrams and drawings.........................................................................................................................1523 Electrical circuit diagram for inside cab (1/5) .....................................................................................................1525 Electrical circuit diagram for inside cab (2/5) HD325-7 Serial No. 7001 – 7025, 7101 – 7161 HD405-7 Serial No. 3001 – 3035, 7101 – 7157..............1527 Electrical circuit diagram for inside cab (2/5) HD325-7 Serial No. 7162 and up HD405-7 Serial No. 7158 and up........................................1529 Electrical circuit diagram for inside cab (3/5) HD325-7 Serial No. 7001 – 7025, 7101 – 7161 HD405-7 Serial No. 3001 – 3035, 7101 – 7157..............1531 Electrical circuit diagram for inside cab (3/5) HD325-7 Serial No. 7162 and up HD405-7 Serial No. 7158 and up........................................1533 Electrical circuit diagram for inside cab (4/5)......................................................................................................1535 Electrical circuit diagram for inside cab (5/5)......................................................................................................1537 Electrical circuit diagram for outside cab (1/3).....................................................................................................1539 Electrical circuit diagram for outside cab (2/3).....................................................................................................1541 Electrical circuit diagram for outside cab (3/3).....................................................................................................1543 Air conditioner electrical circuit diagram...........................................................................................................1545 Payload meter electrical circuit diagram.............................................................................................................1547 Electrical circuit diagram of external power supply heater...........................................................................................1549 Connectors table and arrangement drawing.............................................................................................................1551
DESCRIPTION:
KOMATSU HD325-7 HD405-7 DUMP TRUCK SHOP MANUAL SEN00486-22 – PDF DOWNLOAD
1. General precautions
1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
A. Always wear safety glasses when hitting parts with a hammer.
B. Always wear safety glasses when grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator’s compartment.
5) Only the approved personnel can do the work in a closed environment or in a prohibited area.
6) Only qualified workers must carry out work and operation which require license or qualification.
7) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
8) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.
9) Before starting work, warm up your body thoroughly to start work under good condition.
10) Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.
S.S 27/12/24
