Komatsu HD325-7R HD405-7R Dump Truck Shop Manual SEN02373-15 PDF

Description

Komatsu HD325-7R HD405-7R Dump Truck Shop Manual SEN02373-15 – PDF DOWNLOAD

FILE DETAILS:

Komatsu HD325-7R HD405-7R Dump Truck Shop Manual SEN02373-15 – PDF DOWNLOAD 

Language : English
Pages : 1440
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Komatsu HD325-7R HD405-7R Dump Truck Shop Manual SEN02373-15 – PDF DOWNLOAD 

SERIAL NUMBERS

HD325-11001 and up
HD405-11001 and up

Cover 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword and general information 19
Safety notice 20
How to read the shop manual 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 63
Weight table 69
Fuel, coolant and lubricants 70
10 Structure, function and maintenance standard 73
Engine and cooling system 73
Radiator, oil cooler, aftercooler 74
Output shaft 76
Power train, Part 1 79
Power train skeleton 80
Drive shaft 82
Torque converter and transmission hydraulic piping 83
Power train charge pump 84
Retarder cooling pump 85
Torque converter 86
Torque converter valve 92
Transmission 93
Transmission control valve 109
ECMV 110
Power train, Part 2 119
Axle 120
Differential 122
Final drive 124
Wheel 126
Steering system 129
Steering column 130
Steering linkage 131
Brake system 135
Brake piping 136
Brake valve 138
Secondary brake valve 141
Relay valve 142
Front brake cut valve 143
Accumulator charge valve 144
Accumulator 148
Slack adjuster 150
Brake 152
Proportional reducing valve 157
Parking brake 158
Parking brake solenoid 160
Hand brake (retarder) 161
Undercarriage and frame 163
Suspension 164
Suspension cylinder 166
Rear axle support 174
Hydraulic system 177
Steering, hoist oil pressure piping diagram 178
Dump body control 180
Hydraulic tank 181
Steering valve 182
Cross-over relief valve 186
Steering control valve 187
Hoist valve 196
EPC valve 202
Steering cylinder 206
Hoist cylinder 207
Work equipment and steering pump 208
Cab and its attachments 211
ROPS cab 212
Air conditioner 213
Rear view monitor 219
Electrical system, Part 1 229
Machine monitor system 230
Electrical system, Part 2 283
Automatic shift control system 284
Transmission controller 288
Auto emergency steering system 302
Retarder control system 304
Dump control lever 316
Auto suspension system 320
Electrical system, Part 3 325
Payload meter II (card type) 326
Payload meter (PLM) controller related 356
Electrical system, Part 4 381
Sensors, switches 382
KOMTRAX terminal system (If equipped) 395
20 Standard value table 399
Standard service value table 399
Standard value table for engine 400
Standard value table for machine 401
30 Testing and adjusting 407
Testing and adjusting, Part 1 407
Precautions before work 409
Tools for testing, adjusting, and troubleshooting 410
Sketches of special tools 416
Testing engine speed 417
Testing intake air pressure (boost pressure) 418
Testing exhaust temperature 419
Testing exhaust gas color 421
Adjusting valve clearance 423
Testing compression pressure 424
Testing blow-by pressure 426
Testing engine oil pressure 427
Handling of fuel system devices 428
Releasing residual pressure from fuel system 428
Testing fuel pressure 429
Reduced cylinder mode operation 430
No-injection cranking 430
Testing fuel return rate and leakage 431
Bleeding air from fuel circuit 434
Testing the fuel circuit for leakage 436
Testing and adjusting alternator belt tension 437
Testing and adjusting fan belt tension 438
Testing and adjusting air conditioner compressor belt tension 440
Testing and adjusting, Part 2 443
Testing torque converter stall speed 445
Testing power train oil pressure 446
Adjusting transmission speed sensor 453
Testing brake oil pressure 454
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas 456
Testing brake performance 464
Testing and adjusting parking brake performance 466
Releasing remaining pressure in brake circuit 467
Bleeding air from brake circuit 468
Testing wear of rear brake disc 469
Testing wear of front brake pad 470
Method for emergency release of parking brake 471
Testing and adjusting front suspension cylinder 472
Testing and adjusting inverted type rear suspension cylinder 477
Testing and adjusting front suspension cylinder (mode selector hydraulic cylnder) 481
Testing and adjusting hydraulic pressure in steering, hoist circuit 482
Testing and adjusting dump EPC circuit oil pressure 485
Air bleeding from steering cylinder 486
Procedure for raising body in emergency 487
Adjusting body positioner sensor 488
Resetting method for dump body seating control 489
Adjustment of tilt lock lever of steering wheel 490
Handling of high voltage circuit of engine controller 491
Adjusting transmission controller 491
Method for emergency escape at electrical system failure 492
Testing and adjusting, Part 3 497
Setting and adjusting of devices 498
Special functions of machine monitor (EMMS) 510
Testing and adjusting, Part 4 569
How to start operation of KOMTRAX terminal 570
Lamp display of KOMTRAX terminal 575
Pm Clinic check sheet 578
Setting of card-type payload meter (PLM-) after installation or replacement 580
Setting of payload meter 586
40 Troubleshooting 595
Failure code table and fuse locations 595
Failure codes table 596
Fuse locations 606
General information on troubleshooting 611
Precautions before work 612
Points to remember when performing troubleshooting 613
How to proceed in troubleshooting 615
Checks before troubleshooting 617
Classification and procedures of troubleshooting 618
Information in troubleshooting table 622
Troubleshooting method for disconnecting wiring harness of pressure sensor system 624
Contents of troubleshooting table 627
Connection table for connector pin numbers 629
T- branch box and T- branch adapter table 665
Troubleshooting by failure code, Part 1 669
Failure code [1500L0] Dual engagement 671
Failure code [15B0NX] Transmission oil filter: Clogging 672
Failure code [15F0KM] R → F shifting abuse 1: Mistake in operation 674
Failure code [15F0MB] R → F shifting abuse 2: Mistake in operation 674
Failure code [15F7KM] Forward clutch disk abuse: Mistake in operation or setting 675
Failure code [15G0MW] R clutch: Slipping 676
Failure code [15G7KM] Reverse clutch disk abuse: Mistake in operation or setting 678
Failure code [15H0MW] Hi clutch: Slipping 680
Failure code [15J0MW] Lo clutch: Slipping 682
Failure code [15K0MW] 1st clutch: Slipping 684
Failure code [15L0MW] 2nd clutch: Slipping 686
Failure code [15M0MW] 3rd clutch: Slipping 688
Failure code [15N0MW] 4th clutch: Slipping 690
Failure code [15SBL1] R clutch solenoid: Fill signal is ON when command current is OFF 692
Failure code [15SBMA] R clutch solenoid: Malfunction 694
Failure code [15SCL1] Hi clutch solenoid: Fill signal is ON when command current is OFF 695
Failure code [15SCMA] Hi clutch solenoid: Malfunction 698
Failure code [15SDL1] Lo clutch solenoid: Fill signal is ON when command current is OFF 699
Failure code [15SDMA] Lo clutch solenoid: Malfunction 702
Failure code [15SEL1] 1st clutch solenoid: Fill signal is ON when command current is OFF 703
Failure code [15SEMA] 1st clutch solenoid: Malfunction 706
Failure code [15SFL1] 2nd clutch solenoid: Fill signal is ON when command current is OFF 707
Failure code [15SFMA] 2nd clutch solenoid: Malfunction 710
Failure code [15SGL1] 3rd clutch solenoid: Fill signal is ON when command current is OFF 711
Failure code [15SGMA] 3rd clutch solenoid: Malfunction 714
Failure code [15SHL1] 4th clutch solenoid: Command current is OFF and fill signal is ON 715
Failure code [15SHMA] 4th clutch solenoid: Malfunction 718
Failure code [15SJMA] Lockup clutch solenoid: Malfunction 720
Failure code [989A00] Engine over run prevention command signal: Operating 722
Failure code [989D00] Rear section tipping over alarm: Alarm is activated 723
Failure code [2F00KM] Parking brake: Mistake in operation or setting 724
Failure code [2G42ZG] Front accumulator: Lowering of oil pressure 726
Failure code [2G43ZG] Rear accumulator: Lowering of oil pressure 726
Failure code [A570NX] Engine oil filter: Clogging 727
Failure code [AA10NX] Air cleaner element: Clogging 728
Failure code [AB00MA] Alternator: Malfunction 730
Failure code [B@BAZG] Abnormal lowering of engine oil pressure: Lowering of oil pressure 732
Failure code [B@BAZK] Engine oil: Level too low 733
Failure code [B@BCZK] Lowering of radiator coolant: Lowering of level 734
Failure code [B@BCNS] Engine: Overheat 736
Failure code [B@C7NS] Rear brake oil: Overheat 736
Failure code [B@CENS] Torque converter oil: Overheat 737
Failure code [B@GAZK] Battery electrolyte level: Lowering of level 738
Failure code [B@JANS] Steering oil: Overheat 739
Troubleshooting by failure code, Part 2 741
Failure code [CA111] Abnormality in engine controller 744
Failure code [CA115] Engine Ne or Bkup speed sensor error 746
Failure code [CA122] Charge (boost) pressure sensor high error 748
Failure code [CA123] Charge (boost) pressure sensor low error 750
Failure code [CA131] Throttle sensor high error 752
Failure code [CA132] Throttle sensor low error 754
Failure code [CA135] Engine oil pressure sensor high error 756
Failure code [CA141] Engine oil pressure sensor low error 758
Failure code [CA144] Coolant temperature sensor high error 760
Failure code [CA145] Coolant temperature sensor low error 762
Failure code [CA153] Charge (boost) temperature sensor high error 764
Failure code [CA154] Charge (boost) temperature sensor low error 766
Failure code [CA187] Sensor power supply 2 low error 768
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 803
Failure code [CA432] Idle validation action error 806
Failure code [CA441] Battery voltage low error 809
Failure code [CA442] Battery voltage high error 810
Failure code [CA449] Common rail pressure high error 2 811
Failure code [CA451] Common rail pressure sensor high error 812
Failure code [CA452] Common rail pressure sensor low error 814
Failure code [CA553] Common rail pressure high error 1 816
Failure code [CA554] Common rail pressure sensor in range error 817
Failure code [CA559] Supply pump pressure very low error 1 818
Failure code [CA689] Engine Ne speed sensor error 822
Failure code [CA731] Engine Bkup speed sensor phase error 824
Failure code [CA757] All continuous data lost error 825
Failure code [CA778] Engine Bkup speed sensor error 826
Troubleshooting by failure code, Part 3 829
Failure code [CA1633] KOMNET datalink timeout error 831
Failure code [CA2185] Throttle sensor power supply voltage high error 832
Failure code [CA2186] Throttle sensor power supply voltage low error 834
Failure code [CA2249] Supply pump pressure very low error 2 836
Failure code [CA2555] Intake air heater relay open circuit error 838
Failure code [CA2556] Intake air heater relay short circuit error 840
Failure code [D19HKB] Stop lamp relay output system: Short circuit 842
Failure code [D5ZKKZ] Front brake cut-off solenoid valve: Disconnection or short circuit 844
Failure code [DAF9KM] Machine monitor: Wrong operation or wrong setting 846
Failure code [DAFRKR] Abnormal CAN communication (machine monitor): Abnormal communication 847
Failure code [DAQ0KK] Transmission controller direct power supply: Lowering of source voltage 848
Failure code [DAQ0KT] Transmission controller nonvolatile memory: Abnormality in controller 850
Failure code [DAQ2KK] Transmission controller solenoid power source: Power source voltage too low 851
Failure code [DAQ9KQ] Transmission controller: Disagreement of model selection 852
Failure code [DAQRKR] Abnormal CAN communication (Transmission): Abnormal communication 853
Failure code [DAQRMA] Transmission controller option setting: Malfunction 858
Failure code [DB10KT] Retarder controller nonvolatile memory: Abnormality in controller 859
Failure code [DB12KK] Retarder controller solenoid power source: Power source voltage too low 860
Failure code [DB13KK] Retarder controller direct power source: Power source voltage too low 862
Failure code [DB19KQ] Retarder controller model selection signal: Disagreement of model selection signals 864
Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled 866
Failure code [DB1RMA] Retarder controller option setting: Defective function 870
Failure code [DB1SKQ] Model selection: Wrong information 871
Failure code [DB2RKR] CAN communication (engine controller): Communication disabled 872
Failure code [DBB0KK] PLM controller: Low source voltage (input) or PLM controller_LED display: “n9” → “01” 878
Failure code [DBB0KQ] PLM controller: Disagreement of model selection signals or PLM controller_LED display: “nF” → “11” 880
Failure code [DBB3KK] PLM controller battery power supply: Low source voltage (input) or PLM controller_LED display: “n9” → “05” 882
Failure code [DBB6KP] PLM controller 24V power supply output: Low output voltage or PLM controller_LED display: “n9” → “02” 884
Failure code [DBBQKR] PLM controller CAN communication: Defective communication or PLM controller_LED display: “n8” → “02” 886
Failure code [DBBRKR] Abnormal CAN communication (PLM) : Defective communication 887
Failure code [DBC9KQ] Disagreement of model selection (ABS controller) 888
Failure code [DBCRMA] Disagreement of option setting (ABS controller) 889
Failure code [DDD7KX] Trouble in travel speed setting switch system: Out of input signal range (If equipped) 890
Failure code [DDD8KA] ARSC system switch system: Disconnection 892
Failure code [DDD8KB] ARSC system switch system: Short circuit 894
Failure code [DDDAKA] ASR system switch: Disconnection (If equipped) 896
Failure code [DDDAKB] ASR system switch: Short circuit 898
Failure code [DDTHKA] Hi clutch fill switch: Disconnection 900
Failure code [DDTJKA] Lo clutch fill switch: Disconnection 902
Failure code [DDTKKA] 1st clutch fill switch: Disconnection 903
Failure code [DDTLKA] 2nd clutch fill switch: Disconnection 904
Failure code [DDTMKA] 3rd clutch fill switch: Disconnection 905
Failure code [DDTNKA] R clutch fill switch: Disconnection 906
Failure code [DDTPKA] 4th clutch fill switch : Disconnection 907
Failure code [DF10KA] Gear shift lever: Disconnection 908
Failure code [DF10KB] Gear shift lever: Short circuit 911
Failure code [DGF1KX] Transmission oil temperature sensor: Out of input signal range 914
Failure code [DGR2KZ] Retarder oil temperature sensor : Disconnection or short circuit 916
Failure code [DGR6KX] Steering oil temperature sensor: Input signal out of range 918
Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range 920
Troubleshooting by failure code, Part 4 923
Failure code [DHP4KY] Short circuit in suspension pressure sensor system (Front right) or PLM controller_LED display: “n5” → “44” 926
Failure code [DHP4KZ] Disconnection or ground fault in suspension pressure sensor system (Front right) or PLM controller_LED display: “n5” → “43” 928
Failure code [DHP5KY] Short circuit in suspension pressure sensor system (Front left) or PLM controller_LED display: “n5” → “54” 930
Failure code [DHP5KZ] Disconnection or ground fault in suspension pressure sensor system (Front left) or PLM controller_LED display: “n5” → “53” 932
Failure code [DHP6KA] (Suspension pressure sensor system (Rear right): Disconnection) 934
Failure code [DHP6KX] (Failure in suspension pressure sensor system trouble (Rear right): Out of input signal range) 936
Failure code [DHP6KY] Suspension pressure sensor system: Short circuit (Right rear) or PLM controller_LED display: “n5” → “64” 938
Failure code [DHP6KZ] Suspension pressure sensor system: Disconnection or ground fault (Right rear) or PLM controller_LED display: “n5” → “63” 940
Failure code [DHP7KA] (Suspension pressure sensor system (Rear left): Disconnection) 942
Failure code [DHP7KX] (Failure in suspension pressure sensor system trouble (Rear left): Out of input signal range) 944
Failure code [DHP7KY] Suspension pressure sensor system: Short circuit (Left rear) or PLM controller_LED display: “n5” → “74” 946
Failure code [DHP7KZ] Suspension pressure sensor system: Disconnection or ground fault (Left rear) or PLM controller_LED display: “n5” → “73” 948
Failure code [DHT5KX] (Torque converter oil pressure sensor: Out of input signal range) 950
Failure code [DHT5L6] (Torque converter oil pressure sensor: Disagreement of run and stop condition with signal) 952
Failure code [DHU2KX] (Front accumulator oil pressure sensor: Out of input signal range) 954
Failure code [DHU3KX] (Rear accumulator oil pressure sensor: Out of input signal range) 956
Failure code [DJF1KA] (Fuel level sensor: Disconnection) 958
Failure code [DK30KX] Trouble in steering angle potentiometer 959
Failure code [DK51L5] (Retarder lever potentiometer: Potentiometer signal is inconsistent with switch signal) 960
Failure code [DK52KX] (Failure in hoist lever potentiometer 1: Out of input signal range) 964
Failure code [DK53L8] (Failure in hoist lever potentiometer 2: Disagreement of analog signal) 966
Failure code [DK54KX] (Body positioner sensor: Out of input signal range) 968
Failure code [DKD0L6] (Failure in steering speed sensor: Disagreement of run and stop condition with signal) (If equipped) 970
Failure code [DKH0KX] (Pitch angle sensor: Out of input signal range) (If equipped) 972
Failure code [DKH1KX] Abnormality in clinometer sensor or PLM controller_LED display: “n4” → “33” 974
Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection) 976
Failure code [DLF1LC] (Transmission input shaft speed sensor: Disagreement of revolution speed signal) 978
Failure code [DLF2KA] (Transmission intermediate shaft speed sensor: Disconnection) 980
Failure code [DLF2LC] (Transmission intermediate shaft speed sensor: Disagreement of revolution speed signal) 982
Failure code [DLF8KA] Disconnection in wheel speed sensor (Right rear) 984
Failure code [DLF8LC] Trouble in wheel speed sensor system (Right rear) 985
Failure code [DLF9KA] Disconnection in wheel speed sensor (Left rear) 986
Failure code [DLF9LC] Trouble in wheel speed sensor system (Left rear) 987
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection) 988
Failure code [DLT3LC] (Transmission output shaft speed sensor: Disagreement of revolution speed signal) (If equipped) 990
Failure code [DLT4KA] (Transmission output shaft speed sensor: Disconnection) (If equipped) 992
Failure code [DLT4MA] (Transmission output shaft speed sensor: Malfunction) 994
Failure code [DV00KB] (Warning buzzer output: Short circuit) 996
Failure code [DW35KZ] (Failure in output system of auto suspension solenoid 1: Disconnection or short circuit) (If equipped) 998
Failure code [DW36KZ] (Failure in output system of auto suspension solenoid 2: Disconnection or short circuit) (If equipped) 1000
Failure code [DW72KZ] (Failure in kick-out solenoid output system: Disconnection or short circuit) 1002
Failure code [DW73KZ] (Failure in hoist select valve output system: Disconnection or short circuit) 1004
Failure code [DW78KZ] (Failure in rear brake BCV command output system: Disconnection or short circuit) 1006
Failure code [DWNBK4] Trouble in ASR shut-off valve (Valve keeps operating) 1008
Failure code [DWNBKA] Disconnection in ASR shut-off valve output circuit 1010
Failure code [DWNBKB] Ground fault in ASR shut-off valve output circuit 1012
Failure code [DWNBKY] Short circuit in ASR shut-off valve output circuit 1014
Failure code [DWNBMA] Trouble in ASR shut-off valve (Valve does not operate) 1015
Failure code [DX11K4] (Rear brake proportional pressure reducing solenoid valve: Out of control) 1016
Failure code [DX11KA] (Rear brake proportional pressure reducing solenoid valve output circuit: Disconnection) 1018
Failure code [DX11KB] (Rear brake proportional pressure reducing solenoid valve: Short circuit) 1019
Failure code [DX11KY] (Rear brake proportional pressure reducing solenoid valve: Short circuit to power source line) 1020
Failure code [DX11MA] (Rear brake proportional pressure reducing solenoid valve: Malfunction) 1022
Failure code [DX13KA] (Output circuit of hoist EPC valve: Disconnection) 1024
Failure code [DX13KB] (Output circuit of hoist EPC valve: Short circuit) 1026
Failure code [DX13KY] (Output circuit of hoist EPC valve: Short circuit with power source line) 1028
Troubleshooting by failure code, Part 5 1031
Failure code [DX17K4] Trouble in ASR proportional pressure reducing solenoid valve (right) (Valve keeps operating) 1034
Failure code [DX17KA] Disconnection in ASR proportional pressure reducing solenoid valve (right) output circuit 1036
Failure code [DX17KB] Ground fault in ASR proportional pressure reducing solenoid valve (right) output circuit 1038
Failure code [DX17KY] Short circuit in ASR proportional pressure reducing solenoid valve (right) output circuit 1040
Failure code [DX17MA] Trouble in ASR proportional pressure reducing solenoid valve (right) (Valve does not operate) 1041
Failure code [DX18K4] Trouble in ASR proportional pressure reducing solenoid valve (left) (Valve keeps operating) 1042
Failure code [DX18KA] Disconnection in ASR proportional pressure reducing solenoid valve (left) output circuit 1044
Failure code [DX18KB] Ground fault in ASR proportional pressure reducing solenoid valve (left) output circuit 1046
Failure code [DX18KY] Short circuit in ASR proportional pressure reducing solenoid valve (left) output circuit 1048
Failure code [DX18MA] Trouble in ASR proportional pressure reducing solenoid valve (left) (Valve does not operate) 1049
Failure code [DXH1KA] Lockup clutch solenoid output circuit: Disconnection 1050
Failure code [DXH1KB] Lock-up clutch solenoid output circuit: Short circuit 1052
Failure code [DXH1KY] Lockup clutch solenoid output circuit: Short circuit to power source line 1053
Failure code [DXH2KA] Hi clutch solenoid output circuit: Disconnection 1054
Failure code [DXH2KB] Hi clutch solenoid output circuit: Short circuit 1056
Failure code [DXH2KY] Hi clutch solenoid output circuit: Short circuit to power source line 1058
Failure code [DXH3KA] Lo clutch solenoid output circuit: Disconnection 1060
Failure code [DXH3KB] Lo clutch solenoid output circuit: Short circuit 1062
Failure code [DXH3KY] Lo clutch solenoid output circuit: Short circuit in power source line 1064
Failure code [DXH4KA] 1st clutch solenoid output circuit: Disconnection 1066
Failure code [DXH4KB] 1st clutch solenoid output circuit: Short circuit 1068
Failure code [DXH4KY] 1st clutch solenoid output circuit: Short circuit to power source line 1070
Failure code [DXH5KA] 2nd clutch solenoid output circuit: Disconnection 1072
Failure code [DXH5KB] 2nd clutch solenoid output circuit: Short circuit 1074
Failure code [DXH5KY] 2nd clutch solenoid output circuit: Short circuit in power source line 1076
Failure code [DXH6KA] 3rd clutch solenoid output circuit: Disconnection 1078
Failure code [DXH6KB] 3rd clutch solenoid output circuit: Short circuit 1080
Failure code [DXH6KY] 3rd clutch solenoid output circuit: Short circuit to power source line 1082
Failure code [DXH7KA] R clutch solenoid output circuit: Disconnection 1084
Failure code [DXH7KB] R clutch solenoid output circuit: Short circuit 1086
Failure code [DXH7KY] R clutch solenoid output circuit: Short circuit to power source line 1087
Failure code [DXHHKA] 4th clutch solenoid output circuit: Disconnection 1088
Failure code [DXHHKB] 4th clutch solenoid output circuit: Short circuit 1090
Failure code [DXHHKY] 4th clutch solenoid output circuit: Short circuit to power source line 1092
Troubleshooting of electrical system (E-mode) 1095
Fuse locations 1097
E-1 Engine does not start 1101
E-2 Automatic preheating does not operate 1104
E-3 Machine monitor does not display all, when starting switch is turned ON 1108
E-4 Machine monitor does not operate when starting switch is OFF 1110
E-5 Alarm buzzer does not stop sounding 1112
E-6 Gauges of machine monitor, caution lamps or character display section do not display properly 1114
E-7 A selection of the display in character display section cannot be changed 1115
E-8 Power mode selecting function does not operate properly 1118
E-9 AISS function does not operate properly 1119
E-10 Seat belt caution lamp does not display properly 1120
E-11 Turn signal lamp or turning lamp (hazard lamp) do not work properly 1121
E-12 Night illumination (lighting) does not work properly 1124
E-13 Emergency steering does not operate 1133
E-14 KOMTRAX system does not operate normally 1138
E-15 Electric priming pump does not operate or does not stop automatically 1140
Troubleshooting of hydraulic and mechanical system (H-mode) 1143
Contents of troubleshooting table 1145
H-1 Machine does not start 1146
H-2 Machine does not travel smoothly (hunting) 1148
H-3 Lockup cannot be cancelled 1148
H-4 Excessive shock when starting or shifting 1149
H-5 Transmission does not shift up 1150
H-6 Machine lacks power or speed when traveling 1151
H-7 Time lag is excessive when starting or shifting gear 1153
H-8 Torque converter oil temperature is high 1154
H-9 Torque converter oil pressure is low 1155
H-10 Front brake is ineffective 1156
H-11 Rear brake is ineffective 1157
H-12 Steering wheel is heavy 1158
H-13 Steering wheel does not work 1159
H-14 Steering wheel vibrates 1160
H-15 Dump body lifting speed is slow 1161
H-16 Dump body does not work 1162
H-17 Excessive hydraulic drift of dump body 1163
Troubleshooting of mechanical system (S-mode) 1165
Method of using troubleshooting chart 1167
S-1 Starting performance is poor 1170
S-2 Engine does not start 1171
S-3 Engine does not pick up smoothly 1174
S-4 Engine stops during operations 1175
S-5 Engine does not rotate smoothly 1176
S-6 Engine lacks output (or lacks power) 1177
S-7 Exhaust gas color is black (incomplete combustion) 1178
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1179
S-9 Oil becomes contaminated quickly 1180
S-10 Fuel consumption is excessive 1181
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 1182
S-12 Oil pressure drops 1183
S-13 Oil level rises (Entry of coolant/fuel) 1184
S-14 Coolant temperature becomes too high (overheating) 1185
S-15 Abnormal noise is made 1186
S-16 Vibration is excessive 1187
S-17 Air cannot be bled from fuel circuit 1188
50 Disassembly and assembly 1191
General information on disassembly and assembly 1191
Precautions before work 1192
How to read this manual 1193
Coating materials list 1195
Special tool list 1198
Sketches of special tools 1201
Engine and cooling system 1205
Removal and installation of engine assembly 1206
Removal and installation of radiator assembly 1212
Removal and installation of output shaft assembly 1218
Disassembly and assembly of output shaft assembly 1220
Removal and installation of fuel supply pump assembly 1223
Removal and installation of fuel injector assembly 1228
Removal and installation of cylinder head assembly 1233
Removal and installation of engine front seal 1241
Removal and installation of engine rear seal 1245
Power train, Part 1 1251
Removal and installation of torque converter and transmission assembly 1252
Disassembly and assembly of torque converter and control valve assembly 1259
Disassembly and assembly of torque converter assembly 1260
Disassembly and assembly of PTO assembly 1268
Disassembly and assembly of transmission assembly 1271
Removal and installation of transmission control valve assembly (ECMV assembly) 1296
Disassembly and assembly of transmission control valve assembly (ECMV assembly) 1297
Power train, Part 2 1303
Removal and installation of differential assembly 1304
Disassembly and assembly of differential assembly 1306
Removal and installation of rear final drive carrier assembly 1319
Disassembly and assembly of rear final drive carrier assembly 1321
Disassembly and assembly of rear final drive assembly 1323
Disassembly and assembly of front wheel hub assembly 1327
Steering system 1333
Disassembly and assembly of steering cylinder assembly 1334
Removal and installation of emergency steering motor pump assembly 1337
Brake system 1339
Removal and installation of front brake caliper pad 1340
Removal and installation of front brake caliper assembly 1341
Disassembly and assembly of front brake caliper assembly 1342
Removal and installation of rear brake assembly 1344
Disassembly and assembly of rear brake assembly 1345
Removal and installation of parking brake pad 1348
Removal and installation of parking brake caliper assembly 1350
Disassembly and assembly of front brake caliper pad assembly 1351
Removal and installation of parking brake spring cylinder assembly 1352
Removal and installation of slack adjuster assembly 1353
Disassembly and assembly of slack adjuster assembly 1354
Undercarriage and frame 1357
Removal and installation of front wheel assembly 1358
Removal and installation of rear wheel assembly 1359
Removal and installation of front suspension cylinder assembly 1360
Disassembly and assembly of front suspension cylinder assembly 1362
Disassembly and assembly of variable damping selector valve assembly 1364
Removal and installation of rear suspension cylinder assembly 1366
Disassembly and assembly of rear suspension cylinder assembly 1367
Hydraulic system 1371
Disassembly and assembly of hoist cylinder assembly 1372
Body 1379
Removal and installation of body assembly 1380
Cab and its attachments 1385
Disassembly and assembly of operator’s seat assembly 1386
Removal and installation of air conditioner unit assembly 1395
Electrical system 1399
Removal and installation of engine controller assembly 1400
Removal and installation of transmission controller assembly 1401
Removal and installation of retarder controller assembly 1402
90 Diagrams and drawings 1405
Hydraulic diagrams and drawings 1405
Power train hydraulic circuit diagram 1406
Steering and hoist hydraulic circuit diagram HD325-7R Serial No 11001 _ 11023 HD405-7R Serial No 11001 _ 11023 1407
Steering and hoist hydraulic circuit diagram HD325-7R Serial No 11024 – HD405-7R Serial No 11024 – 1409
Brake hydraulic circuit diagram 1411
Electrical diagrams and drawings 1415
Electrical circuit diagram for inside cab (1/5) 1417
Electrical circuit diagram for inside cab (2/5) 1419
Electrical circuit diagram for inside cab (3/5) 1421
Electrical circuit diagram for inside cab (4/5) 1423
Electrical circuit diagram for inside cab (5/5) 1425
Electrical circuit diagram for outside cab (1/3) 1427
Electrical circuit diagram for outside cab (2/3) 1429
Electrical circuit diagram for outside cab (3/3) 1431
Air conditioner electrical circuit diagram 1433
Payload meter electrical circuit diagram 1435
Connectors table and arrangement drawing 1437

IMAGES PREVIEW OF THE MANUAL:

S.V  25/12/24