Komatsu Mining Dump Trucks 3.75 GB PDF Updated 2022 Shop Manuals, Operator & Maintenance Manual Complete Set – PDF DOWNLOAD
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Komatsu Mining Dump Trucks 3.75 GB PDF Updated 2022 Shop Manuals, Operator & Maintenance Manual Complete Set – PDF DOWNLOAD
Description
Komatsu Mining Dump Trucks 3.75 GB PDF Updated 2022 Shop Manuals, Operator & Maintenance Manual Complete Set – PDF DOWNLOAD
FILE DETAILS:
Komatsu Mining Dump Trucks 3.75 GB PDF Updated 2022 Shop Manuals, Operator & Maintenance Manual Complete Set – PDF DOWNLOAD
Size: 3.75 Gb
Languages: EN (English)
Format: PDF
Brand: Komatsu
Markets: USA, JPN, EU
Types of Vehicle: Mining Rigid Dump Trucks
Quantity of CD: 1 DVD
Updated: 2022
IMAGES PREVIEW OF THE MANUAL:
DETAIL CONTENTS:
Komatsu Mining Dump Trucks 3.75 GB PDF Updated 2022 Shop Manuals, Operator & Maintenance Manual Complete Set – PDF DOWNLOAD
Operation & Maintenance Manual
Field Assembly Instruction
Shop Manual
Electric Circuit Diagram
Hydraulic Circuit Diagram
Detail Contents:
170D(USA)
325M(USA)
330M (USA)
730E-10
830E-5
860E-1K
930E-4SE
930E-5
960E-2K
980E-5
HD320-3
HD325-3
HD325-5
HD325-6
HD325-6W
HD325-7
HD325-7R
HD325-8
HD325-8E0
HD405-6
HD405-7
HD405-7R
HD405-8
HD405-8E0
HD465-5
HD465-8
HD465-8E0
HD605-5
HD605-8
HD605-8E0
HD785-5
HD785-8
HD785-8E0
HM300-5
HM300-5E0
HM400-5
HM400-5E0
170D(USA)\170D(USA) SN AFE28-A-UP
170D(USA)\170D(USA) SN AFE28-A-UP\DG534 Operation & Maintena.PDF
170D(USA)\170D(USA) SN AFE28-A-UP\DG536-1 Shop Manual.PDF
325M(USA)\325M(USA) SN BFA30-AA-BFA30-CK
325M(USA)\325M(USA) SN BFA30-AA-BFA30-CK\DG611 Shop Manual.PDF
330M (USA)\DG666 Shop Manual.PDF
330M (USA)\DG745 Operation & Maintenance Manual.PDF
730E-10\CEAM034506 Operation & Maintenance Manual.pdf
730E-10\CEAW012006 Field Assembly Instruction.pdf
730E-10\CEBM033405 Shop Manual.pdf
830E-5\CEAM032209 Operation & Maintenance Manual.pdf
830E-5\CEAW008922 Field Assembly Instruction.pdf
830E-5\CEBM032107 Shop Manual.pdf
860E-1K\CEAM031802 Operation & Maintenance Manual.pdf
860E-1K\CEAW007201 Field Assembly Instruction.pdf
860E-1K\CEBM022007 Shop Manual.pdf
930E-4SE\CEAM031505 Operation & Maintenance Manual.pdf
930E-4SE\CEAW005000 Field Assembly Instruction.pdf
930E-4SE\CEBM030102 Shop Manual.pdf
930E-5\CEAM035500 Operation & Maintenance Manual.pdf
930E-5\CEAW010622 Field Assembly Instruction.pdf
930E-5\CEBM036500 Shop Manual.pdf
960E-2K\CEAM028204 Operation & Maintenance Manual.pdf
960E-2K\CEAW006511 Field Assembly Instruction.pdf
960E-2K\CEBM028401 Shop Manual.pdf
980E-5\CEAM033902 Shop Manual.pdf
980E-5\CEAM035603 Operation & Maintenance Manual.pdf
980E-5\CEAW013301 Field Assembly Instruction.pdf
HD320-3\SEAM566D01 Operation & Maintenance Manual.PDF
HD320-3\SEBM0566D03 Shop Manual.PDF
HD325-3\SEAM566D01 Operation & Maintenance Manual.PDF
HD325-3\SEBM0566D03 Shop Manual.PDF
HD325-5\SEAM05660501 Operation & Maintenance Manual.PDF
HD325-5\SEBM05660510 Shop Manual.PDF
HD325-6\SEAM000817T Operation & Maintenance Manual.PDF
HD325-6\SEAT000903 Operation & Maintenance Manual.PDF
HD325-6\SEBM015115 Shop Manual.PDF
HD325-6\SEBMW00401 Shop Manual.PDF
HD325-6W\SEAM000817T Operation & Maintenance Manual.PDF
HD325-6W\SEBM015115 Shop Manual.PDF
HD325-7\SEN00486-19 Shop Manual.pdf
HD325-7\TEN00807-09 Operation & Maintenance Manual.pdf
HD325-7R\GEN00084-00 Operation & Maintenance Manual.pdf
HD325-7R\SEN02373-12 Shop Manual.pdf
HD325-8\GEN00151-07 Field Assembly Instruction.pdf
HD325-8\SEN06618-12 Shop Manual.pdf
HD325-8\TEN00946-03 Operation & Maintenance Manual.pdf
HD325-8E0\EENAM03790_HD325_405-8E0_1904 Operation & Maintenance Manual.pdf
HD325-8E0\GEN00189-04 Field Assembly Instruction.pdf
HD325-8E0\SEN06745-06 Shop Manual.pdf
HD405-6\SEAM000817T Operation & Maintenance Manual.PDF
HD405-6\SEAT000903 Operation & Maintenance Manual.PDF
HD405-6\SEBM015115 Shop Manual.PDF
HD405-6\SEBMW00401 Shop Manual.PDF
HD405-7\SEN00486-19 Shop Manual.pdf
HD405-7\TEN00807-09 Operation & Maintenance Manual.pdf
HD405-7R\GEN00084-00 Operation & Maintenance Manual.pdf
HD405-7R\SEN02373-12 Shop Manual.pdf
HD405-8\GEN00189-04 Field Assembly Instruction.pdf
HD405-8\SEN06745-06 Shop Manual.pdf
HD405-8\TEN00946-03 Operation & Maintenance Manual.pdf
HD405-8E0\EENAM03790_HD325_405-8E0_1904 Operation & Maintenance Manual.pdf
HD405-8E0\GEN00189-04 Field Assembly Instruction.pdf
HD405-8E0\SEN06745-06 Shop Manual.pdf
HD465-5\SEAT000903 Operation & Maintenance Manual.PDF
HD465-5\SEBMW00401 Shop Manual.PDF
HD465-8\EENAM03552_HD465_605-8_1808 Operation & Maintenance Manual.pdf
HD465-8\GEN00153-07 Field Assembly Instruction.pdf
HD465-8\SEN06605-19 Shop Manual.pdf
HD465-8E0\EENAM03870_HD465_605-8E0_1906 Field Assembly Instruction.pdf
HD465-8E0\GEN00198-03 Operation & Maintenance Manual.pdf
HD465-8E0\SEN06768-08 Shop Manual.pdf
HD605-5\SEAT000903 Operation & Maintenance Manual.PDF
HD605-5\SEBMW00401 Shop Manual.PDF
HD605-8\EENAM03870_HD465_605-8E0_1906 Operation & Maintenance Manual.pdf
HD605-8\GEN00198-03 Field Assembly Instruction.pdf
HD605-8\SEN06768-08 Shop Manual.pdf
HD605-8E0\EENAM03870_HD465_605-8E0_1906 Operation & Maintenance Manual.pdf
HD605-8E0\GEN00198-03 Field Assembly Instruction.pdf
HD605-8E0\SEN06768-08 Shop Manual.pdf
HD785-5\SEAT000903 Operation & Maintenance Manual.PDF
HD785-5\SEBMW00401 Shop Manual.PDF
HD785-8\GEN00183-05 Field Assembly Instruction.pdf
HD785-8\SEN06772-11 Shop Manual.pdf
HD785-8\TEN01012-02 Operation & Maintenance Manual.pdf
HD785-8E0\EENAM04000_HD785-8E0_2007 Operation & Maintenance Manual.pdf
HD785-8E0\FEN04789-00-MA4 Parts Book.pdf
HD785-8E0\GEN00209-02 Field Assembly Instruction.pdf
HD785-8E0\SEN06801-06 Shop Manual.pdf
HM300-5\GEN00190-03 Field Assembly Instruction.pdf
HM300-5\PEN01447-04 Operation & Maintenance Manual.pdf
HM300-5\SEN06511-20 Shop Manual.pdf
HM300-5E0\EENAM03880_HM300-5E0_1906 Operation & Maintenance Manual.pdf
HM300-5E0\SEN06746-10 Shop Manual.pdf
HM400-5\GEN00163-05 Field Assembly Instruction.pdf
HM400-5\PEN01001-05 Operation & Maintenance Manual.pdf
HM400-5\SEN06519-19 Shop Manual.pdf
HM400-5E0\GEN00191-02 Field Assembly Instruction.pdf
HM400-5E0\SEN06747-10 Shop Manual.pdf
HM400-5E0\TEN00618-18 Operation & Maintenance Manual.pdf
DESCRIPTION:
Komatsu Mining Dump Trucks 3.75 GB PDF Updated 2022 Shop Manuals, Operator & Maintenance Manual Complete Set – PDF DOWNLOAD
GENERAL PRECAUTIONS:
2.When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
- Always wear safety glasses when hitting parts with a hammer.
- Always wear safety glasses when grinding parts with a grinder, etc.
6. 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 or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
7. Before adding or making any repairs, park the machine on hard, level ground, and block the wheels to
prevent the machine from moving.
8. Before starting work, lower outrigger, bucket or any other work equipment to the ground. If this is not possible,
use blocks to prevent the work equipment from falling down. In addition, be sure to lock all the control levers and hang warning sign on them.
9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting
work.
10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine.Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
TABLE OF CONTENTS:
Komatsu Mining Dump Trucks 3.75 GB PDF Updated 2022 Shop Manuals, Operator & Maintenance Manual Complete Set – PDF DOWNLOAD
MAIN MENU………………………………………………………………………………………………………………………….. 0
COVER……………………………………………………………………………………………………………………………… 1
CONTENTS…………………………………………………………………………………………………………………………… 2
SAFETY…………………………………………………………………………………………………………………………….. 9
FOREWARD…………………………………………………………………………………………………………………………… 11
GENERAL………………………………………………………………………………………………………………………… 11
HOW TO READ THE SHOP MANUAL………………………………………………………………………………………………………. 12
HOISTING INSTRUCTIONS……………………………………………………………………………………………………………. 13
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER…………………………………………………………………………… 14
COATING MATERIALS……………………………………………………………………………………………………………….. 16
STANDARD TIGHTENING TORQUE……………………………………………………………………………………………………….. 18
ELECTRIC WIRE CODE………………………………………………………………………………………………………………. 21
CONVERSION TABLE………………………………………………………………………………………………………………… 22
UNITS………………………………………………………………………………………………………………………….. 28
01 GENERAL…………………………………………………………………………………………………………………………. 29
GENERAL ASSEMBLY DRAWING…………………………………………………………………………………………………………. 30
SPECIFICATIONS………………………………………………………………………………………………………………….. 32
WEIGHT TABLE……………………………………………………………………………………………………………………. 39
LIST OF LUBRICANT AND WATER………………………………………………………………………………………………………. 42
10 STRUCTURE AND FUNCTION……………………………………………………………………………………………………………. 44
RADIATOR, TORQUE CONVERTER, OIL COOLER, AFTER COOLER………………………………………………………………………………… 46
POWER TRAIN SKELETON…………………………………………………………………………………………………………….. 47
OUTPUT SHAFT……………………………………………………………………………………………………………………. 51
DRIVE SHAFT…………………………………………………………………………………………………………………….. 52
TORQUE CONVERTER, TRANSMISSION AND BRAKE COOLING HYDRAULIC PIPING…………………………………………………………………….. 53
HYDRAULIC CIRCUIT DIAGRAM FOR TORQUE CONVERTER, TRANSMISSION AND BRAKE COOLING…………………………………………………………. 56
TORQUE CONVERTER, TRANSMISSION AND BRAKE COOLING HYRDAULIC CIRCUIT SCHEMATICS………………………………………………………….. 57
TORQUE CONVERTER………………………………………………………………………………………………………………… 58
TORQUE CONVERTER VALVE…………………………………………………………………………………………………………… 62
LOCKUP SOLENOID VALVE……………………………………………………………………………………………………………. 67
TRANSMISSION……………………………………………………………………………………………………………………. 68
TRANSMISSION VALVE………………………………………………………………………………………………………………. 73
ECMV (ELECTRONIC CONTROL MODULATION VALVE)…………………………………………………………………………………………. 75
FRONT AXLE……………………………………………………………………………………………………………………… 80
REAR AXLE………………………………………………………………………………………………………………………. 84
DIFFERENTIAL……………………………………………………………………………………………………………………. 85
FINAL DRIVE…………………………………………………………………………………………………………………….. 87
FRONT BRAKE…………………………………………………………………………………………………………………….. 88
REAR BRAKE……………………………………………………………………………………………………………………… 89
PARKING BRAKE…………………………………………………………………………………………………………………… 90
WHEELS…………………………………………………………………………………………………………………………. 91
REAR AXLE SUPPORT……………………………………………………………………………………………………………….. 92
STEERING SYSTEM…………………………………………………………………………………………………………………. 93
STEERING WHEEL………………………………………………………………………………………………………………….. 94
STEERING LINKAGE………………………………………………………………………………………………………………… 95
SUSPENSION SYSTEM……………………………………………………………………………………………………………….. 97
SUSPENSION CYLINDER……………………………………………………………………………………………………………… 99
AIR PIPING……………………………………………………………………………………………………………………… 104
AIR CIRCUIT DIAGRAM……………………………………………………………………………………………………………… 106
AIR GOVERNOR……………………………………………………………………………………………………………………. 108
AIR DRYER………………………………………………………………………………………………………………………. 110
SAFETY VALVE……………………………………………………………………………………………………………………. 113
CHECK VALVE…………………………………………………………………………………………………………………….. 113
DOUBLE CHECK VALVE………………………………………………………………………………………………………………. 114
HAND BRAKE VALVE………………………………………………………………………………………………………………… 115
BRAKE VALVE…………………………………………………………………………………………………………………….. 117
EMERGENCY BRAKE CONTROL VALVE…………………………………………………………………………………………………….. 120
PARKING BRAKE CONTROL VALVE………………………………………………………………………………………………………. 123
RELAY VALVE…………………………………………………………………………………………………………………….. 125
PARKING BRAKE RELAY VALVE………………………………………………………………………………………………………… 128
FRONT BRAKE CHAMBER……………………………………………………………………………………………………………… 130
REAR BRAKE CHAMBER………………………………………………………………………………………………………………. 131
PARKING BRAKE CHAMBER……………………………………………………………………………………………………………. 134
SLACK ADJUSTER………………………………………………………………………………………………………………….. 135
FRONT DRIVE HYDRAULIC CIRCUIT DIAGRAM……………………………………………………………………………………………… 138
FRONT DRIVE PISTON PUMP………………………………………………………………………………………………………….. 141
FRONT DRIVE PISTON MOTOR…………………………………………………………………………………………………………. 143
CHARGE PUMP OIL FILTER…………………………………………………………………………………………………………… 145
HYDRAULIC PIPING………………………………………………………………………………………………………………… 147
HYDRAULIC CIRCUIT DIAGRAM………………………………………………………………………………………………………… 150
HYDRAULIC CIRCUIT SCHEMATICS……………………………………………………………………………………………………… 151
DUMP BODY CONTROL……………………………………………………………………………………………………………….. 152
HYDRAULIC TANK, FILTER…………………………………………………………………………………………………………… 155
DEMAND VALVE……………………………………………………………………………………………………………………. 158
STEERING CONTROL VALVE…………………………………………………………………………………………………………… 162
CROSS-OVER RELIEF VALVE………………………………………………………………………………………………………….. 166
HOIST VALVE…………………………………………………………………………………………………………………….. 167
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB………………………………………………………………………………………….. 168
DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB…………………………………………………………………………………………. 169
FRONT BRAKE CUT-OFF VALVE………………………………………………………………………………………………………… 170
OVERRUN PREVENTION VALVE ………………………………………………………………………………………………………… 171
EXHAUST BRAKE VALVE……………………………………………………………………………………………………………… 171
HORN VALVE……………………………………………………………………………………………………………………… 172
WIPER SWITCH……………………………………………………………………………………………………………………. 172
WIPER RELAY…………………………………………………………………………………………………………………….. 173
AIR CONDITIONER…………………………………………………………………………………………………………………. 174
PIPING DIAGRAM………………………………………………………………………………………………………………. 174
ELECTRICAL CIRCUIT DIAGRAM……………………………………………………………………………………………………. 176
REFRIGERANT CIRCUIT DIAGRAM…………………………………………………………………………………………………… 178
UNIT……………………………………………………………………………………………………………………….. 179
RECEIVER DRYER………………………………………………………………………………………………………………. 179
CONDENSER…………………………………………………………………………………………………………………… 180
COMPRESSOR………………………………………………………………………………………………………………….. 180
ENGINE CONTROL SYSTEM……………………………………………………………………………………………………………. 181
EXHAUST BRAKE…………………………………………………………………………………………………………………… 184
SYSTEM DIAGRAM………………………………………………………………………………………………………………. 184
AUTOMATIC RETARD SPEED CONTROL SYSTEM (OP)…………………………………………………………………………………………. 187
SYSTEM DRAWING………………………………………………………………………………………………………………. 187
STRUCTURE OF SYSTEM………………………………………………………………………………………………………….. 188
ELECTRICAL CIRCUIT DIAGRAM……………………………………………………………………………………………………. 189
AIR CIRCUIT DIAGRAM………………………………………………………………………………………………………….. 190
AUTOMATIC RETARD SPEED CONTROL………………………………………………………………………………………………… 191
AUTOMATIC RETARD SPEED CONTROLLER……………………………………………………………………………………………… 192
AUTOMATIC SHIFT CONTROL SYSTEM……………………………………………………………………………………………………. 193
SYSTEM DIAGRAM………………………………………………………………………………………………………………. 193
ELECTRICAL CIRCUIT DIAGRAM……………………………………………………………………………………………………. 195
TRANSMISSION CONTROLLER………………………………………………………………………………………………………. 196
CONNECTOR SIGNALS……………………………………………………………………………………………………………. 198
SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES…………………………………………………………………………. 199
AUTOMATIC GEAR SHIFT LINE GRAPH……………………………………………………………………………………………….. 200
SHIFT LEVER SWITCH…………………………………………………………………………………………………………… 202
SENSORS, SWITCHES……………………………………………………………………………………………………………. 203
ENGINE SPEED SENSOR………………………………………………………………………………………………………. 203
TRANSMISSION SPEED SENSOR…………………………………………………………………………………………………. 203
TRANSMISSION OIL TEMPERATURE SENSORS……………………………………………………………………………………….. 203
FILL SWITCH……………………………………………………………………………………………………………… 204
ACCELERATOR SENSOR……………………………………………………………………………………………………….. 204
MODE SELECTOR SWITCH……………………………………………………………………………………………………… 205
SELF-DIAGNOSTIC FUNCTION………………………………………………………………………………………………….. 205
AUTOMATIC EMERGENCY STEERING SYTEM………………………………………………………………………………………………… 206
SYSTEM DIAGRAM………………………………………………………………………………………………………………. 206
ELECTRICAL CIRCUIT DIAGRAM……………………………………………………………………………………………………. 207
FLOW SWITCH…………………………………………………………………………………………………………………. 208
RELAY TIMER…………………………………………………………………………………………………………………. 210
AUTOMATIC SUSPENSION SYSTEM………………………………………………………………………………………………………. 211
STRUCTURE OF SYSTEM………………………………………………………………………………………………………….. 212
SYSTEM CIRCUIT DIAGRAM……………………………………………………………………………………………………….. 213
AUTOMATIC SUSPENSION MODE SELECTION CONTROL…………………………………………………………………………………….. 214
SUSPENSION CONTROLLER………………………………………………………………………………………………………… 215
SENSORS, SWITCHES……………………………………………………………………………………………………………. 216
STEERING ANGLE SENSOR…………………………………………………………………………………………………….. 216
PRESSURE SENSOR………………………………………………………………………………………………………….. 216
SELF-DIAGNOSTIC FUNCTION………………………………………………………………………………………………….. 217
PAYLOAD METER (PRINTER TYPE)……………………………………………………………………………………………………… 218
STRUCTURE OF SYSTEM………………………………………………………………………………………………………….. 218
ELECTRICAL CIRCUIT DIAGRAM……………………………………………………………………………………………………….. 219
PRINCIPLE OF CALCULATION…………………………………………………………………………………………………………. 220
FEATURES OF EQUIPMENT……………………………………………………………………………………………………………. 222
1. PAYLOAD METER…………………………………………………………………………………………………………….. 222
2. PRESSURE SENSOR…………………………………………………………………………………………………………… 225
3. CLINOMETER……………………………………………………………………………………………………………….. 226
4. LAMP DRIVE RELAY………………………………………………………………………………………………………….. 226
SELF-DIAGNOSTIC FUNCTION……………………………………………………………………………………………………… 227
PAYLOAD METER II (CARD TYPE)……………………………………………………………………………………………………… 228
STRUCTURE OF SYSTEM………………………………………………………………………………………………………….. 228
ELECTRICAL CIRCUIT DIAGRAM……………………………………………………………………………………………………. 229
PAYLOAD METER BLOCK DIAGRAM…………………………………………………………………………………………………… 229
PRINCIPLE OF MEASUREMENT……………………………………………………………………………………………………… 230
FEATURES OF EACH DEVICE…………………………………………………………………………………………………… 231
1. PAYLOAD METER II………………………………………………………………………………………………………. 231
LEFT FACE……………………………………………………………………………………………………………. 232
2. PRESSURE SENSOR……………………………………………………………………………………………………….. 259
3. CLINOMETER……………………………………………………………………………………………………………. 260
4. LAMP DRIVE RELAY………………………………………………………………………………………………………. 260
5. SELF-DIAGNOSTIC FUNCTION……………………………………………………………………………………………….. 262
MACHINE MONITOR SYSTEM…………………………………………………………………………………………………………… 268
SYSTEM DRAWING………………………………………………………………………………………………………………. 268
MONITOR PANEL DIAGRAM………………………………………………………………………………………………………… 270
MACHINE MONITOR NORMAL DISPLAY FUNCTIONS……………………………………………………………………………………….. 271
SELF-DIAGNOSTIC FUNCTION WHEN STARTING SWITCH IS OPERATED………………………………………………………………………… 278
TRAVEL SPEED COMPENSATION ROTARY SWITCH………………………………………………………………………………………… 278
ENGINE OIL PRESSURE………………………………………………………………………………………………………….. 279
ENGINE WATER TEMPERATURE SENSOR……………………………………………………………………………………………….. 280
RETARDER OIL TEMPERATURE SENSOR……………………………………………………………………………………………….. 280
TORQUE CONVERTER OIL TEMPERATURE SENSOR………………………………………………………………………………………… 280
AIR PRESSURE SENSOR………………………………………………………………………………………………………….. 280
FUEL LEVEL SENSOR……………………………………………………………………………………………………………. 281
TILT SWITCH…………………………………………………………………………………………………………………. 282
TRANSMISSION OIL FILTER SENSOR………………………………………………………………………………………………… 283
RADIATOR WATER LEVEL SENSOR…………………………………………………………………………………………………… 283
BODY SEATED SWITCH…………………………………………………………………………………………………………… 284
STEERING OIL TEMPERATURE SENSOR……………………………………………………………………………………………….. 285
BRAKE STROKE SENSOR………………………………………………………………………………………………………….. 285
OIL FILTER CAUTION SYSTEM (IF EQUIPPED)……………………………………………………………………………………………. 286
SYSTEM DIAGRAM………………………………………………………………………………………………………………. 286
MONITOR PANEL……………………………………………………………………………………………………………….. 287
CIRCUIT DIAGRAM OF OIL FILTER CAUTION MONITOR…………………………………………………………………………………… 288
ITEMS DISPLAYED BY MONITOR AND FUNCTIONS……………………………………………………………………………………….. 289
FUNCTIONS OF SWITCHES………………………………………………………………………………………………………… 291
HYDRAULIC OIL FILTER SENSOR…………………………………………………………………………………………………… 293
FRONT DRIVE SYSTEM………………………………………………………………………………………………………………. 295
SYSTEM DIAGRAM………………………………………………………………………………………………………………. 295
4-WHEEL DRIVE CONTROLLER…………………………………………………………………………………………………………. 298
ECMV…………………………………………………………………………………………………………………………… 299
SENSORS, SWITCHES……………………………………………………………………………………………………………….. 300
STEERING ANGLE SENSOR (POTENTIOMETER)………………………………………………………………………………………….. 300
HIGH-PRESSURE OIL PRESSURE SENSOR……………………………………………………………………………………………… 303
CLUTCH OIL PRESSURE SENSOR……………………………………………………………………………………………………. 304
WHEEL SPEED SENSOR…………………………………………………………………………………………………………… 305
20 TESTING AND ADJUSTING…………………………………………………………………………………………………………….. 307
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS………………………………………………………………………………………. 310
STANDARD VALUE TABLE FOR CHASSIS………………………………………………………………………………………………….. 312
STANDARD VALUE TABLE FOR ELECTRICAL PARTS………………………………………………………………………………………….. 317
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING…………………………………………………………………………… 335
ADJUSTING VALVE CLEARANCE………………………………………………………………………………………………………… 339
MEASURING COMPRESSION PRESSURE……………………………………………………………………………………………………. 342
MEASURING BLOW-BY……………………………………………………………………………………………………………….. 343
ADJUSTING ALTERNATOR BELT TENSION…………………………………………………………………………………………………. 344
ADJUSTING FAN BELT TENSION……………………………………………………………………………………………………….. 345
MEASURING ENGINE SPEED…………………………………………………………………………………………………………… 347
MEASURING ENGINE OIL PRESSURE…………………………………………………………………………………………………….. 348
MEASURING BOOST PRESSURE…………………………………………………………………………………………………………. 349
MEASURING EXHAUST TEMPERATURE…………………………………………………………………………………………………….. 350
MEASURING EXHAUST GAS COLOR………………………………………………………………………………………………………. 351
TESTING AND ADJUSTING FUEL INJECTION TIMING………………………………………………………………………………………… 352
AIR BLEEDING FROM FUEL SYSTEM…………………………………………………………………………………………………….. 356
CHECKING FOR LEAKAGE IN FUEL SYSTEM……………………………………………………………………………………………….. 359
MEASURING FUEL PRESSURE………………………………………………………………………………………………………….. 360
REALEASING REMAINING PRESSURE IN FUEL SYSTEM……………………………………………………………………………………….. 360
HANDLING EQUIPMENT IN FUEL CIRCUIT………………………………………………………………………………………………… 361
REDUCED CYLINDER MODE OPERATION…………………………………………………………………………………………………… 362
HANDLING OF ENGINE CONTROLLER HIGH CONTROLLER HIGH TENSION CIRCUIT……………………………………………………………………. 363
ADJUSTING ENGINE STOP MOTOR CABLE…………………………………………………………………………………………………. 365
ADJUSTING ACCELERATOR PEDAL………………………………………………………………………………………………………. 366
ADJUSTING ENGINE SPEED SENSOR…………………………………………………………………………………………………….. 367
ADJUSTING TRANSMISSION SPEED SENSOR……………………………………………………………………………………………….. 367
TESTING HYDRAULIC PRESSURE OF TORQUE CONVERTER VALVE………………………………………………………………………………… 368
TESTING ECMV OIL PRESSURE………………………………………………………………………………………………………… 369
TESTING TORQUE CONVERTER STALL SPEED………………………………………………………………………………………………. 371
TESTING BRAKE PRESSURE…………………………………………………………………………………………………………… 372
BLEEDING AIR FROM BRAKE CIRCUIT…………………………………………………………………………………………………… 373
TESTING AND ADJUSTING PARKING BRAKE PERFORMANCE…………………………………………………………………………………….. 374
TESTING WEAR OF FRONT BRAKE PAD…………………………………………………………………………………………………… 375
TESTING WEAR OF FRONT BRAKE DISC………………………………………………………………………………………………….. 375
TESTING WEAR OF REAR BRAKE DISC…………………………………………………………………………………………………… 376
TESTING REAR BRAKE CAUTION SYSTEM…………………………………………………………………………………………………. 377
TESTING AND ADJUSTING SUSPENSION CYLINDER………………………………………………………………………………………….. 379
TESTING AND ADJUSTING SET PRESSURE OF AIR GOVERNOR………………………………………………………………………………….. 385
ADJUSTING HOIST LEVER LINKAGE…………………………………………………………………………………………………….. 386
ADJUSTING BODY POSITIONER………………………………………………………………………………………………………… 389
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING, HOIST CIRCUIT…………………………………………………………………… 390
AIR BLEEDING FROM STEERING CYLINDER……………………………………………………………………………………………….. 392
BLEEDING AIR FROM FRONT DRIVE HYDAULIC CIRCUIT……………………………………………………………………………………… 393
ADJUSTING ELECTRONIC MONITOR …………………………………………………………………………………………………….. 395
SETTING ROTARY SWITCH……………………………………………………………………………………………………………. 396
METHOD OF DELETING DATA FROM TRANSMISSION CONTROLLER MEMORY………………………………………………………………………….. 397
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM………………………………………………………………… 400
PM CLINIC CHECK SHEET……………………………………………………………………………………………………………. 407
TROUBLESHOOTING…………………………………………………………………………………………………………………. 411
POINTS TO REMEMBER WHEN TROUBLESHOOTING………………………………………………………………………………………… 412
SEQUENCE OF EVENTS IN TROUBLESHOOTING………………………………………………………………………………………….. 413
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE………………………………………………………………………………… 414
CHECKS BEFORE TROUBLESHOOTING…………………………………………………………………………………………………. 422
TYPE OF CONNECTOR AND POSITION OF INSTALLATION………………………………………………………………………………….. 424
(HD325-6 SERIAL NO. 5680-6000, HD325-6W SERIAL NO. 5706-6000,HD405-6 SERIAL NO. 1055-2000)……………………………………….. 424
CONNECTOR PIN ALLOCATION CHART………………………………………………………………………………………………… 430
(HD325-6 SERIAL NO. 5680-6000, HD325-6W SERIAL NO. 5706-6000,HD405-6 SERIAL NO. 1055-2000)……………………………………….. 430
TYPE OF CONNECTOR AND POSITION OF INSTALLATION………………………………………………………………………………….. 437
(HD325-6 SERIAL NO. 6001 AND UP, HD325-6W SERIAL NO. 6001 AND UP,HD405-6 SERIAL NO. 2001 AND UP)………………………………….. 437
CONNECTOR PIN ALLOCATION CHART………………………………………………………………………………………………… 444
(HD325-6 SERIAL NO. 6001 AND UP, HD325-6W SERIAL NO. 6001 AND UP,HD405-6 SERIAL NO. 2001 AND UP)………………………………….. 444
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS……………………………………………………………………………………… 450
EXPLANATIONS OF FUNCTIONS (CONTROL MECHANISM)OF ELECTRICAL SYSTEM…………………………………………………………………. 472
MONITOR PANEL USER CODES AND SERVICE MODE FUNCTION………………………………………………………………………………. 478
SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL AND CONTROLLERS………………………………………………………………….. 498
TABLE OF SERVICE CODES AND USER CODES………………………………………………………………………………………….. 505
METHOD OF USING JUDGEMENT TABLES………………………………………………………………………………………………. 517
METHOD OF USING TROUBLESHOOTING CHARTS…………………………………………………………………………………………. 518
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)………………………………………………………………………………………. 521
METHOD OF USING TROUBLESHOOTING CHARTS……………………………………………………………………………………… 522
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…………………………………………………………………. 526
S-2 ENGINE DOES NOT START…………………………………………………………………………………………………. 528
(1) ENGINE DOES NOT TURN………………………………………………………………………………………………. 528
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)………………………………………………… 529
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)………………………………………………. 530
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)……………………………………………………………………… 531
S-4 ENGINE STOPS DURING OPERATIONS…………………………………………………………………………………………. 532
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)……………………………………………………………………………….. 533
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)……………………………………………………………………………………. 534
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)…………………………………………………………………………… 535
S-8 OIL CONSUMPTION IS EXCESSIV (OR EXHAUST SMOKE IS BLUE)……………………………………………………………………. 536
S-9 OIL BECOMES CONTAMINATED QUICKLY……………………………………………………………………………………….. 537
S-10 FUEL CONSUMPTION IS EXCESSIVE…………………………………………………………………………………………. 538
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN……………………………………………………. 539
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)……………………………………………………………….. 540
S-13 OIL LEVEL RISES……………………………………………………………………………………………………… 541
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)………………………………………………………………………… 542
S-15 ABNORMAL NOISE IS MADE……………………………………………………………………………………………….. 543
S-16 VIBRATION IS EXCESSIVE……………………………………………………………………………………………….. 544
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A MODE)……………………………………………………………………….. 545
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM…………………………………………… 548
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE………………………………………………………………… 550
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS………………………………………………………… 570
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM…………………………………………………………………. 572
ABNORMALITY IN POWER SOURCE……………………………………………………………………………………………….. 573
A-1 ………………………………………………………………………………………………………………… 573
A) [OFF] CONTROLLER SELF-DIAGNOSTIC DISPLAY LED DOES NOT LIGHT UP………………………………………………………. 573
B) DROP IN VOLTAGE OF CONTROLLER POWER SOURCE IS DISPLAYED…………………………………………………………….. 574
C) DROP IN VOLTAGE OF BATTERY DIRECT POWER SOURCE IS DISPLAYED…………………………………………………………. 575
D) DROP IN VOLTAGE OF MAIN POWER SOURCE IS DISPLAYED………………………………………………………………….. 576
E) ABNORMALITY IN TRANSMISSION CUT RELAY POWER SOURCE IS DISPLAYED……………………………………………………… 577
A-2 A) ABNORMALITY IN NEUTRAL SAFETY SYSTEM IS DISPLAYED…………………………………………………………………. 578
ABNORMALITY IN CONTROLLER SYSTEM…………………………………………………………………………………………… 579
A-3 DOUBLE ENGAGEMENT FOR CLUTCH IS DISPLAYED……………………………………………………………………………. 579
A-4 ABNORMALITY IN TRANSMISSION [CUT RELAY] SYSTEM IS DISPLAYED……………………………………………………………. 580
A-5 ABNORMALITY IN REAR BRAKE SOLENOID SYSTEM IS DISPLAYED………………………………………………………………… 581
A-6 ABNORMALTIY IN EXHAUST BRAKE SOLENOID SYSTEM IS DISPLAYED……………………………………………………………… 582
ABNORMALITY IN SPEED SENSOR SYSTEM…………………………………………………………………………………………. 583
A-7 ………………………………………………………………………………………………………………… 583
A) DISCONNECTION IN ENGINE SPEED SENSOR [B]SYSTEM IS DISPLAYED OR FAILURE IN ENGINE SPEED SENSOR IS DISPLAYED……………….. 583
B) DISCONNECTION IN INPUT SHAFT SPEED SENSOR SYSTEM IS DISPLAYED OR FAILURE OF INPUT SHAFT SPEED SENSOR IS DISPLAYED…………. 584
C) DISCONNECTION IN INTERMEDIATE SHAFT-SPEED SENSOR SYSTEM IS DISPLAYED OR FAILURE OF INTERMEDIATE SHAFT SPEED SENSOR IS DISP…. 585
D) DISCONNECTION IN TRAVEL SPEED SENSOR (TRANSMISSION OUTPUT SHAFT SPEED SENSOR) SYSTEM IS DISPLAYED OR FAILURE OF OUTPUT SHA…. 586
SPEED SENSOR SYSTEM, CLUTCH SLIPPING……………………………………………………………………………………….. 587
A-8…………………………………………………………………………………………………………………. 587
A) INPUT SHAFT SPEED SENSOR OR H, L CLUTCH SYSTEM IS DISPLAYED…………………………………………………………. 587
B) TRAVEL SPEED SENSOR SYSTEM OR SPEED CLUTCH (1,2,3,4,R) SYSTEM IS DISPLAYED……………………………………………. 588
ABNORMALITY IN MODEL SELECTION SYSTEM………………………………………………………………………………………. 589
A-9…………………………………………………………………………………………………………………. 589
A) ABNORMALITY IN MODEL SELECTION (WIRING HARNESS) IS DISPLAYED………………………………………………………… 589
B) ABNORMALITY IN MODEL SELECTION (ROTARY SWITCH) IS DISPLAYED…………………………………………………………. 590
ABNORMALITY IN SHIFT LEVER SYSTEM………………………………………………………………………………………….. 591
A-10 ……………………………………………………………………………………………………………….. 591
A) SHORT CIRCUIT IN SHIFT LEVER ASSEMBLY POWER SOURCE IS DISPLAYED……………………………………………………… 591
B) SHIFT LEVER POSITION SIGNAL INPUT FOR 2 OR MORE SYSTEMS IS DISPLAYED…………………………………………………. 592
C) SHIFT LEVER POSITION IN NOT INPUT………………………………………………………………………………… 594
A-11 ABNORMALITY IN ACCELERATOR SIGNAL IS DISPLAYED………………………………………………………………………. 596
A-12 ABNORMALITY IN TRANSMISSION OIL TEMPERATURE SENSOR IS DISPLAYED……………………………………………………….. 597
ABNORMALITY IN PRESSURE CONTROL VALVEDE418-1098……………………………………………………………………………… 598
A-13 ……………………………………………………………………………………………………………….. 598
A) FILL SIGNAL (CLUTCH ON) IS DISPLAYED REGARDLESS OF COMMAND………………………………………………………….. 598
B) FILL SIGNAL IS NOT INPUT AND CLUTCH SLIPPING IS DISPLAYED…………………………………………………………… 600
B-1) INSPECTING FILL SIGNAL SYSTEM………………………………………………………………………………. 600
B-2) INSPECTING TRANMISSION INPUT SHAFT SPEED SIGNAL SYSTEM, H, L CLUTCH SYSTEM (INSPECTING CLUTCH SLIPPAGE)…………….. 601
B-3) INSPECTING TRANSMISSION OUTPUT SHAFT SPEED SIGNAL SYSTEM, 1-4, R CLUTCH SYSTEM (INSPECTING CLUTCH SLIPPAGE)…………. 601
A-14 WHEN FILL SIGNAL IS NOT INPUT (FLOW DETECTOR VALVE SYSTEM)……………………………………………………………. 602
A-15 SHORT CIRCUIT IN PRESSURE CONTROL VALVE SOLENOID SYSTEM IS DISPLAYED…………………………………………………… 603
DISCONNECTION IN PRESSURE CONTROL VLAVE SOLENOID SYSTEM IS DISPLAYED……………………………………………………. 603
ABNORMALITY IN SENSOR SYSTEM………………………………………………………………………………………………. 605
A-16 ……………………………………………………………………………………………………………….. 605
A) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM IS DISPLAYED……………………………………………. 605
B) ABNORMALITY IN FUEL LEVEL SENSOR SYSTEM IS DISPLAYED……………………………………………………………….. 606
C) ABNORMALITY IN COOLING WATER TEMPERATURE SENSOR SYTEM IS DISPLAYED…………………………………………………… 607
D) ABNORMALITY IN AIR PRESSURE SENSOR SYSTEM IS DISPLAYED……………………………………………………………… 608
E) ABNORMALITIY IN RETARD BRAKE OIL TEMPERATURE SENSOR SYSTEM IS DISPLAYED………………………………………………. 609
WARNING DISPLAY………………………………………………………………………………………………………….. 610
A-17………………………………………………………………………………………………………………… 610
A) TRANSMISSION FILTER CLOGGED WARNING IS DISPLAYED…………………………………………………………………… 610
B) TILT WARNING IS DISPLAYED……………………………………………………………………………………….. 611
C) DROP IN RADIATOR WATER LEVEL WARNING IS DISPLAYED………………………………………………………………….. 612
D) BATTERY CHARGE LEVEL WARNING IS DISPLAYED…………………………………………………………………………. 613
E) STEERING OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED……………………………………………………………… 614
F) DROP IN ENGINE OIL PRESSURE WARNING IS DISPLAYED…………………………………………………………………… 615
G) REAR BRAKE OIL PRESSURE WARNING IS DISPLAYED………………………………………………………………………. 616
A-18 ABNORMALITY IN ENGINE OIL PRESSURE SENSOR SYSTEM IS DISPLAYED…………………………………………………………. 617
A-19 ABNORMALITY IN CONNECTOR CONNECTION IS DISPLAYED…………………………………………………………………….. 618
A-20 ……………………………………………………………………………………………………………….. 619
A) TORQUE CONVERTER OIL TEMPERATUER OVERHEAT WARNING IS DISPLAYED………………………………………………………. 619
B) ENGINE WATER TEMPERATURE OVERHEAT WARNING IS DISPLAYED……………………………………………………………… 619
C) AIR PRESSURE DROP WARNING IS DISPLAYED……………………………………………………………………………. 619
D) RETARDER BRAKE OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED………………………………………………………… 619
E) ENGINE OVERRUN ACUTATED IS DISPLAYED……………………………………………………………………………… 620
F) ENGINE OVERSHOOTI ACTUATED IS DISPLAYED…………………………………………………………………………… 620
TROUBLESHOOTING OF SUSPENSION CONTROLLER SYSTEM (SP MODE)………………………………………………………………………… 621
JUDGEMENT TABLE FOR SUSPENSION CONTROLLER, SUSPENSION RELATED PARTS……………………………………………………………. 622
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE………………………………………………………………… 624
ELECTRICAL CIRCUIT DIAGRAM OF SUSPENSION CONTROLLER SYSTEM……………………………………………………………………. 628
SP-1 ABNORMALITY IN POWER SOURCE IS DISPLAYED……………………………………………………………………………….. 632
SP-2 ABNORMALITY IN PRESSURE SENSOR [RIGHT] SYSTEM IS DISPLAYED……………………………………………………………….. 633
SP-3 ABNORMALITY IN PRESSURE SENSOR [LEFT] SYSTEM IS DISPLAYED………………………………………………………………… 635
SP-4 ABNORMALITY IN TRAVEL SPEED SENSOR SYSTEM IS DISPLAYED…………………………………………………………………… 637
SP-5 ABNORMALITY IN STEERING SENSOR SYSTEM IS DISPLAYED………………………………………………………………………. 638
SP-6 DEFECTIVE MODEL SELECTION DATA IS DISPLAYED…………………………………………………………………………….. 639
SP-7 ABNORMALITY IN SOLENOID [1] SYSTEM IS DISPLAYED…………………………………………………………………………. 640
SP-8 ABNORMALITY IN SOLENOID [2] SYSTEM IS DISPLAYED…………………………………………………………………………. 641
SP-9 ABNORMALITY IN SOLENOID………………………………………………………………………………………………. 642
SP-10 DISCONNECTION IN NETWORK IS DISPLAYED…………………………………………………………………………………. 643
SP-11 DEFECTIVE TRAVEL SPEED COMPENSATION DATA IS DISPLAYED…………………………………………………………………… 644
TROUBLESHOOTING OF PAYLOAD METER (PRINTER TYPE) SYSTEM (LP MODE)………………………………………………………………….. 645
(HD325-6 SERIAL NO. 5680-6000, HD325-6W SERIAL NO. 5706-6000, HD405-6 SERIAL NO. 1055-2000)………………………………………. 645
SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER (PRINTER TYPE)………………………………………………………………. 646
ELECTRICAL CIRCUIT DIAGRAM FOR PAYLOAD METER (PRINTER TYPE) SYSTEM…………………………………………………………….. 648
LP-1 NO DISPLAY APPEARS WHEN STARTING SWITCH IS TURNED ON ……………………………………………………………………. 650
LP-2 CALIBRATION DEMAND (CAL FLASHES) IS SHOWN CONTINUOUSLY AFTER STARTING SWITCH IS TURNED ON……………………………………. 651
LP-3 CALIBRATION CANNOT BE CARRIED OUT……………………………………………………………………………………… 652
LP-4 AFTER STARTING SWITCH IS TURNED ON, ALL EXTERNAL DISPLAY LAMPS DO NOT LIGHT UP…………………………………………….. 655
LP-5 CONDITION DOES NOT EXIST FOR LAMPS TO LIGHT UP, BUT EXTERNAL DISPLAY LAMPS LIGHT UP…………………………………………. 657
LP-6 LEVEL OF LIGHTING UP OF EXTERNAL DISPLAY LAMPS IS NOT CORRECT…………………………………………………………….. 658
LP-7 ABNORMALITY IN DISPLAY LOGIC………………………………………………………………………………………….. 660
LP-8 E01-E04 IS DISPLAYED…………………………………………………………………………………………………. 665
LP-9 E11-E14 IS DISPLAYED…………………………………………………………………………………………………. 666
LP-10 E21-E28 IS DISPLAYED BY SENSOR CHECK………………………………………………………………………………….. 667
LP-11 E31 IS DISPLAYED……………………………………………………………………………………………………. 668
LP-12 E32 IS DISPLAYED……………………………………………………………………………………………………. 670
LP-13 E41 IS DISPLAYED……………………………………………………………………………………………………. 672
LP-14 E42 IS DISPLAYED……………………………………………………………………………………………………. 673
LP-15 PRINTER DOES NOT PRINT ANYTHING (BLANK PAPER COMES OUT)…………………………………………………………………. 674
LP-16 PRINTER PRINTS ONLY “NO DATA”………………………………………………………………………………………… 674
LP-17 PRINTER DOES NOT PRINT OUT WHE PRT SWITCH IS PRESSED……………………………………………………………………. 674
LP-18 “PAPE” FLASHES……………………………………………………………………………………………………… 675
LP-19 TIME IS WRONG………………………………………………………………………………………………………. 675
LP-20 E33 IS DISPLAYED……………………………………………………………………………………………………. 675
TROUBLESHOOTING OF PAYLOAD METER (PRINTER TYPE) SYSTEM (LP MODE)………………………………………………………………….. 677
(HD325-6 SERIAL NO. 6001 AND UP, HD325-6W SERIAL NO. 6001 AND UP, HD405-6 SERIAL NO. 2001 AND UP)…………………………………. 677
SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER (PRINTER TYPE)………………………………………………………………. 678
ELECTRICAL CIRCUIT DIAGRAM FOR PAYLOAD METER (PRINTER TYPE) SYSTEM…………………………………………………………….. 680
LP-1 NO DISPLAY APPEARS WHEN STARTING SWITCH IS TURNED ON ……………………………………………………………………. 682
LP-2 CALIBRATION DEMAND (CAL FLASHES) IS SHOWN CONTINUOUSLY AFTER STARTING SWITCH IS TURNED ON……………………………………. 683
LP-3 CALIBRATION CANNOT BE CARRIED OUT……………………………………………………………………………………… 684
LP-4 AFTER STARTING SWITCH IS TURNED ON, ALL EXTERNAL DISPLAY LAMPS DO NOT LIGHT UP…………………………………………….. 687
LP-5 CONDITION DOES NOT EXIST FOR LAMPS TO LIGHT UP, BUT EXTERNAL DISPLAY LAMPS LIGHT UP…………………………………………. 689
LP-6 LEVEL OF LIGHTING UP OF EXTERNAL DISPLAY LAMPS IS NOT CORRECT…………………………………………………………….. 690
LP-7 ABNORMALITY IN DISPLAY LOGIC………………………………………………………………………………………….. 692
A) EVEN WHEN DUMP BODY IS OPERATED, DISPLAY DOES NOT SHOW 0 TON……………………………………………………………. 692
B) DISPLAY STAYS AT 0 TON AND DOES NOT CHANGE……………………………………………………………………………. 693
C) WHEN TRANSMISSION IS AT N, WEIGHT DISPLAY IS NOT GIVEN (STAYS AT TIME DISPLAY)……………………………………………. 694
D) WHEN TRANSMISSION LEVER IS AT POSITION OTHER THAN N, DISPLAY DOES NOT CHANGE TIME DISPLAY………………………………….. 696
LP-8 E01-E04 IS DISPLAYED…………………………………………………………………………………………………. 697
LP-9 E11-E14 IS DISPLAYED…………………………………………………………………………………………………. 698
LP-10 E21-E28 IS DISPLAYED BY SENSOR CHECK………………………………………………………………………………….. 699
LP-11 E31 IS DISPLAYED……………………………………………………………………………………………………. 700
LP-12 E32 IS DISPLAYED……………………………………………………………………………………………………. 702
LP-13 E41 IS DISPLAYED……………………………………………………………………………………………………. 704
LP-14 E42 IS DISPLAYED……………………………………………………………………………………………………. 705
LP-15 PRINTER DOES NOT PRINT ANYTHING (BLANK PAPER COMES OUT)…………………………………………………………………. 706
LP-16 PRINTER PRINTS ONLY “NO DATA”………………………………………………………………………………………… 706
LP-17 PRINTER DOES NOT PRINT OUT WHE PRT SWITCH IS PRESSED……………………………………………………………………. 706
LP-18 “PAPE” FLASHES……………………………………………………………………………………………………… 707
LP-19 TIME IS WRONG………………………………………………………………………………………………………. 707
LP-20 E33 IS DISPLAYED……………………………………………………………………………………………………. 707
TROUBLESHOOTING OF PAYLOAD METER II (CARD TYPE) SYSTEM (LC MODE)………………………………………………………………….. 709
SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER II (CARD TYPE)………………………………………………………………. 710
ELECTRICAL CIRCUIT DIAGRAM FOR PAYLOAD METER II (CARD TYPE) SYSTEM…………………………………………………………….. 714
LC-1 NO DISPLAY APPEARS WHEN STARTING SWITCH IS TURNED ON…………………………………………………………………….. 718
LC-2 AFTER STARTING SWITCH IS TURNED ON, ALL EXTERNAL DISPLAY LAMPS DO NOT LIGHT UP……………………………………………… 720
LC-3 CONDITION DOES NOT EXIST FOR LAMPS TO LIGHT UP, BUT EXTERNAL DISPLAY LAMPS LIGHT UP…………………………………………. 722
LC-4 LEVEL OF LIGHTING UP OF EXTERNAL DISPLAY LAMPS IS NOT CORRECT…………………………………………………………….. 725
LC-5 CYCLE DATA IS NOT RECORDED, ON/OFF DATA IS NOT RECORDED: BATTERY CHARGE SIGNAL SYSTEM: ENGINE NOT STARTED IS DETECTED………….. 729
LC-6 CALIBRATION CANNOT BE CARRIED OUT, TIME DISPLAY DOES NOT MATCH CONDITIONS: SHIFT LEVER N POSITION SIGNAL SYSTEM……………….. 730
LC-7 ABNORMAITY IN DISPLAY LOGIC…………………………………………………………………………………………… 733
LC-8 B-FL REMAINS DISPLAYED AND DOES NOT CHANGE: BODY FLOAT RELAY SYSTEMS: WHEN NOT DUMPING AND WHEN DUMP LEVER IS NOT AT ………… 735
LC-9 F-09 IS DISPLAYED: DROP IN VOLTAGE OF BACK-UP BATTERY BUILT INTO PAYLOAD METER…………………………………………….. 736
LC-10 FULL DISPLAY APPEARS………………………………………………………………………………………………… 736
LC-11 F-20 IS DISPLAYED: SENSOR POWER SOURCE VOLTAGE SYSTEM ………………………………………………………………….. 737
LC-12 F-21-F-24 IS DISPLAYED: DISCONNECTION, SHORT CIRCUIT WITH GROUND IN SUSPENSION PRESSURE SENSOR SYSTEM……………………….. 740
LC-13 F-25-F-28 IS DISPLAYED: SHORT CIRCUIT IN SUSPENSION PRESSURE SENSOR SYSTEM POWER SOURCE……………………………………. 742
LC-14 ECAL IS DISPLAYED: CALIBRATION NOT CARRIED OUT, DAMAGED DATA INSIDE PAYLOAD METER…………………………………………. 744
LC-15 F-41 – F-45 IS DISPLAYED: SHORT CIRCUIT IN EXTERNAL DISPLAY LAMP SYSTEM POWER SOURCE………………………………………. 744
LC-16 L-BAD IS DISPLAYED: CYCLE DATA SAVED WHEN MACHINE WAS SWAYING…………………………………………………………… 748
LC-17 MACHINE IS NOT LOADING BUT EXTERNAL DISPLAY LAMPS GIVE LOAD ESTIMATE DISPLAY. AFTER LOADING, DISPLAY SWITCHES TO TIME………… 750
LC-18 F-31 IS DISPLAYED: DISCONNECTION, SHORT CIRCUIT WITH GROUND IN CLINOMETER SYSTEM………………………………………….. 750
LC-19 F-32 IS DISPLAYED: SHORT CIRCUIT WITH CLINOMETER SYSTEM POWER SOURCE…………………………………………………….. 753
LC-20 F-18 IS DISPLAYED: DISCONNECTION IN BATTERY CHARGE SIGNAL………………………………………………………………. 756
TROUBLESHOOTING OF ARSC (AUTOMATIC RETARDER SPEED CONTROLLER) SYSTEM (R MODE)………………………………………………………. 757
OUTLINE…………………………………………………………………………………………………………………. 758
ELECTRICAL CIRCUIT DIAGRAM FOR ARSC (AUTOMATIC RETARDER SPEED CONTROLLER) SYSTEM………………………………………………… 762
R-1 0.1 (ABNORMALITY IN POWER SOURCE VOLTAGE) IS DISPLAYED……………………………………………………………………. 764
R-2 1.0 (DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED…………………………………………………………….. 765
R-3 1.3 (DISCONNECTION IN TRANSMISSION OUTPUT SHAFT SPEED SENSOR SYSTEM) IS DISPLAYED……………………………………………. 766
R-4 1.5 (FAILURE IN RETARDER OIL TEMPERATURE SENSOR SYSTEM) IS DISPLAYED………………………………………………………. 767
R-5 1.7 (FAILURE IN ACCELERATOR SIGNAL SYSTEM) IS DISPLAYED…………………………………………………………………… 768
R-6 1.8 (FAILURE IN SUSPENSION PRESSURE SENSOR “LEFT” SYSTEM) IS DISPLAYED……………………………………………………… 769
R-7 1.9 (FAILURE IN SUSPENSION PRESSURE SENSOR “RIGHT” SYSTEM) IS DISPLAYED…………………………………………………….. 770
R-8 4.2 (DISCONNECTION IN EXHAUST BRAKE SELECTOR SIGNAL SYSTEM) IS DISPLAYED……………………………………………………. 771
R-9 4.3 (DISCONNECTION IN ARSC CAUTION LAMP SYSTEM) IS DISPLAYED………………………………………………………………. 772
R-10 4.4 (DISCONNECTION IN READY LAMP SYSTEM) IS DISPLAYED……………………………………………………………………. 773
R-11 4.5 (DISCONNECTION IN PANEL CAUTION AND BUZZER SYSTEM) IS DISPLAYED……………………………………………………….. 774
R-12 5.2 (SHORT CIRCUIT WITH GROUND IN EXHAUST BRAKE SELECTOR SIGNAL OUTPUT SYSTEM) IS DISPLAYED………………………………….. 775
R-13 5.3 (SHORT CIRCUIT WITH GROUND IN ARSC CAUTION LAMP SYSTEM) IS DISPLAYED…………………………………………………… 776
R-14 5.4 (SHORT CIRCUIT WITH GROUND IN READY OUTPUT CIRCUIT SYSTEM) IS DISPLAYED………………………………………………… 777
R-15 5.5 (SHORT CIRCUIT WITH GROUND IN PANEL CAUTION LAMP AND BUZZER OUTPUT SYSTEM) IS DISPLAYED………………………………….. 778
R-16 6.0 (FAILURE IN ENGINE SPEED SYSTEM) IS DISPLAYED……………………………………………………………………….. 779
R-17 7.0 (DISCONNECTION IN TRAVEL SPEED DISPLAY UP OUTPUT SYSTEM) IS DISPLAYED………………………………………………….. 780
R-18 7.1 (DISCONNECTION IN TRAVEL SPEED DISPLAY DOWN OUTPUT SYSTEM) IS DISPLAYED………………………………………………… 781
R-19 7.2 (DISCONNECTION IN TRAVEL SPEED DISPLAY CLEAR OUTPUT SYSTEM) IS DISPLAYED……………………………………………….. 782
R-20 7.3 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY UP OUTPUT SYSTEM) IS DISPLAYED……………………………………….. 783
R-21 7.4 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY DOWN OUTPUT SYSTEM) IS DISPLAYED……………………………………… 784
R-22 7.5 (SHORT CIRCUIT WITH GROUD IN TRAVEL SPEED DISPLAY CLEAR OUTPUT SYSTEM) IS DISPLAYED……………………………………… 785
R-23 8.1 (SHORT CIRCUIT WITH GROUND IN PRESSURE CONTROL VALVE SYSTEM) IS DISPLAYED………………………………………………. 786
R-24 8.3 (DISCONNECTION IN PRESSURE CONTROL VALVE SYSTEM) IS DISPLAYED…………………………………………………………. 787
R-25 8.5 (FAILURE IN PRESSURE CONTROL VALVE (PRESSURE CONTROL VALVE REMAINS OPEN) IS DISPLAYED……………………………………. 788
R-26 8.7 (FAILURE IN PRESSURE CONTROL VALVE (PRESSURE CONTROL VALVE DOES NOT OPEN) IS DISPLAYED…………………………………… 789
R-27 8.9 (SHORT CIRCUIT WITH GROUND IN PRESSURE SWITCH VALVE SYSTEM) IS DISPLAYED……………………………………………….. 790
R-28 9.0 (DISCONNECTION IN PRESSURE SWITCH VALVE SYSTEM) IS DISPLAYED………………………………………………………….. 791
R-29 9.1 (FAILURE IN PRESSURE SWITCH VALVE SYSTEM (REMAINS OPEN)) IS DISPLAYED………………………………………………….. 792
R-30 9.2 (FAILURE IN PRESSURE SWITCH VALVE SYSTEM (DOES NOT OPEN)) IS DISPLAYED…………………………………………………. 793
R-31 9.3 (DISCONNECTION IN SYSTEM SWITCH SYSTEM) IS DISPLAYED…………………………………………………………………. 794
R-32 9.4 (SHORT CIRCUIT WITH GROUND IN SYSTEM SWITCH SYSTEM) IS DISPLAYED………………………………………………………. 795
R-33 9.5 (DISCONNECTION, SHORT CIRCUIT WTH GROUND IN TRAVEL SPEED SETTING SWITCH SYSTEM) IS DISPLAYED……………………………… 796
R-101 SET SPEED CANNOT BE SET……………………………………………………………………………………………… 797
R-102 FAILURE CODE IS ALWAYS CLEARED (CONTROLLER DISPLAY WINDOW ALWAYS SHOWS ‘–“) OR FAILURE CODE CANNOT BE CLEARED………………… 800
R-103 EFFECT OF RETARDER IS TOO STRONG WHEN MACHINE IS EMPTY, OR TOO WEAK WHEN MACHINE IS LOADED (DOES NOT JUDGE LOADED/UNLOA………… 801
R-104 ABNORMALITY APPEARS IN OTHER CONTROLLER……………………………………………………………………………….. 801
R-105 WHEN TRAVELING DOWNHILL, EVEN WHEN SET SPEED IS EXCEEDED, NO CONTROL IS CARRIED OUT………………………………………… 802
R-106 MONITOR LAMP (BUZZER) STAY ON (OR OFF)………………………………………………………………………………… 803
R-107 READY LAMP DOES NOT LIGHT UP (OR STAY LIT UP)………………………………………………………………………….. 804
R-108 EXHAUST BRAKE DOES NOT WORK PROPERLY …………………………………………………………………………………. 806
[EXHAUST BRAKE IS ACTUATED WHEN EXHAUST BRAKE SWITCH IS OFF; OR EXHAUST BRAKE IS NOT ACTUATED WHEN EXHAUST BRAKE SWITCH IS ON…….. 806
R-109 THERE IS DIFFERENCE BETWEEN TRAVEL SPEED ROD VALUE AND ACTUAL MACHINE VALUE……………………………………………….. 808
R-110 RETARDER LAMP DOES NOT LIGHT UP, OR STAY LIT UP………………………………………………………………………… 810
R-111 TRAVEL SPEED DISPLAY ALWAYS GIVES DISPLAY (OR DOES NOT GIVE ANY DISPLAY)………………………………………………….. 811
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)……………………………………………………………………… 813
H-1 MACHINE DOES NOT START………………………………………………………………………………………………… 814
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE JERKS)…………………………………………………………………………. 816
H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED (ENGINE STALLS)………………………………………………………………………. 816
H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING……………………………………………………………………………….. 817
H-5 TRANSMISSION DOES NOT SHIFT UP…………………………………………………………………………………………. 817
H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING……………………………………………………………………………… 818
H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR……………………………………………………………………… 822
H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH………………………………………………………………………………… 824
H-9 TORQUE CONVERTER OIL PRESSURE IS LOW……………………………………………………………………………………. 825
H-10 FRONT BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE………………………………………………………………… 826
H-11 REAR BRAKE IS INEFFECTIVE, OR EFFECTIVE ON ONE SIDE……………………………………………………………………… 829
H-12 STEERING WHEEL IS HEAVY………………………………………………………………………………………………. 830
H-13 STEERING WHEEL DOES NOT WORK………………………………………………………………………………………….. 831
H-14 STEERING WHEEL VIBRATES………………………………………………………………………………………………. 831
H-15 HOIST CYLINDER LACKS LIFTING FORCE (LIFTING SPEED)………………………………………………………………………. 832
H-16 HOIST CYLINDER DOES NOT WORK………………………………………………………………………………………….. 833
H-17 EXCESSIVE HYRDRAULIC DRIFT OF DUMP BODY………………………………………………………………………………… 834
H-18 AIR PRESSURE DOES NOT RISE …………………………………………………………………………………………… 835
TROUBLESHOOTING OF MONITOR PANEL SYSTEM (P MODE)………………………………………………………………………………… 837
METHOD OF SELF-DIAGNOSTIC DISPLAY FOR MONITOR PANEL AND CONTROLLERS……………………………………………………………. 839
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE (MONITOR PANEL SYSTEM)……………………………………………. 840
ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR PANEL SYSTEM………………………………………………………………………….. 844
P-1 CHECK PATTERN FOR WIRING HARNESSES BETWEEN MODULES……………………………………………………………………….. 846
P-2 NOTHING ON MONITOR PANEL WORKS…………………………………………………………………………………………. 850
P-3 LH, RH MODULE AND FUEL GAUGE DO NOT WORK………………………………………………………………………………… 851
P-4 LH, RH MODULE AND FUEL GAUGE DO NOT WORK………………………………………………………………………………… 852
P-5 RH MODULE DOES NOT WORK……………………………………………………………………………………………….. 853
P-6 LH MODULE DOES NOT WORK……………………………………………………………………………………………….. 854
P-7 TRAVEL CALCULATOR DOES NOT WORK………………………………………………………………………………………… 855
P-8 SERVICE METER DISPLAY DOES NOT WORK CORRECTLY……………………………………………………………………………. 856
P-9 CENTRAL WARNING LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS FAILURE CODE (MONITOR PANEL DISPLAY)[A002]………………………… 857
P-10 CENTRAL WARNING LAMP STAYS LIT UP……………………………………………………………………………………… 858
P-11 ALARM BUZZER DOES NOT WORK, OR MONITOR PANEL DETECTS FAILURE CODE [A003]…………………………………………………… 859
P-12 ALARM BUZZER CONTINUES TO SOUND……………………………………………………………………………………….. 860
P-13 ALL DATA FROM SHIFT CONTROLLER (SPPEDOMETER, TACHOMETER, SHIFT INDICATOR, ETC.) ARE ABNORMAL (NOTHING IS DISPLAYED, OR D………… 861
P-14 SUSPENSION MODE, POWER/ECONOMY MODE DISPLAYS ARE ABNORMAL (NOTHIND IS DISPLAYED, OR DISPLAY DOES NOT CHANGE), OR MONITOR………… 862
P-15 GAUGE DISPLAYS ARE ABNORMAL (NOTHING IS DISPLAYED, OR DISPLAY DOES NOT CHANGE)……………………………………………… 863
P-16 COOLING WATER LEVEL DROP CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]…………………………….. 864
P-17 COOLING WATER LEVEL DROP CAUTION LAMP STAY LIT UP……………………………………………………………………….. 865
P-18 EMERGENCY STEERING PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]……………………………………. 866
P-19 EMERGENCY STEERING PILOT LAMP STAYS LIT UP……………………………………………………………………………… 867
P-20 ENGINE OIL PRESSURE DROP CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]…………………………….. 868
P-21 ENGINE OIL PRESSURE DROP CAUTION LAMP STAYS LIT UP………………………………………………………………………. 869
P-22 EXHAUST BRAKE PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]………………………………………… 870
P-23 EXHAUST BRAKE PILOT LAMP STAYS LIT UP………………………………………………………………………………….. 871
P-24 CHARGING CIRCUIT ABNORMALITY CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]…………………………. 872
P-25 CHARGING CIRCUIT ABNORMALTIY CAUTION LAMP STAY LIT UP……………………………………………………………………. 873
P-26 TRANSMISSION FILTER CLOGGING CAUTION LAMP DOES NOT WORK OR MONITOR PANEL DETECTS SERVICE CODE [A001]………………………….. 874
P-27 TRANSMISSION FILTER CLOGGING CAUTION LAMP STAYS LIT UP…………………………………………………………………… 875
P-28 BRAKE STROKE CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]……………………………………….. 876
P-29 BRAKE STROKE CAUTION LAMP STAY LIT UP………………………………………………………………………………….. 877
P-30 PREHEATING SWITCH PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]…………………………………….. 878
P-31 PREHEATING SWITCH PILOT LAMP STAYS LIT UP………………………………………………………………………………. 879
P-32 TILT WARNING LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]………………………………………………. 880
P-33 TILT WARNING LAMP STAYS LIT UP………………………………………………………………………………………… 881
P-34 BODY FLOAT (EXCEPT FLOAT) PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]……………………………… 882
P-35 BODY FLOAT (EXCEPT FLOAT) PILOT LAMP STAYS LIGHTED UP……………………………………………………………………. 883
P-36 REAR BRAKE PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE……………………………………………………… 884
P-37 REAR BRAKE PILOT LAMP STAYS LIT UP…………………………………………………………………………………….. 885
P-38 PARKING BRAKE PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]………………………………………… 886
P-39 PARKING BRAKE PILOT LAMP STAYS LIT UP………………………………………………………………………………….. 887
P-40 MAINTENANCE CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]………………………………………… 888
P-41 MAINTENANCE CAUTION LAMP STAYS LIT UP …………………………………………………………………………………. 889
P-42 STEERING OIL TEMPERATURE CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]…………………………….. 890
P-43 STEERING OIL TEMPERATURE CAUTION LAMP STAYS LIT UP………………………………………………………………………. 891
P-44 DIFFERENTIAL LOCK PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]…………………………………….. 892
P-45 DIFFERENTIAL LOCK PILOT LAMP STAYS LIT UP………………………………………………………………………………. 893
P-46 HIGH BEAM DISPLAY DOES NOT LIGHT UP……………………………………………………………………………………. 894
P-47 TURN SIGNAL LAMP (RIGHT) DOES NOT LIGHT UP……………………………………………………………………………… 896
P-48 TURN SIGNAL LAMP (LEFT) DOES NOT LIGHT UP………………………………………………………………………………. 897
P-49 LAMP CHEK SWITCH DOES NOT WORK………………………………………………………………………………………… 898
P-50 EXHAUST BRAKE SWITCH DOES NOT WORK……………………………………………………………………………………. 899
P-51 MODE CHANGE SWITCH (1) DOES NOT WORK…………………………………………………………………………………… 900
P-52 MODE CHANGE SWITCH (2) DOES NOT WORK…………………………………………………………………………………… 901
P-53 KPH/MPH SPEEDOMETER UNIT SELECTOR DOES NOT WORK…………………………………………………………………………. 902
P-54 DEFECTIVE OPERATION OF ALL SWITCH INPUTS……………………………………………………………………………….. 903
P-55 MONITOR PANEL DETECTS SERVICE CODES [A014] OR [A019]…………………………………………………………………….. 904
P-56 MONITOR PANEL DETECTS SERVICE CODE [A015]………………………………………………………………………………. 905
P-57 MONITOR PANEL DETECTS SERVICE CODE [A011]………………………………………………………………………………. 906
P-58 MONITOR PANEL DETECTS SERVICE CODE [A012]………………………………………………………………………………. 906
P-59 MONITOR PANEL DETECTS SERVICE CODE [A000]………………………………………………………………………………. 906
TROUBLESHOOTING OF ABS/ASR SYSTEM (OP)…………………………………………………………………………………………. 907
TROUBLESHOOTING FLOWCHART…………………………………………………………………………………………………. 908
FOR MACHINES WITH ABS INSTALLED INDEPENDENTLY……………………………………………………………………………. 908
FOR MACHINES WITH ABS/ASR INSTALLED…………………………………………………………………………………….. 909
METHOD OF DELETING ECU TROUBLE DATA FROM MEMORY……………………………………………………………………………… 910
PROCEDURE FOR DELETING TROUBLE DATA FROM MEMORY………………………………………………………………………….. 910
METHOD OF TROUBLESHOOTING USING SELF-DIAGNOSTIC FUNCTION OF ECU……………………………………………………………….. 911
INDEX (TROUBLESHOOTING CODE)…………………………………………………………………………………………… 912
SYSTEM CHECK SHEET FOR USING SYSTEM CHECKER…………………………………………………………………………………. 914
TROUBLESHOOTING………………………………………………………………………………………………………….. 922
W-1 WARNING LAMP DOES NOT LIGHT UP……………………………………………………………………………………… 922
I-1 ASR INFORMATION SWITCH DOES NOT GO OUT………………………………………………………………………………. 923
ASR-1 FAILURE IN ASR CONTROL VALVE (ONLY MACHINES WITH ABS/ASR INSTALLED)…………………………………………………… 924
ASR-2……………………………………………………………………………………………………………….. 925
ABS-1 FAILURE INSIDE ECU………………………………………………………………………………………………. 926
ABS-2 FAILURE IN FRONT RIGHT PRESSURE CONTROL VALVE………………………………………………………………………. 927
ABS-3 FAILURE IN FRONT LEFT PRESSURE CONTROL VALVE……………………………………………………………………….. 928
ABS-4 FAILURE IN REAR LEFT PRESSURE CONTROL VALVE………………………………………………………………………… 929
ABS-5 FAILURE IN REAR RIGHT PRESSURE CONTROL VALVE……………………………………………………………………….. 930
ABS-6 FAILURE IN FRONT RIGHT WHEEL SPEED SENSOR………………………………………………………………………….. 931
ABS-10 ABNORMALITY IN FRONT RIGHT WHEEL SPEED SENSOR OUTPUT……………………………………………………………….. 931
ABS-7 FAILURE IN FRONT LEFT WHEEL SPEED SENSOR…………………………………………………………………………… 932
ABS-11 ABNORMALITY IN FRONT LEFT WHEEL SPEED SENSOR OUTPUT………………………………………………………………… 932
ABS-8 FAILURE IN REAR LEFT WHEEL SPEED SENSOR……………………………………………………………………………. 933
ABS-12 ABNORMALITY IN REAR LEFT WHEEL SPEED SENSOR OUTPUT…………………………………………………………………. 933
ABS-9 FAILURE IN REAR RIGHT WHEEL SPEED SENSOR…………………………………………………………………………… 934
ABS-13 ABNORMALITY IN REAR RIGHT WHEEL SPEED SENSOR OUTPUT………………………………………………………………… 934
ABS-14 FAILURE IN VALVE RELAY (VR2)…………………………………………………………………………………….. 935
ABS-15 FAILURE IN VALVE RELAY (VR1)…………………………………………………………………………………….. 936
ABS-16 FAILURE IN VALVE RELAY (VR2)…………………………………………………………………………………….. 937
ABS-17 FAILURE IN VALVE RELAY (VR1)…………………………………………………………………………………….. 938
ABS-18 ABNORMALITY IN POWER SOURCE VOLTAGE………………………………………………………………………………. 939
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (G MODE)…………………………………………………………………………….. 941
(HD325-6 SERIAL NO. 6001 AND UP, HD325-6W SERIAL NO. 6001 AND UP, HD405-6 SERIAL NO. 2001 AND UP)…………………………………. 941
ERROR CODE DISPLAYS AND POINTS TO REMEMBER WHEN TROUBLESHOOTING……………………………………………………………….. 943
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED………………………………………………… 946
ENGINE CONTROLLER RELATED JUDGEMENT TABLE…………………………………………………………………………………… 954
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE CONTROLLER SYSTEM………………………………………………………………………. 956
G-1 ERROR CODE [C01B] [ABNORMALITY IN NE REVOLUTION SENSOR SYSTEM]…………………………………………………………….. 958
G-2 ERROR CODE [C01C] [ABNORMALITY IN G REVOLUTION SENSOR SYSTEM]……………………………………………………………… 959
G-3 ERROR CODE [C020] [ABNORMALITY IN MODEL SELECTION SYSTEM]…………………………………………………………………. 960
G-4 ERROR CODE [C022] [OVERRUN]……………………………………………………………………………………………. 961
G-5 ERROR CODE [C022] [OVERHEAT]…………………………………………………………………………………………… 961
G-6 ERROR CODE [C024] [DROP IN OIL PRESSURE]………………………………………………………………………………… 962
G-7 ERROR CODE [C030] [ABNORMALITY IN IDLING VALIDATION SIGNAL SYSTEM]…………………………………………………………. 963
G-8 ERROR CODE [C031] [ABNORMALITY IN ACCELERATOR SENSOR SYSTEM]………………………………………………………………. 965
G-9 ERROR CODE [C034] [ABNORMALITY IN HIGH WATER TEMPERATURE SENSOR SYSTEM]…………………………………………………….. 967
G-10 ERROR CODE [C036] [ABNORMALITY IN OIL PRESSURESWITCH SYSTEM] …………………………………………………………….. 968
G-11 ERROR CODE [C03C] [ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM]…………………………………………………………… 970
G-12 ERROR CODE [C03D] [ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM………………………………………………………….. 971
G-13 ERROR CODE [C050] [ABNORMALITY IN PREHEATING RELAY CONNECTING POINT SYSTEM…………………………………………………. 972
G-14 ERROR CODE [C051] [ABNORMALITY IN PREHEATING RELAY COIL SYSTEM]…………………………………………………………… 973
G-15 ERROR CODE [C054] [SHORT CIRCUIT IN STARTING SWITCH C SYSTEM]…………………………………………………………….. 974
G-16 ERROR CODE [C055] [ABNORMALITY IN NETWORK]……………………………………………………………………………… 975
G-17 ERROR CODE [C056] [POWER SOURCE SYSTEM ABNORMALITY 1]……………………………………………………………………. 976
G-18 ERROR CODE [C057] [POWER SOURCE SYSTEM ABNORMALITY 2]……………………………………………………………………. 978
G-19 ERROR CODE [C06A] [ABNORMALITY IN FUEL INJECTION QUANITY CONTROL SWITCH SYSTEM]…………………………………………….. 979
G-20 ERROR CODE [ABNORMALITY IN HIGH ENGINE WATER TEMPERATURE SENSOR SYSTEM]……………………………………………………. 979
G-21 ERROR CODE [C070] EXCESS CURRENT IN FUEL SUPPLY PUMP PCV1 SYSTEM]…………………………………………………………. 980
G-22 ERROR CODE [C071] EXCESS CURRENT IN FUEL SUPPLY PUMP PCV2 SYSTEM]…………………………………………………………. 981
G-23 ERROR CODE [C074] [DISCONNECTION IN FUEL SUPPLY PUMP PCV1 SYSTEM]…………………………………………………………. 982
G-24 ERROR CODE [C075] [DISCONNECTION IN FUEL SUPPLY PUMP PCV2 SYSTEM]…………………………………………………………. 983
G-25 ERROR CODE [C077] ABNORMALITY IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM]………………………………………………….. 984
G-26 ERROR CODE [C079] [COMMON RAIL HIGH FUEL PRESSURE ABNORMALITY 1]………………………………………………………….. 985
ERROR CODE [E-7A] [COMMON RAIL HIGH FUEL PRESSURE ABNORMALITY 2]…………………………………………………………… 985
G-27 ERROR CODE [C07B] [FUEL SUPPLY PUMP NON-FORCE FEED 1] …………………………………………………………………… 986
ERROR CODE [C07C] [FUEL SUPPLY PUMP NON-FORCE FEED 2] ……………………………………………………………………. 986
G-28 ERROR CODE [C07D] [ABNORMALITY IN COMMON RAIL FUEL PRESSURE]……………………………………………………………… 988
G-29 ERROR CODE [CO80] [DEFECTIVE CONTROLLER]……………………………………………………………………………….. 988
G-30 ERROR CODE [C081] [DISCONNECTION IN N0. FUEL INJECTOR <A> SYSTEM]…………………………………………………………. 989
G-31 ERROR CODE [C082] [DISCONNECTION IN N0.2 FUEL INJECTOR <E> SYSTEM]………………………………………………………… 990
G-32 ERROR CODE [C083] [DISCONNECTION IN N0.3 FUEL INJECTOR <C> SYSTEM]………………………………………………………… 991
G-33 ERROR CODE [C084] [DISCONNECTION IN N0.4 FUEL INJECTOR <F> SYSTEM]………………………………………………………… 992
G-34 ERROR CODE [C085] [DISCONNECTION IN N0.5 FUEL INJECTOR <B> SYSTEM]………………………………………………………… 993
G-35 ERROR CODE [C086] [DISCONNECTION IN N0.6 FUEL INJECTOR <D> SYSTEM]………………………………………………………… 994
G-36 ERROR CODE [CO8A] [SHORT CIRCUIT IN NO. 1 ,<A>, NO. 2 <E>, NO.3 <C> FUEL INJECTOR SYSTEM]……………………………………. 995
G-37 ERROR CODE [CO8A] [SHORT CIRCUIT IN NO. 4 ,<F>, NO. 5 <B>, NO.6 <D> FUEL INJECTOR SYSTEM]……………………………………. 998
TROUBLESHOOTING OF FRONT DRIVE SYSTEM (W MODE) SERIAL NO. 5706-6000………………………………………………………………..1001
ELECTRICAL CIRCUIT DIAGRAM FOR FRONT DRIVE SYSTEM…………………………………………………………………………….1002
W-1 SELF-DIAGNOSTIC DISPLAY UNIT OF CONTROLLER DOES NOT LIGHT UP……………………………………………………………….1004
W-2 E-0.1 (DROP IN CONTROLLER POWER SUPPLY VOLTAGE) IS DISPLAYED……………………………………………………………….1005
W-3 E-0.4 (ABNORMALITY IN ANALOG POWER SOURCE RELAY) IS DISPLAYED………………………………………………………………1006
W-4 E-1.1 (DISCONNECTION IN CLUTCH CONTROL VALVE OUTPUT WIRING) IS DISPLAYED…………………………………………………….1007
W-4 E-1.2 (SHORT CIRCUIT IN CLUTCH CONTROL VALVE OUTPUT WIRING) IS DIPLAYED……………………………………………………..1007
W-5 E-1.3 (DEFECTIVE CLUTCH CONTROL VALVE SYSTEM) IS DISPLAYED…………………………………………………………………1008
W-5 E-1.4 (DEFECTIVE FILL SIGNAL INPUT SYSTEM) IS DISPLAYED……………………………………………………………………1008
W-6 E-2.0 (DISCONNECTION IN PUMP OUTPUT WIRING) IS DISPLAYED…………………………………………………………………..1009
W-6 E-2.1 (SHORT CIRCUIT IN PUMP OUTPUT WIRING) IS DISPLAYED…………………………………………………………………..1009
W-7 E-2.2 (DISCONNECTION IN LEFT MOTOR OUPUT WIRING) IS DISPLAYED………………………………………………………………1010
W-7 E-2.3 (SHORT CIRCUIT IN LEFT MOTOR OUTPUT WIRING) IS DISPLAYED……………………………………………………………..1010
W-8 E-2.4 (DISCONNECTION IN RIGHT MOTOR OUTPUT WIRING) IS DISPLAYED…………………………………………………………….1011
W-8 E-2.5 (SHORT CIRCUIT IN RIGHT MOTOR OUTPUT WIRING) IS DISPLAYED…………………………………………………………….1011
W-9 E-5.0 (ABNORMALITY (DISCONNECTION) IN PRESSURE SENSOR [A] IS DISPLAYED………………………………………………………1012
W-9 E-5.2 (ABNORMALITY (DISCONNECTION) IN PRESSURE SENSOR [B]) IS DISPLAYED……………………………………………………..1012
W-10 E-5.1 (SHORT CIRCUIT IN PRESSOR SENSOR [A]) IS DISPLAYED………………………………………………………………….1013
W-10 E-5.3 (SHORT CIRCUIT IN PRESSURE SENSOR [B]) IS DISPLAYED…………………………………………………………………1013
W-11 E-5.4, E-5.5, E-5.6 (ABNORMALITY IN HST HYDRAULIC SYSTEM) IS DISPLAYED……………………………………………………..1014
W-12 E-6.1 (DISCONNECTION IN STEERING ANGLE SENSOR) IS DISPLAYED……………………………………………………………….1015
W-12 E-6.2 (SHORT CIRCUIT IN STEERING ANGLE SENSOR) IS DISPLAYED……………………………………………………………….1015
W-12 E-6.3 (DEFECTIVE MOUNT OF STEERING ANGLE SENSOR) IS DISPLAYED……………………………………………………………..1015
W-13 E-7.1 (DISCONNECTION IN ENGINE SPEED SENSOR) IS DISPLAYED…………………………………………………………………1016
W-14 E-7.2 (DISCONNECTION IN TRANSMISSION INPUT SHAFT SPEED SENSOR) IS DISPLAYED…………………………………………………1017
W-15 E-7.3 (ABNORMALITY IN LEFT FRONT WHEEL SPEED SENSOR SYSTEM) IS DISPLAYED……………………………………………………1018
W-15 E-7.4 (ABNORMALITY IN RIGHT FRONT WHEEL SPEED SENSOR SYSTEM) IS DISPLAYED…………………………………………………..1018
W-16 E-7.5 (ABNORMALITY IN FRONT WHEEL SPEED SENSOR SYSTEM) IS DISPLAYED………………………………………………………..1018
W-17 E-8.2 (SHORT CIRCUIT IN 4-WHEEL DRIVE LAMP RELAY) IS DISPLAYED…………………………………………………………….1019
W-18 E-9.0 (CLOGGING OF FRONT DRIVE OIL FILTER) IS DISPLAYED…………………………………………………………………..1020
W-19 E-9.1 (RISE IN TEMPERATURE OF FRONT DRIVE OIL) IS DISPLAYED……………………………………………………………….1021
W-20 E-9.3 (ABNORMALITY IN CLUTCH OIL PRESSURE SYSTEM) IS DISPLAYED…………………………………………………………….1022
TROUBLESHOOTING OF FRONT DRIVE SYSTEM (W MODE) SERIAL NO. 6001 AND UP………………………………………………………………1023
ELECTRICAL CIRCUIT DIAGRAM FOR FRONT DRIVE SYSTEM…………………………………………………………………………….1024
W-1 SELF-DIAGNOSTIC DISPLAY UNIT OF CONTROLLER DOES NOT LIGHT UP……………………………………………………………….1026
W-2 E-0.1 (DROP IN CONTROLLER POWER SUPPLY VOLTAGE) IS DISPLAYED……………………………………………………………….1027
W-3 E-0.4 (ABNORMALITY IN CLUTCH POWER SUPPLY CUT RELAY) IS DISPLAYED…………………………………………………………..1028
W-4 E-1.1 (DISCONNECTION IN CLUTCH CONTROL VALVE OUTPUT WIRING) IS DISPLAYED…………………………………………………….1029
W-4 E-1.2 (SHORT CIRCUIT IN CLUTCH VALVE OUTPUT WIRING) IS DISPLAYED……………………………………………………………1029
W-5 E-1.3 (DEFECTIVE CLUTCH CONTROL VALVE SYSTEM) IS DISPLAYED…………………………………………………………………1030
W-5 E-1.4 (DEFECTIVE FILL SIGNAL INPUT SYSTEM) IS DISPLAYED……………………………………………………………………1030
W-6 E-2.0 (DISCONNECTION IN PUMP OUTPUT WIRING) IS DISPLAYED…………………………………………………………………..1031
W-6 E-2.1 (SHORT CIRCUIT IN PUMP OUTPUT WIRING) IS DISPLAYED…………………………………………………………………..1031
W-7 E-2.2 (DISCONNECTION IN LEFT MOTOR OUTPUT WIRING) IS DISPLAYED……………………………………………………………..1032
W-7 E-2.3 (SHORT CIRCUIT IN LEFT MOTOR OUTPUT WIRING) IS DISPLAYED……………………………………………………………..1032
W-8 E-2.4 (DISCONNECTION IN RIGHT MOTOR OUTPUT WIRING) IS DISPLAYED…………………………………………………………….1033
W-8 E-2.5 (SHORT CIRCUIT IN RIGHT MOTOR OUTPUT WIRING) IS DISPLAYED…………………………………………………………….1033
W-9 E-5.0 (ABNORMALITY (DISCONNECTION) IN PRESSURE SENSOR [A]) IS DISPLAYED……………………………………………………..1034
W-9 E-5.2 (ABNORMALITY (DISCONNECTION) IN PRESSURE SENSOR [B]) IS DISPLAYED……………………………………………………..1034
W-10 E-5.1 (SHORT CIRCUIT IN PRESSURE SENSOR [A]) IS DISPLAYED…………………………………………………………………1035
W-10 E-5.3 (SHORT CIRCUIT IN PRESSURE SENSOR [B]) IS DISPLAYED…………………………………………………………………1035
W-11 E-5.4, E-5.5, E-5.6 (ABNORMALITY IN HST HYDRAULIC SYSTEM) IS DISPLAYED……………………………………………………..1036
W-12 E-6.1 (DISCONNECTION IN STEERING ANGLE SENSOR) IS DISPLAYED……………………………………………………………….1037
W-12 E-6.2 (SHORT CIRCUIT IN STEERING ANGLE SENSOR) IS DISPLAYED……………………………………………………………….1037
W-12 E-6.3 (DEFECTIVE MOUNT OF STEERING ANGLE SENSOR) IS DISPLAYED……………………………………………………………..1037
W-13 E-7.1 (DISCONNECTION IN ENGINE SPEED SENSOR) IS DISPLAYED…………………………………………………………………1038
W-14 E-7.2 (DISCONNECTION IN TRANSMISSION INPUT SHAFT SPEED SENSOR) IS DISPLAYED…………………………………………………1039
W-15 E-7.3 (ABNORMALITY IN LEFT FRONT WHEEL SPEED SENSOR SYSTEM) IS DISPLAYED……………………………………………………1040
W-15 E-7.4 (ABNORMALITY IN RIGHT FRONT WHEEL SPEED SENSOR SYSTEM) IS DISPLAYED…………………………………………………..1040
W-16 E-7.5 (ABNORMALITY IN FRONT WHEEL SPEED SENSOR SYSTEM) IS DISPLAYED………………………………………………………..1040
W-17 E-8.2 (SHORT CIRCUIT IN 4-WHEEL DRIVE LAMP RELAY) IS DISPLAYED…………………………………………………………….1041
W-18 E-9.0 (CLOGGING OF FRONT DRIVE OIL FILTER) IS DISPLAYED…………………………………………………………………..1042
W-19 E-9.1 (RISE IN TEMPERATURE OF FRONT DRIVE OIL) IS DISPLAYED ………………………………………………………………1043
W-20 E-9.3 (ABNORMALITY IN CLUTCH OIL PRESSURE SYSTEM) IS DISPLAYED…………………………………………………………….1044
30 DISASSEMBLY AND ASSEMBLY…………………………………………………………………………………………………………..1045
METHOD OF USING MANUAL……………………………………………………………………………………………………………1049
PRECAUTIONS WHEN CARRYING OUT OPERATION…………………………………………………………………………………………….1050
SPECIAL TOOL LIST………………………………………………………………………………………………………………..1053
SKETCHES OF SPECIAL TOOLS…………………………………………………………………………………………………………1056
STARTING MOTOR…………………………………………………………………………………………………………………..1064
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1064
ALTERNATOR ……………………………………………………………………………………………………………………..1065
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1065
ENGINE OIL COOLER ……………………………………………………………………………………………………………….1066
REMOVAL …………………………………………………………………………………………………………………….1066
INSTALLATION…………………………………………………………………………………………………………………1067
FUEL INJECTION PUMP ASSEMBLY………………………………………………………………………………………………………1069
REMOVAL …………………………………………………………………………………………………………………….1069
INSTALLATION…………………………………………………………………………………………………………………1070
FUEL SUPPLY PUMP…………………………………………………………………………………………………………………1071
REMOVAL……………………………………………………………………………………………………………………..1071
INSTALLATION…………………………………………………………………………………………………………………1073
AIR COMPRESSOR…………………………………………………………………………………………………………………..1074
REMOVAL……………………………………………………………………………………………………………………..1074
INSTALLATION…………………………………………………………………………………………………………………1075
AIR CONDITIONER COMPRESSOR ……………………………………………………………………………………………………….1077
REMOVAL……………………………………………………………………………………………………………………..1077
INSTALLATION…………………………………………………………………………………………………………………1078
AIR CONDITIONER CONDENSER ………………………………………………………………………………………………………..1079
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1079
WATER PUMP………………………………………………………………………………………………………………………1080
REMOVAL……………………………………………………………………………………………………………………..1080
INSTALLATION…………………………………………………………………………………………………………………1081
AFTERCOOLER……………………………………………………………………………………………………………………..1083
REMOVAL……………………………………………………………………………………………………………………..1083
INSTALLATION…………………………………………………………………………………………………………………1085
EXHAUST BRAKE CYLINDER …………………………………………………………………………………………………………..1086
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1086
TURBOCHARGER ……………………………………………………………………………………………………………………1087
REMOVAL …………………………………………………………………………………………………………………….1087
INSTALLATION…………………………………………………………………………………………………………………1088
NOZZLE HOLDER……………………………………………………………………………………………………………………1090
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1090
FUEL INJECTOR……………………………………………………………………………………………………………………1091
REMOVAL …………………………………………………………………………………………………………………….1091
INSTALLATION…………………………………………………………………………………………………………………1092
CYLINDER HEAD……………………………………………………………………………………………………………………1095
REMOVAL……………………………………………………………………………………………………………………..1095
INSTALLATION…………………………………………………………………………………………………………………1103
ENGINE …………………………………………………………………………………………………………………………1110
REMOVAL……………………………………………………………………………………………………………………..1110
INSTALLATION…………………………………………………………………………………………………………………1118
RADIATOR, TORQUE CONVERTER OIL COOLER………………………………………………………………………………………………1121
REMOVAL……………………………………………………………………………………………………………………..1121
INSTALLATION…………………………………………………………………………………………………………………1128
RADIATOR, FRONT DRIVE COOLER (HD325-6W)…………………………………………………………………………………………….1131
REMOVAL……………………………………………………………………………………………………………………..1131
INSTALLATION…………………………………………………………………………………………………………………1132
FRONT DRIVE OIL COOLER (HD325-6W)………………………………………………………………………………………………….1133
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1133
OUTPUT SHAFT…………………………………………………………………………………………………………………….1135
REMOVAL……………………………………………………………………………………………………………………..1135
INSTALLATION…………………………………………………………………………………………………………………1138
DISASSEMBLY………………………………………………………………………………………………………………….1139
ASSEMBLY…………………………………………………………………………………………………………………….1140
TORQUE CONVERTER, TRANSMISSION (HD325-6, 405-6)……………………………………………………………………………………..1142
REMOVAL……………………………………………………………………………………………………………………..1142
INSTALLATION…………………………………………………………………………………………………………………1144
TORQUE CONVERTER, TRANSMISSION (HD325-6W)…………………………………………………………………………………………..1146
REMOVAL……………………………………………………………………………………………………………………..1146
INSTALLATION…………………………………………………………………………………………………………………1148
TORQUE CONVERTER VALVE……………………………………………………………………………………………………………1150
REMOVAL AND ASSEMBLY………………………………………………………………………………………………………….1150
DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………………1151
TORQUE CONVERTER, TRANSMISSION…………………………………………………………………………………………………….1152
DISCONNECTION………………………………………………………………………………………………………………..1152
CONNECTION…………………………………………………………………………………………………………………..1153
TORQUE CONVERTER…………………………………………………………………………………………………………………1154
DISASSEMBLY………………………………………………………………………………………………………………….1154
ASSEMBLY…………………………………………………………………………………………………………………….1159
PTO (HD325, 405-6)……………………………………………………………………………………………………………….1164
DISASSEMBLY………………………………………………………………………………………………………………….1164
ASSEMBLY…………………………………………………………………………………………………………………….1165
PTO (HD325-6W)…………………………………………………………………………………………………………………..1167
DISASSEMBLY………………………………………………………………………………………………………………….1167
ASSEMBLY…………………………………………………………………………………………………………………….1168
TRANSMISSION…………………………………………………………………………………………………………………….1169
DISASSEMBLY………………………………………………………………………………………………………………….1169
ASSEMBLY…………………………………………………………………………………………………………………….1187
TRANSMISSION CONTROL VALVE (ECMV ASSEMBLY)………………………………………………………………………………………….1205
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1205
DISASSEMBLY………………………………………………………………………………………………………………….1206
ASSEMBLY…………………………………………………………………………………………………………………….1207
DIFFERENTIAL…………………………………………………………………………………………………………………….1208
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1208
DISASSEMBLY (STANDARD)………………………………………………………………………………………………………..1209
DISASSEMBLY (WITH DIFFERENTIAL LOCK)……………………………………………………………………………………………1214
DIFFERENTIAL GEAR………………………………………………………………………………………………………………..1219
ASSEMBLY (STANDARD)…………………………………………………………………………………………………………..1219
ASSEMBLY (WITH DIFFERENTIAL LOCK)………………………………………………………………………………………………1229
FRONT WHEEL (HD325, 405-6)………………………………………………………………………………………………………..1241
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1241
FRONT WHEEL (HD325-6W)……………………………………………………………………………………………………………1242
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1242
REAR WHEEL………………………………………………………………………………………………………………………1244
REMOVAL……………………………………………………………………………………………………………………..1244
INSTALLATION…………………………………………………………………………………………………………………1245
FRONT BRAKE CALIPER PAD…………………………………………………………………………………………………………..1246
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1246
FRONT BRAKE CALIPER ……………………………………………………………………………………………………………..1247
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1247
DISASSEMBLY………………………………………………………………………………………………………………….1248
ASSEMBLY……………………………………………………………………………………………………………………1249
FRONT WHEEL HUB………………………………………………………………………………………………………………….1251
DISASSEMBLY………………………………………………………………………………………………………………….1251
ASSEMBLY…………………………………………………………………………………………………………………….1253
FRONT FINAL DRIVE CLUTCH, CARRIER (HD325-6W)………………………………………………………………………………………..1256
DISASSEMBLY………………………………………………………………………………………………………………….1256
ASSEMBLY…………………………………………………………………………………………………………………….1260
FRONT FINAL DRIVE, BRAKE (HD325-6W)………………………………………………………………………………………………..1265
DISASSEMBLY………………………………………………………………………………………………………………….1265
ASSEMBLY…………………………………………………………………………………………………………………….1270
FRONT DRIVE SHAFT (HD325-6W)………………………………………………………………………………………………………1277
DISASSEMBLY………………………………………………………………………………………………………………….1277
ASSEMBLY…………………………………………………………………………………………………………………….1281
REAR FINAL DRIVE CARRIER………………………………………………………………………………………………………….1288
REMOVAL……………………………………………………………………………………………………………………..1288
INSTALLATION…………………………………………………………………………………………………………………1289
DISASSEMBLY………………………………………………………………………………………………………………….1290
ASSEMBLY…………………………………………………………………………………………………………………….1291
REAR FINAL DRIVE…………………………………………………………………………………………………………………1292
DISASSEMBLY………………………………………………………………………………………………………………….1292
ASSEMBLY…………………………………………………………………………………………………………………….1294
REAR BRAKE ……………………………………………………………………………………………………………………..1296
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1296
DISASSEMBLY………………………………………………………………………………………………………………….1297
ASSEMBLY…………………………………………………………………………………………………………………….1298
PARKING BRAKE PAD………………………………………………………………………………………………………………..1300
REMOVAL……………………………………………………………………………………………………………………..1300
INSTALLATION…………………………………………………………………………………………………………………1301
PARKING BRAKE CALIPER…………………………………………………………………………………………………………….1302
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1302
DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………………1303
FRONT SUSPENSION CYLINDER (HD325, 405-6)…………………………………………………………………………………………..1304
REMOVAL……………………………………………………………………………………………………………………..1304
INSTALLATION…………………………………………………………………………………………………………………1305
FRONT SUSPENSION CYLINDER (HD325-6W)………………………………………………………………………………………………1306
REMOVAL……………………………………………………………………………………………………………………..1306
INSTALLATION…………………………………………………………………………………………………………………1307
DISASSEMBLY………………………………………………………………………………………………………………….1308
ASSEMBLY…………………………………………………………………………………………………………………….1309
VARIABLE DAMPING SELECTOR VALVE……………………………………………………………………………………………………1312
DISASSEMBLY………………………………………………………………………………………………………………….1312
ASSEMBLY…………………………………………………………………………………………………………………….1313
REAR SUSPENSION………………………………………………………………………………………………………………….1314
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1314
DISASSEMBLY………………………………………………………………………………………………………………….1315
ASSEMBLY…………………………………………………………………………………………………………………….1316
AIR GOVERNOR…………………………………………………………………………………………………………………….1317
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1317
DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………………1318
BRAKE VALVE……………………………………………………………………………………………………………………..1319
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1319
DISASSEMBLY………………………………………………………………………………………………………………….1320
ASSEMBLY…………………………………………………………………………………………………………………….1322
PARKING BRAKE CHAMBER…………………………………………………………………………………………………………….1324
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1324
DISASSEMBLY………………………………………………………………………………………………………………….1325
ASSEMBLY…………………………………………………………………………………………………………………….1326
FRONT BRAKE CHAMBER (HD325, 405-60…………………………………………………………………………………………………1328
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1328
REAR BRAKE CHAMBER……………………………………………………………………………………………………………….1329
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1329
FRONT BRAKE CHAMBER ……………………………………………………………………………………………………………..1330
DISASSEMBLY………………………………………………………………………………………………………………….1330
ASSEMBLY…………………………………………………………………………………………………………………….1332
REAR BRAKE CHAMBER……………………………………………………………………………………………………………….1334
DISASSEMBLY………………………………………………………………………………………………………………….1334
ASSEMBLY…………………………………………………………………………………………………………………….1338
SLACK ADJUSTER…………………………………………………………………………………………………………………..1341
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1341
DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………………1342
TRANSMISSION LUBRICATION, RETARDER BRAKE PUMP (HD325, 405-6) …………………………………………………………………………1343
TRANSMISSION LUBRICATION, RETARDER BRAKE PUMP (HD325-6W)……………………………………………………………………………..1344
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1344
BRAKE COOLING PUMP (HD325, HD405-6)………………………………………………………………………………………………..1345
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1345
BRAKE COOLING PUMP (HD325-6W)……………………………………………………………………………………………………..1346
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1346
HOIST, STEERING PUMP……………………………………………………………………………………………………………..1347
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1347
FRONT DRIVE PUMP (HD325-6W)……………………………………………………………………………………………………….1348
REMOVAL……………………………………………………………………………………………………………………..1348
INSTALLATION…………………………………………………………………………………………………………………1349
EMERGENCY STEERING MOTOR PUMP……………………………………………………………………………………………………..1350
REMOVAL AND INSTALLATION……………………………………………………………………………………………………..1350
TRAVEL DRIVE MOTOR (HD325-6W)……………………………………………………………………………………………………..1351
REMOVAL……………………………………………………………………………………………………………………..1351
INSTALLATION…………………………………………………………………………………………………………………1352
TRAVEL MOTOR (HD325-6W)…………………………………………………………………………………………………………..1353
DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………………1353
STEERING VALVE…………………………………………………………………………………………………………………..1357
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1357
DISASSEMBLY………………………………………………………………………………………………………………….1358
ASSEMBLY…………………………………………………………………………………………………………………….1362
DEMAND VALVE…………………………………………………………………………………………………………………….1368
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1368
DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………………1369
RELIEF VALVE…………………………………………………………………………………………………………………….1370
HOIST VALVE……………………………………………………………………………………………………………………..1371
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1371
DISASSEMBLY………………………………………………………………………………………………………………….1372
ASSSEMBLY……………………………………………………………………………………………………………………1373
STEERING CYLINDER………………………………………………………………………………………………………………..1374
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1374
DISASSEMBLY………………………………………………………………………………………………………………….1375
ASSEMBLY…………………………………………………………………………………………………………………….1377
HOIST CYLINDER…………………………………………………………………………………………………………………..1379
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1379
DISASSEMBLY………………………………………………………………………………………………………………….1380
ASSEMBLY…………………………………………………………………………………………………………………….1382
BODY ASSEMBLY……………………………………………………………………………………………………………………1386
REMOVAL …………………………………………………………………………………………………………………….1386
INSTALLATION…………………………………………………………………………………………………………………1387
TRANSMISSION CONTROLLER…………………………………………………………………………………………………………..1388
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1388
SUSPENSION CONTROLLER…………………………………………………………………………………………………………….1388
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1388
FRONT DRIVE CONTROLLER……………………………………………………………………………………………………………1388
REMOVAL AND INSTALLATION………………………………………………………………………………………………………1388
40 MAINTENANCE STANDARD………………………………………………………………………………………………………………1389
OUTPUT SHAFT…………………………………………………………………………………………………………………….1390
TORQUE CONVERTER VALVE……………………………………………………………………………………………………………1391
TORQUE CONVERTER…………………………………………………………………………………………………………………1392
TRANSMISSION…………………………………………………………………………………………………………………….1394
ECMV (ELECTRONIC CONTROL MODULATION VALVE)………………………………………………………………………………………….1398
FRONT AXLE………………………………………………………………………………………………………………………1399
DIFFERENTIAL…………………………………………………………………………………………………………………….1400
FINAL DRIVE (REAR)……………………………………………………………………………………………………………….1402
FINAL DRIVE (FRONT) HD325-6W………………………………………………………………………………………………………1403
FRONT BRAKE (HD325-6, 405-6)………………………………………………………………………………………………………1405
FRONT BRAKE (HD325-6W)……………………………………………………………………………………………………………1406
REAR BRAKE………………………………………………………………………………………………………………………1408
PARKING BRAKE……………………………………………………………………………………………………………………1409
REAR AXLE SUPPORT………………………………………………………………………………………………………………..1410
STEERING LINKAGE…………………………………………………………………………………………………………………1411
FRONT SUSPENSION CYLINDER…………………………………………………………………………………………………………1413
REAR SUSPENSION CYLINDER………………………………………………………………………………………………………….1414
PARKING BRAKE CHAMBER…………………………………………………………………………………………………………….1415
SLACK ADJUSTER…………………………………………………………………………………………………………………..1416
HYDRAULIC PUMP…………………………………………………………………………………………………………………..1417
DEMAND VALVE…………………………………………………………………………………………………………………….1420
CROSS-OVER RELIEF VALVE…………………………………………………………………………………………………………..1420
HOIST VALVE……………………………………………………………………………………………………………………..1421
STEERING CYLINDER………………………………………………………………………………………………………………..1422
HOIST CYLINDER…………………………………………………………………………………………………………………..1423
90 OTHER……………………………………………………………………………………………………………………………1425
AIR PIPING DIAGRAM (HD325-6, 6W: 6001 AND UP, HD405-6: 2001 AND UP)……………………………………………………………………1427
AIR PIPING DIAGRAM (HD325-6W: 5485 – 6000)………………………………………………………………………………………….1428
AIR PIPING DIAGRAM (HD325-6W: 6001 AND UP)………………………………………………………………………………………….1429
AIR CIRCUIT DIAGRAM (HD325-6W: 5485 – 6000)…………………………………………………………………………………………1430
AIR CIRCUIT DIAGRAM (HD325-6, 6W: 6001 AND UP, HD405-6: 2001 AND UP)…………………………………………………………………..1431
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (1/3 – 3/3) (HD325-6: 5680-6000, HD325-6W: 5706-6000, HD405-6: 1055-2000)…………………………1432
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (1/4-4/4) (HD325-6, 6W: 6001 AND UP, HD405-6: 2001 AND UP)………………………………………1435
DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (1/2-2/2) (HD325-6: 5680-6000, HD325-6W: 5706-6000, HD405-6: 1055-2000)………………………….1439
DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (1/2-2/2) (HD325-6, 6W: 6001-6613, HD405-6: 2001 -2229)………………………………………..1441
DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (1/2-2/2) (HD325-6, 6W: 6614 AND UP, HD405-6: 2230 AND UP)……………………………………..1443
AUTOMATIC RETARD SPEED CONTROL SYSTEM ELECTRICAL CIRCUIT DIAGRAM………………………………………………………………………1445
AUTOMATIC SHIFT CONTROLLER (HD325-6: 5680-6000, HD325-6W: 5706-6000, HD405-6: 1055-2000)…………………………………………………1446
AUTOMATIC SHIFT CONTROLLER (HD325-6, 6W: 6001 AND UP, HD405-6: 2001 AND UP)…………………………………………………………….1447
AUTOMATIC SUSPENSION SYSTEM……………………………………………………………………………………………………….1448
SYSTEM CIRCUIT DIAGRAM (1/2-2/2) (HD325-6: 5680-6000, HD325-6W: 5706-6000, HD405-6: 1055-2000)………………………………………..1448
SYSTEM CIRCUIT DIAGRAM (HD325-6, 6W: 6001 AND UP, HD405-6: 2001 AND UP)…………………………………………………………….1450
PAYLOAD METER (PRINTER TYPE)………………………………………………………………………………………………………1451
ELECTRICAL CIRCUIT DIAGRAM (HD325-6: 5680-6000, HD325-6W: 5706-6000, HD405-6: 1055-2000)……………………………………………..1451
PAYLOAD METER II (CARD TYPE)………………………………………………………………………………………………………1453
ELECTRICAL CIRCUIT DIAGRAM (HD325-6: 5680-6000, HD325-6W: 5706-6000, HD405-6: 1055-2000)……………………………………………..1453
PAYLOAD METER II (PRINTER – CARD TYPE)…………………………………………………………………………………………….. 0
ELECTRICAL CIRCUIT DIAGRAM (HD325-6, 6W: 6001 AND UP, HD405-6: 2001 AND UP)…………………………………………………………1452
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM (HD325-6, 6W: 6001 AND UP, HD405-6: 2001 AND UP)……………………………..1454
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM (1/2-2/2) (HD325-6, 6W: 6001 AND UP, HD405-6: 2001 AND UP)…………………….1455
OIL FILTER CAUTION SYSTEM…………………………………………………………………………………………………………1457
FRONT DRIVE SYSTEM- ELECTRICAL COMPONENT LAYOUT……………………………………………………………………………………..1458
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