Complete service repair manual with Electrical Wiring Diagrams for Komatsu Dump Trucks HD325, HD405, HD465, HD605, HD785, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Dump Trucks HD325, HD405, HD465, HD605, HD785 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
SEN06618-04 – Dump Truck HD325-8, HD405-8 Shop Manual.pdf
SEN00486-14 – Dump Truck HD325-7, HD405-7 Shop Manual.pdf
SEN00486-13 – Dump Truck HD325-7, HD405-7 Shop Manual.pdf
SEBMW00401 – Dump Truck HD325-6, HD405-6, HD465-5, HD605-5, HD785-5 Shop Manual.pdf
SEBM05660510 – Dump Truck HD325-5 Shop Manual.pdf
SEBM015115 – Dump Truck HD325-6, HD405-6 Shop Manual.pdf
SEBM000704 – Dump Truck HD325-6, HD405-6 Shop Manual.pdf
TEN00425-07 – Dump Truck HD325-7, HD405-7 Operation & Maintenance Manual.pdf
TEN00348-02 – Dump Truck HD325-7, HD405-7 Operation & Maintenance Manual.pdf
TEN00331-00 – Dump Truck HD325-7, HD405-7 Operation & Maintenance Manual.pdf
TEN00137-09 – Dump Truck HD325-7, HD405-7 Operation & Maintenance Manual.pdf
TEN00041-05 – Dump Truck HD325-6, HD405-6 Operation & Maintenance Manual.pdf
SEAMW00500 – Dump Truck HD325-6 Operation & Maintenance Manual.pdf
SEAM05660505 – Dump Truck HD325-5 Operation & Maintenance Manual.pdf
SEAM05660501 – Dump Truck HD325-5 Operation & Maintenance Manual.pdf
SEAM000819T – Dump Truck HD325-6, HD405-6 Operation & Maintenance Manual.pdf
SEAM000817T – Dump Truck HD325-6, HD405-6 Operation & Maintenance Manual.pdf
SEAM000808 – Dump Truck HD325-6 Operation & Maintenance Manual.pdf
SEAM000807 – Dump Truck HD325-6 Operation & Maintenance Manual.pdf
SEAM000806 – Dump Truck HD325-6 Operation & Maintenance Manual.pdf
SEAM000805 – Dump Truck HD325-6 Operation & Maintenance Manual.pdf
SEAM000803 – Dump Truck HD325-6 Operation & Maintenance Manual.pdf
SEAM000802 – Dump Truck HD325-6 Operation & Maintenance Manual.pdf
SEAM566D01 – Dump Truck HD320-3, HD325-3 Operation & Maintenance Manual.pdf
GEN00045-05 – Dump Truck HD325-7, HD405-7 Field Assembly Manual.pdf
GEN00020-00 – Dump Truck HD325-6, HD405-6 Field Assembly Manual.pdf
EPAM025104 – Camião Basculante HD325-7, HD405-7 Manual de Operação e Manutenção (PT).pdf
EEAM029201 – Dump Truck HD325-7, HD405-7 Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 15,124 pages
File Format: PDF
Language: English
TABLE OF CONTENTS
EEAM029201 – Dump Truck HD325-7, HD405-7 Operation & Maintenance Manual….3
FOREWORD….5
BEFORE READING THIS MANUAL….6
SAFETY INFORMATION….7
Noise emission levels….8
Vibration levels….9
Guide to Reduce Vibration Levels on Machine….9
INTENDED USE….11
USE OF MACHINE….11
DIRECTIONS OF MACHINE….11
VISIBILITY FROM OPERATOR'S SEAT….11
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….12
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….12
EPA REGULATIONS, ENGINE NUMBER PLATE….12
SERVICE METER POSITION….13
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….13
MACHINE SERIAL NUMBER PLATE (according directive 2006/42/EC)….14
Declaration according Directive 2006/42/EC Annex I point 1.7.4.2 (c)….15
FOREWORD….16
SAFETY….16
OPERATION….17
MAINTENANCE….19
SPECIFICATIONS….22
ATTACHMENTS, OPTIONS….22
INDEX….23
COLOPHON….23
SAFETY….25
SAFETY….26
SAFETY LABELS….29
POSITION FOR ATTACHING SAFETY LABELS….30
SAFETY LABELS….31
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE….38
PRECAUTIONS BEFORE STARTING OPERATION….38
PREPARATIONS FOR SAFE OPERATION….38
FIRE PREVENTION….40
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE….42
DO NOT GET CAUGHT IN DUMP BODY….44
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES….44
UNAUTHORIZED MODIFICATION….44
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS….45
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING….45
PRECAUTIONS FOR OPERATION….46
PRECAUTIONS FOR JOBSITE….46
STARTING ENGINE….48
OPERATION….51
TRANSPORTATION….55
TOWING….56
PRECAUTIONS FOR MAINTENANCE….57
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE….57
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….61
TIRES….66
DISMANTLING THE MACHINE END OF SERVICE LIVE….67
OPERATION….69
GENERAL VIEW….70
GENERAL VIEW OF MACHINE….70
GENERAL VIEW OF CONTROLS AND GAUGES….71
EXPLANATION OF COMPONENTS….73
MACHINE MONITOR….73
CHARACTER DISPLAY….75
CAUTION ITEMS….81
EMERGENCY STOP ITEM….84
METER DISPLAY PORTION….88
CENTRAL WARNING LAMP….94
OTHER FUNCTIONS OF MACHINE MONITOR….95
SWITCHES….99
CONTROL LEVERS AND PEDALS….110
BODY PIVOT PIN….115
LOCATION OF FIRE EXTINGUISHER….115
DUST INDICATOR….116
BATTERY DISCONNECT SWITCH….116
FUSES….117
FUSE CAPACITY AND CIRCUIT NAME….117
POWER SOURCE….120
RELAY LOCATIONS….121
CAR RADIO….122
EXPLANATION OF COMPONENTS….122
METHOD OF OPERATION….125
PRECAUTIONS FOR USE….127
CAR STEREO….128
EXPLANATION OF COMPONENTS….128
METHOD OF OPERATION….133
PRECAUTIONS FOR USE….135
AIR CONDITIONER….136
GENERAL LOCATIONS ON CONTROL PANEL….136
METHOD OF OPERATION….139
PRECAUTIONS WHEN USING AIR CONDITIONER….141
INSPECTION AND MAINTENANCE….141
OPERATION….142
CHECK BEFORE STARTING ENGINE….142
WALK-AROUND CHECK….142
CHECK BEFORE STARTING….145
ADJUSTMENT BEFORE OPERATION….156
OPERATIONS, CHECKS BEFORE STARTING….161
STARTING ENGINE….163
OPERATIONS, CHECKS AFTER STARTING ENGINE….165
BREAKING-IN THE MACHINE….165
WARMING-UP OPERATION….165
STOPPING ENGINE….166
CHECKS AFTER STOPPING ENGINE….166
MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING….167
MOVING MACHINE FORWARD….167
MOVING MACHINE IN REVERSE….169
STOPPING MACHINE….170
SHIFTING GEAR….172
TRAVELLING DOWNHILL….174
BRAKE PERFORMANCE CURVE….176
STEERING THE MACHINE….183
LOADING OPERATIONS….183
DUMP OPERATIONS….184
PRECAUTIONS FOR OPERATION….186
PARKING MACHINE….187
CHECKS AFTER COMPLETION OF WORK….188
LOCKING….188
HANDLING TIRES….189
PRECAUTIONS WHEN HANDLING TIRES….189
T.Km.P.H (Ton-Km-Per-Hour Rating)….189
TIRE T.Km.P.H.AND MAXIMUM SPEED FOR CONTINUOUS TRAVEL (REFERENCE)….190
METHOD OF CALCULATING WORK T.Km.P.H….190
PRECAUTIONS FOR LONG DISTANCE TRAVEL….191
DETERMINING AND MAINTAINING TRAVEL ROAD….192
DETERMINING TRAVEL ROAD….192
MAINTAINING TRAVEL ROAD….192
TRANSPORTATION….193
PRECAUTIONS WHEN TRANSPORTING….193
STEPS FOR TRANSPORTATION….193
METHOD OF SECURING MACHINE….194
METHOD OF LIFTING MACHINE….195
LOCATION OF LIFTING POSITION MARK….196
WEIGHT TABLE….196
LIFTING PROCEDURE….197
COLD WEATHER OPERATION….198
PRECAUTIONS FOR LOW TEMPERATURE….198
FUEL AND LUBRICANTS….198
COOLANT….198
BATTERY….199
INSTALLATION OF RADIATOR CURTAIN….199
PRECAUTIONS AFTER COMPLETION OF WORK….200
AFTER COLD WEATHER….200
LONG-TERM STORAGE….201
BEFORE STORAGE….201
DURING STORAGE….201
AFTER STORAGE….202
PRECAUTIONS BEFORE TRAVELLING AFTER LONG-TERM STORAGE….202
TROUBLESHOOTING….203
AFTER RUNNING OUT OF FUEL….203
IF TRANSMISSION HAS TROUBLE….204
METHOD OF LOWERING DUMP BODY IN EMERGENCY….205
METHOD OF TOWING MACHINE….206
WHEN ENGINE RUNS….208
WHEN ENGINE DOES NOT RUN….208
WHEN PARKING BRAKE HAS BEEN ACTUATED IN EMERGENCY….209
METHOD OF RELEASING PARKING BRAKE IN EMERGENCY….209
IF BATTERY IS DISCHARGED….210
REMOVAL AND INSTALLATION OF BATTERY….210
PRECAUTIONS FOR CHARGING BATTERY….211
STARTING ENGINE WITH BOOSTER CABLE….212
OTHER TROUBLE….214
ELECTRICAL SYSTEM….214
CHASSIS….215
ENGINE….217
ACTION CODE….219
MAINTENANCE….221
GUIDES TO MAINTENANCE….222
OUTLINE OF SERVICE….226
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….226
OIL….226
FUEL….227
COOLANT AND WATER FOR DILUTION….228
GREASE….228
CARRYING OUT KOWA (Komatsu Oil Wear Analysis)….228
STORING OIL AND FUEL….229
FILTERS….230
OUTLINE OF ELECTRIC SYSTEM….230
WEAR PARTS….231
WEAR PARTS LIST….231
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….232
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….233
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….235
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….236
TORQUE LIST….236
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….237
SAFETY CRITICAL PARTS….238
MAINTENANCE SCHEDULE CHART….239
MAINTENANCE SCHEDULE CHART….239
EXPLANATION OF LUBRICATION CHART DECAL….242
SERVICE PROCEDURE….244
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)….244
WHEN REQUIRED….245
CHECK, CLEAN OR REPLACE AIR CLEANER….245
CLEAN INSIDE OF COOLING SYSTEM….252
CHECK LEVEL OF WINDOW WASHER FLUID, ADD FLUID….254
CLEAN AIR CONDITIONER AIR FILTER….254
CHECK REFRIGERANT (GAS) LEVEL….256
CHECK DUMP BODY….257
CHECK LENGTH OF SUSPENSION CYLINDER, CHECK OIL LEVEL….258
BLEED AIR FROM REAR BRAKE….260
BLEED AIR FROM FRONT BRAKE….261
ADJUST PARKING BRAKE….262
CLEAN, CHECK RADIATOR FINS AND AFTER COOLER FINS….263
CHECK PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT….264
SELECTION AND INSPECTION OF TIRES….265
CHECK BEFORE STARTING….268
EVERY 250 HOURS SERVICE….269
CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL….269
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….269
LUBRICATION….270
LUBRICATE DRIVE SHAFT (5 PLACES)….272
CHECK DRIVE SHAFT….272
CHECK LEVEL OF BATTERY ELECTROLYTE….273
CHECK ALTERNATOR BELT TENSION, ADJUST….275
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST….276
CLEAN BREATHERS….277
CHECK FRAME….278
CHECK BRAKING CAPACITY OF FOOT BRAKE….278
CHECK BRAKING CAPACITY OF RETARDER BRAKE….279
CHECK BRAKING CAPACITY OF PARKING BRAKE….280
CHECK, CLEAN AUTOMATIC SUSPENSION….281
CHECK OF ACCUMULATOR GAS PRESSURE….282
EVERY 500 HOURS SERVICE….283
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….283
REPLACE FUEL PREFILTER CARTRIDGE….284
REPLACE TRANSMISSION OIL FILTER ELEMENT….286
CHECK WEAR OF FRONT DISC BRAKE PADS….287
CHECK FAN BELT TENSION, ADJUST….288
EVERY 1000 HOURS SERVICE….289
REPLACE FUEL MAIN FILTER CARTRIDGE….289
CHANGE OIL IN TRANSMISSION CASE, BRAKE SUB TANK, WASH STRAINER….291
REPLACE TRANSMISSION AND REAR BRAKE COOLING OIL FILTER ELEMENT….294
REPLACE BRAKE OIL FILTER ELEMENT….295
LUBRICATION….296
LUBRICATING PARKING BRAKE….297
CHECK WEAR OF REAR BRAKE DISC….298
RECOVER OIL LEAKING FROM FLOATING SEAL….299
CHECK OF ENGINE AIR INTAKE PIPING CLAMPS FOR LOOSENESS….300
EVERY 2000 HOURS SERVICE….301
REPLACE STEERING, HOIST OIL TANK FILTER ELEMENT….301
CLEAN HYDRAULIC TANK STRAINER….301
CHANGE OIL IN FINAL DRIVE CASE….302
CHANGE OIL IN DIFFERENTIAL CASE….302
CLEAN DIFFERENTIAL CASE BREATHER….303
CHECK ALTERNATOR….303
CHECK, ADJUST ENGINE VALVE CLEARANCE….303
CHECK VIBRATION DAMPER….303
CHECK ACCUMULATOR GAS PRESSURE….303
EVERY 4000 HOURS SERVICE….304
CHANGE OIL IN STEERING, HOIST OIL TANK….304
GREASE EXTENDED GREASING INTERVAL DRIVE SHAFT (4 places)….304
CHECK STARTING MOTOR….304
CHECK WATER PUMP….305
CHECK FAN PULLEY AND TENSION PULLEY….305
CHECK ACCUMULATOR….305
CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER….305
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER….306
EVERY 8000 HOURS SERVICE….307
REPLACE HIGH-PRESSURE PIPING CLAMP….307
REPLACE FUEL SPRAY PREVENTION CAP….307
OVERHAUL STARTING MOTOR AND ALTERNATOR….307
EVERY 15000 HOURS SERVICE….308
CHECK, REPLACE STEERING A ARM MOUNTING BOLT….308
SPECIFICATIONS….309
SPECIFICATIONS….310
ATTACHMENTS, OPTIONS….311
SELECTING DUMP BODY….312
HANDLING AIR SUSPENSION SEAT….313
SEAT ADJUSTMENT….313
REMOVAL AND INSTALLATION OF HEADREST….315
HANDLING AUTOMATIC SPIN REGULATOR (ASR)….316
EXPLANATION OF COMPONENTS….316
ACTUATION OF ASR SYSTEM….317
PRECAUTIONS WHEN USING….317
BLEEDING AIR FROM ASR CIRCUIT….318
HANDLING ABS….319
EXPLANATION OF COMPONENTS….319
ABS SYSTEM CHECK AFTER STARTING ENGINE….321
OPERATION OF ABS….321
PRECAUTIONS WHEN USING….322
HANDLING PAYLOAD METER II (CARD TYPE)….323
METHOD OF USING ACCURATELY….324
GENERAL LOCATIONS….325
CONTROLLER SCREEN….325
LEFT FACE OF CONTROLLER….326
EXTERNAL DISPLAY LAMPS….329
COMMUNICATIONS CABLE CONNECTION PORT FOR PERSONAL COMPUTER….329
CONTENT OF DISPLAY (CONTROLLER, EXTERNAL DISPLAY LAMPS)….330
WHEN THE POWER IS ON….330
DISPLAY DURING NORMAL OPERATIONS….331
EXTERNAL DISPLAY LAMPS….334
DISPLAY LEVEL FOR LAMPS….334
ESTIMATE DISPLAY….335
DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER….335
CYCLE DATA….336
ENGINE ON/OFF DATA….338
PROBLEM, WARNING DATA….339
TOTAL PAYLOAD, OVERALL NUMBER OF CYCLES DATA….340
OTHER DATA….340
OPERATION OF SWITCHES….341
CARRYING OUT CALIBRATION….342
FORCED DISPLAY OF TOTAL PAYLOAD AND OVERALL NUMBER OF CYCLES….344
OPERATOR CHECK MODE….346
DIMMING LIGHTS ON MONITOR DISPLAY….361
ADJUSTING BUZZER SOUND LEVEL….361
SETTING MASS UNIT (SELECTING METRIC TON OR SHORT TON)….361
SETTING FORCED PROHIBITION FOR SWITCHES….362
SERVICE CHECK MODE….362
PROBLEM AND WARNING DISPLAY (ERROR CODE)….364
WHEN ERROR CODE F-09 IS DISPLAYED (PROCEDURE FOR REPLACING BATTERY)….371
REPLACING BATTERY….371
PROCEDURE AFTER REPLACING BATTERY….373
OPERATION WHEN ERROR CODE F.CAL IS DISPLAYED OR CONTROLLER HAS BEEN REPLACED….374
CARRYING OUT FORCED INITIALIZATION….375
ARSC (AUTOMATIC RETARDER SPEED CONTROL)….377
EXPLANATION OF COMPONENTS….378
METHOD OF OPERATION….381
USE OF REAR VIEW MONITOR….384
NAME AND FUNCTION OF EACH PART OF REAR VIEW MONITOR….384
SETTING OF REAR VIEW MONITOR….387
CAUTIONS WHEN USING REAR VIEW MONITOR….388
HANDLING DUMPING COUNTER….389
METHOD OF DISPLAYING, RESETTING DUMPING COUNTER….389
HANDLING MACHINES EQUIPPED WITH KOMTRAX….390
BASIC PRECAUTIONS….390
INDEX….393
<A>….395
<B>….395
<C>….395
<D>….395
<E>….395
<F>….395
<G>….395
<H>….395
<I>….395
<L>….396
<M>….396
<O>….396
<P>….396
<R>….396
<S>….396
<T>….396
<U>….396
<W>….397
COLOPHON….399
EPAM025104 – Camião Basculante HD325-7, HD405-7 Manual de Operação e Manutenção (PT)….401
PREFÁCIO….403
ANTES DE LER ESTE MANUAL….404
INFORMAÇÃO DE SEGURANÇA….405
Níveis de emissão de ruído….406
Níveis de vibração….407
Guia de Redução de Níveis de Vibração na Máquina….408
FINALIDADE….409
UTILIZAÇÃO DA MÁQUINA….409
DIRECÇÕES DA MÁQUINA….409
VISIBILIDADE A PARTIR DO ASSENTO DO OPERADOR….409
LOCALIZAÇÃO DAS CHAPAS, QUADRO PARA INTRODUZIR O N.º DE SÉRIE E REPRESENTANTE….410
NÚMERO DE IDENTIFICAÇÃO DO PRODUTO (PIN)/CHAPA DO NÚMERO DE SÉRIE DA MÁQUINA….410
REGULAMENTOS DA EPA, CHAPA DO NÚMERO DO MOTOR….410
POSIÇÃO DO CONTADOR DE SERVIÇO….411
QUADRO PARA INTRODUZIR O N.º DE SÉRIE E O REPRESENTANTE….411
CHAPA DO NÚMERO DE SÉRIE DA MÁQUINA….412
CHAPA DO NÚMERO DE SÉRIE DA MÁQUINA (em conformidade com a Directiva 2006/42/CE)….413
Declaração conforme a Directiva 2006/42/CE, Anexo I, ponto 1.7.4.2 (c)….414
PREFÁCIO….416
SEGURANÇA….416
OPERAÇÃO….417
MANUTENÇÃO….419
ESPECIFICAÇÕES….422
ACESSÓRIOS, OPÇÕES….422
ÍNDICE….423
CÓLOFON….423
SEGURANÇA….425
SEGURANÇA….426
ETIQUETAS DE SEGURANÇA….429
LOCAIS PARA AFIXAÇÃO DE ETIQUETAS DE SEGURANÇA….430
ETIQUETAS DE SEGURANÇA….431
PRECAUÇÕES GERAIS HABITUAIS PARA OPERAÇÃO E MANUTENÇÃO….438
PRECAUÇÕES ANTES DE INICIAR AS OPERAÇÕES….438
PREPARAÇÕES PARA OPERAÇÃO SEGURA….438
PREVENÇÃO DE INCÊNDIO….440
PRECAUÇÕES QUANDO ENTRAR OU SAIR DA MÁQUINA….442
NÃO SE DEIXE APANHAR PELA CARROÇARIA BASCULANTE….444
PRECAUÇÕES RELATIVAS ÀS ESTRUTURAS DE PROTECÇÃO….444
MODIFICAÇÕES NÃO AUTORIZADAS….444
PRECAUÇÕES RELACIONADAS COM OS ACESSÓRIOS E OPÇÕES….445
PRECAUÇÕES QUANDO COLOCAR O MOTOR A TRABALHAR DENTRO DE UM EDIFÍCIO….445
PRECAUÇÕES DE OPERAÇÃO….446
PRECAUÇÕES NO LOCAL DE TRABALHO….446
ARRANQUE DO MOTOR….448
OPERAÇÃO….451
TRANSPORTE….455
REBOCAR….456
PRECAUÇÕES DURANTE A MANUTENÇÃO….457
PRECAUÇÕES ANTES DE INICIAR A INSPECÇÃO E A MANUTENÇÃO….457
PRECAUÇÕES DURANTE A INSPECÇÃO E A MANUTENÇÃO….461
PNEUS….466
DESMONTAGEM DA MÁQUINA NO FIM DA SUA VIDA ÚTIL….467
OPERAÇÃO….469
VISÃO GERAL….470
VISÃO GERAL DA MÁQUINA….470
VISÃO GERAL DE CONTROLOS E INDICADORES….471
EXPLICAÇÃO DOS COMPONENTES….473
MONITOR DA MÁQUINA….473
VISOR DE CARACTERES….475
ITENS DE AVISO….481
ITEM DE PARAGEM DE EMERGÊNCIA….484
PARTE DO VISOR DE MEDIÇÃO….488
LUZ CENTRAL DE AVISO….494
OUTRAS FUNÇÕES DO MONITOR DA MÁQUINA….495
INTERRUPTORES….499
PEDAIS E ALAVANCAS DE CONTROLO….510
CAVILHA PIVÔ DA CARROÇARIA….515
LOCALIZAÇÃO DO EXTINTOR….515
INDICADOR DE POEIRAS….516
INTERRUPTOR DE DESCONEXÃO DA BATERIA (se instalado)….516
FUSÍVEIS….517
CAPACIDADE DOS FUSÍVEIS E NOME DO CIRCUITO….517
FONTE DE ALIMENTAÇÃO….520
LOCALIZAÇÕES DE RELÉS….521
AUTO-RÁDIO….522
EXPLICAÇÃO DOS COMPONENTES….522
MÉTODO DE OPERAÇÃO….525
PRECAUÇÕES DURANTE A UTILIZAÇÃO….527
AUTO-RÁDIO ESTÉREO….528
EXPLICAÇÃO DOS COMPONENTES….528
MÉTODO DE OPERAÇÃO….533
PRECAUÇÕES DURANTE A UTILIZAÇÃO….535
AR CONDICIONADO….536
LOCALIZAÇÕES GERAIS NO PAINEL DE CONTROLO….536
MÉTODO DE OPERAÇÃO….539
PRECAUÇÕES AO UTILIZAR O AR CONDICIONADO….541
INSPECÇÃO E MANUTENÇÃO….541
OPERAÇÃO….542
VERIFICAÇÕES ANTES DO ARRANQUE DO MOTOR….542
VERIFICAÇÃO GERAL DA MÁQUINA….542
VERIFICAÇÕES ANTES DO ARRANQUE….545
REGULAÇÕES ANTES DA OPERAÇÃO….556
OPERAÇÕES E VERIFICAÇÕES ANTES DO ARRANQUE….561
ARRANQUE DO MOTOR….563
OPERAÇÕES E VERIFICAÇÕES APÓS O ARRANQUE DO MOTOR….565
RODAGEM DA MÁQUINA….565
OPERAÇÃO DE AQUECIMENTO….565
PARAR O MOTOR….566
VERIFICAÇÕES APÓS A PARAGEM DO MOTOR….566
ANDAMENTO DA MÁQUINA (AVANÇAR, MARCHA-ATRÁS), PARAGEM….567
DESLOCAR A MÁQUINA PARA A FRENTE….567
ANDAMENTO DA MÁQUINA EM MARCHA-ATRÁS….569
PARAR A MÁQUINA….570
MUDANÇA DE VELOCIDADES….572
DESLOCAÇÃO EM DESCIDAS….574
GRÁFICO DE DESEMPENHO DO TRAVÃO….576
DIRECÇÃO DA MÁQUINA….583
OPERAÇÕES DE CARGA….583
OPERAÇÕES DE DESCARGA….584
PRECAUÇÕES DE OPERAÇÃO….586
ESTACIONAR A MÁQUINA….587
VERIFICAÇÕES DEPOIS DE TERMINAR O TRABALHO….588
FECHAR….588
MANUSEAMENTO DOS PNEUS….589
PRECAUÇÕES QUANDO MANUSEAR OS PNEUS….589
T.Km.P.H (Ton-Km-Por Hora)….589
T.Km.P.H. DOS PNEUS E VELOCIDADE MÁXIMA PARA DESLOCAÇÃO CONTÍNUA (REFERÊNCIA)….590
MÉTODO DE CÁLCULO DA T.Km.P.H. DE TRABALHO….590
PRECAUÇÕES EM VIAGENS DE LONGA DISTÂNCIA….591
DETERMINAR E MANTER AS VIAS DE DESLOCAÇÃO….592
DETERMINAR AS VIAS DE DESLOCAÇÃO….592
MANTER AS VIAS DE DESLOCAÇÃO….592
TRANSPORTE….593
PRECAUÇÕES DURANTE O TRANSPORTE….593
PROCEDIMENTOS PARA O TRANSPORTE….593
MÉTODO PARA PRENDER A MÁQUINA….594
MÉTODO DE ELEVAÇÃO DA MÁQUINA….595
LOCALIZAÇÃO DA MARCA DA POSIÇÃO DE ELEVAÇÃO….596
TABELA DE PESOS….596
PROCEDIMENTO DE ELEVAÇÃO….597
OPERAÇÃO EM TEMPO FRIO….598
PRECAUÇÕES PARA BAIXAS TEMPERATURAS….598
COMBUSTÍVEL E LUBRIFICANTES….598
LÍQUIDO DE REFRIGERAÇÃO….598
BATERIA….599
INSTALAÇÃO DA CORTINA DO RADIADOR….599
PRECAUÇÕES DEPOIS DE TERMINAR O TRABALHO….600
DEPOIS DO TEMPO FRIO….600
ARMAZENAMENTO PROLONGADO….601
ANTES DE ARMAZENAR….601
DURANTE O ARMAZENAMENTO….601
DEPOIS DO ARMAZENAMENTO….602
PRECAUÇÕES ANTES DO ANDAMENTO APÓS ARMAZENAMENTO PROLONGADO….602
RESOLUÇÃO DE PROBLEMAS….603
DEPOIS DE FICAR SEM COMBUSTÍVEL….603
SE A TRANSMISSÃO TIVER PROBLEMAS….604
MÉTODO DE BAIXAR A CARROÇARIA BASCULANTE NUMA EMERGÊNCIA….605
MÉTODO DE REBOQUE DA MÁQUINA….606
QUANDO O MOTOR FUNCIONA….608
QUANDO O MOTOR NÃO FUNCIONA….608
QUANDO O TRAVÃO DE ESTACIONAMENTO FOI ACTIVADO EM SITUAÇÃO DE EMERGÊNCIA….609
MÉTODO PARA DESTRAVAR O TRAVÃO DE ESTACIONAMENTO NUMA EMERGÊNCIA….609
SE A BATERIA ESTIVER DESCARREGADA….610
REMOÇÃO E INSTALAÇÃO DA BATERIA….610
PRECAUÇÕES AO CARREGAR A BATERIA….611
ARRANQUE DO MOTOR COM CABOS AUXILIARES….612
OUTROS PROBLEMAS….615
SISTEMA ELÉCTRICO….615
CHASSI….616
MOTOR….618
CÓDIGO DE ACÇÃO….620
MANUTENÇÃO….621
LINHAS DE ORIENTAÇÃO PARA A MANUTENÇÃO….622
LINHAS GERAIS DE ASSISTÊNCIA….626
MANUSEAMENTO DE ÓLEO, COMBUSTÍVEL, LÍQUIDO DE REFRIGERAÇÃO E REALIZAÇÃO DO TESTE CLÍNICO DO ÓLEO….627
ÓLEO….627
COMBUSTÍVEL….628
LÍQUIDO DE REFRIGERAÇÃO E ÁGUA PARA DILUIÇÃO….629
LUBRIFICANTES….629
REALIZAÇÃO DA KOWA (Análise ao Desgaste do Óleo da Komatsu)….630
ARMAZENAMENTO DE ÓLEO E COMBUSTÍVEL….631
FILTROS….631
LINHAS GERAIS DO SISTEMA ELÉCTRICO….631
PEÇAS SUJEITAS A DESGASTE….632
LISTA DE PEÇAS SUJEITAS A DESGASTE….632
COMBUSTÍVEL, LÍQUIDO DE REFRIGERAÇÃO E LUBRIFICANTE RECOMENDADOS….633
UTILIZAÇÃO DO COMBUSTÍVEL, DO LÍQUIDO REFRIGERANTE E DOS LUBRIFICANTES DE ACORDO COM A TEMPERATURA AMBIENTE….634
MARCAS RECOMENDADAS, QUALIDADE RECOMENDADA PARA PRODUTOS QUE NÃO SEJAM ÓLEO DE ORIGEM DA KOMATSU….636
BINÁRIOS DE APERTO STANDARD PARA PARAFUSOS E PORCAS….637
LISTA DE BINÁRIOS….637
SUBSTITUIÇÃO PERIÓDICA DE PEÇAS ESSENCIAIS À SEGURANÇA….638
PEÇAS ESSENCIAIS À SEGURANÇA….639
ESQUEMA DO PROGRAMA DE MANUTENÇÃO….640
ESQUEMA DO PROGRAMA DE MANUTENÇÃO….640
EXPLICAÇÃO DA ETIQUETA COM O PLANO DE LUBRIFICAÇÃO….642
PROCEDIMENTOS DE MANUTENÇÃO….644
MANUTENÇÃO DAS 250 HORAS DE SERVIÇO INICIAIS (SÓ APÓS AS PRIMEIRAS 250 HORAS)….644
QUANDO NECESSÁRIO….645
VERIFIQUE, LIMPE OU SUBSTITUA O FILTRO DE AR….645
LIMPE O INTERIOR DO SISTEMA DE REFRIGERAÇÃO….652
VERIFIQUE O NÍVEL DO LÍQUIDO LIMPA-VIDROS, ADICIONE LÍQUIDO….655
LIMPEZA DO FILTRO DE AR DO AR CONDICIONADO….655
VERIFIQUE O NÍVEL DO REFRIGERANTE (GÁS)….656
VERIFICAÇÃO DA CARROÇARIA BASCULANTE….657
VERIFIQUE O COMPRIMENTO DO CILINDRO DE SUSPENSÃO, VERIFIQUE O NÍVEL DE ÓLEO….658
PURGUE O AR DOS TRAVÕES DE TRÁS….660
PURGUE O AR DOS TRAVÕES DIANTEIROS….661
AFINAR O TRAVÃO DE ESTACIONAMENTO….662
LIMPE E VERIFIQUE AS ALETAS DO RADIADOR E AS ALETAS DO REFRIGERADOR POSTERIOR….663
VERIFIQUE A FOLGA DO ENCAIXE DE SAÍDA DO EIXO DE SAÍDA….664
SELECÇÃO E INSPECÇÃO DOS PNEUS….665
VERIFICAÇÕES ANTES DO ARRANQUE….668
CADA 250 HORAS DE SERVIÇO….669
VERIFIQUE O NÍVEL DO ÓLEO DA CAIXA DO DIFERENCIAL, ADICIONE ÓLEO….669
VERIFIQUE O NÍVEL DE ÓLEO DA CAIXA DE TRANSMISSÃO FINAL, ADICIONE ÓLEO….669
LUBRIFICAÇÃO….670
LUBRIFIQUE O EIXO DA TRANSMISSÃO (5 PONTOS)….672
VERIFIQUE O VEIO DE TRANSMISSÃO….672
VERIFIQUE O NÍVEL DO ELECTRÓLITO DA BATERIA….673
VERIFIQUE E AJUSTE A TENSÃO DA CORREIA DO ALTERNADOR….674
VERIFIQUE E AJUSTE A TENSÃO DA CORREIA DO COMPRESSOR DO AR CONDICIONADO….676
LIMPE OS RESPIRADORES….677
VERIFIQUE A CARROÇARIA….678
VERIFIQUE A CAPACIDADE DE TRAVAGEM DO TRAVÃO DE PÉ….678
VERIFIQUE A CAPACIDADE DE TRAVAGEM DO TRAVÃO RETARDADOR….679
VERIFIQUE A CAPACIDADE DO TRAVÃO DE ESTACIONAMENTO….680
VERIFIQUE E LIMPE A SUSPENSÃO AUTOMÁTICA….681
VERIFIQUE A PRESSÃO DO GÁS DO ACUMULADOR….682
CADA 500 HORAS DE SERVIÇO….683
MUDE O ÓLEO DO CÁRTER DE ÓLEO DO MOTOR, SUBSTITUA O CARTUCHO DO FILTRO DE ÓLEO DO MOTOR….683
SUBSTITUA O CARTUCHO DO PRÉ-FILTRO DE COMBUSTÍVEL….684
SUBSTITUA O ELEMENTO DO FILTRO DO ÓLEO DA TRANSMISSÃO….686
VERIFIQUE O DESGASTE DOS CALÇOS DOS TRAVÕES DE DISCO….687
VERIFIQUE A TENSÃO DA CORREIA DA VENTOINHA, AJUSTE….688
CADA 1000 HORAS DE SERVIÇO….689
SUBSTITUA O CARTUCHO DO FILTRO PRINCIPAL DE COMBUSTÍVEL….689
SUBSTITUA O CARTUCHO DO AGENTE ANTICORROSÃO….691
MUDE O ÓLEO DA CAIXA DE TRANSMISSÃO, DEPÓSITO DE RESERVA DO TRAVÃO, FILTRO DE LAVAGEM….692
SUBSTITUA O ELEMENTO DO FILTRO DO ÓLEO DE REFRIGERAÇÃO DA TRANSMISSÃO E DO TRAVÃO TRASEIRO….695
SUBSTITUA O ELEMENTO DO FILTRO DO ÓLEO DOS TRAVÕES….696
LUBRIFICAÇÃO….697
LUBRIFICAÇÃO DO TRAVÃO DE ESTACIONAMENTO….698
VERIFIQUE O DESGASTE DOS DISCOS DOS TRAVÕES DE TRASEIROS….699
RECOLHA O ÓLEO QUE VERTE DA VEDAÇÃO FLUTUANTE….700
VERIFIQUE SE AS BRAÇADEIRAS DA TUBAGEM DE ADMISSÃO DE AR DO MOTOR ESTÃO SOLTAS….701
CADA 2000 HORAS DE SERVIÇO….702
SUBSTITUA O ELEMENTO DO FILTRO DO DEPÓSITO DO ÓLEO DA DIRECÇÃO, ELEVAÇÃO….702
LIMPE O FILTRO DO DEPÓSITO HIDRÁULICO….702
MUDE O ÓLEO DA CAIXA DE TRANSMISSÃO FINAL….703
MUDE O ÓLEO DA CAIXA DO DIFERENCIAL….703
LIMPE O RESPIRADOR DA CAIXA DO DIFERENCIAL….704
VERIFIQUE O ALTERNADOR….704
VERIFIQUE E AJUSTE A FOLGA DA VÁLVULA DO MOTOR….704
VERIFIQUE O AMORTECEDOR DE VIBRAÇÃO….704
VERIFIQUE A PRESSÃO DO GÁS DO ACUMULADOR….704
CADA 4000 HORAS DE SERVIÇO….705
MUDE O ÓLEO NO DEPÓSITO DO ÓLEO DA DIRECÇÃO, ELEVAÇÃO….705
LUBRIFIQUE O EIXO DE TRACÇÃO DE INTERVALO DE LUBRIFICAÇÃO PROLONGADO (4 pontos)….705
VERIFIQUE O MOTOR DE ARRANQUE….706
VERIFIQUE A BOMBA DE ÁGUA….706
VERIFIQUE A POLIA DA VENTOINHA E A POLIA DE TENSÃO….706
VERIFIQUE O ACUMULADOR….706
VERIFIQUE SE A BRAÇADEIRA DE ALTA PRESSÃO ESTÁ DESAPERTADA E SE A BORRACHA ENDURECEU….706
VERIFIQUE SE O TAMPÃO DE PREVENÇÃO DA PULVERIZAÇÃO DE COMBUSTÍVEL SE PERDEU E SE A BORRACHA ENDURECEU….707
CADA 8000 HORAS DE SERVIÇO….708
SUBSTITUA A BRAÇADEIRA DA TUBAGEM DE ALTA PRESSÃO….708
SUBSTITUA O TAMPÃO DE PREVENÇÃO DE PULVERIZAÇÃO DE COMBUSTÍVEL….708
INSPECCIONE O ALTERNADOR E O MOTOR DE ARRANQUE….708
CADA 15000 HORAS DE SERVIÇO….709
VERIFIQUE, SUBSTITUA O PARAFUSO DE MONTAGEM DO BRAÇO “A” DA DIRECÇÃO….709
ESPECIFICAÇÕES….711
ESPECIFICAÇÕES….712
ACESSÓRIOS, OPÇÕES….713
SELECÇÃO DA CARROÇARIA BASCULANTE….714
MANUSEAR O ASSENTO COM SUSPENSÃO DE AR….715
REGULAÇÃO DO ASSENTO….715
REMOÇÃO E INSTALAÇÃO DO APOIO DA CABEÇA….717
MANUSEAMENTO DO REGULADOR AUTOMÁTICO DE ROTAÇÃO (ASR)….718
EXPLICAÇÃO DOS COMPONENTES….718
ACTIVAÇÃO DO SISTEMA ASR….719
PRECAUÇÕES DURANTE A UTILIZAÇÃO….719
PURGA DO AR DO CIRCUITO ASR….720
MANUSEAMENTO DO CONTADOR DE CARGA ÚTIL II (TIPO CARTÃO)….721
MÉTODO DE UTILIZAÇÃO COM PRECISÃO….722
LOCALIZAÇÕES GERAIS….723
VISOR DO CONTROLADOR….723
LADO ESQUERDO DO CONTROLADOR….724
LUZES INDICADORAS EXTERNAS….727
PORTA DE LIGAÇÃO DO CABO DE COMUNICAÇÕES AO PC….727
VISOR DE CONTEÚDO (CONTROLADOR, LUZES INDICADORAS EXTERNAS)….728
QUANDO A ALIMENTAÇÃO ESTÁ LIGADA….728
VISOR DURANTE AS OPERAÇÕES NORMAIS….729
LUZES INDICADORAS EXTERNAS….732
LUZES DE NÍVEL DO VISOR….732
VISOR DE ESTIMATIVA….733
DETALHES DOS DADOS GUARDADOS NA MEMÓRIA DO CONTADOR DE CARGA ÚTIL….733
DADOS DO CICLO….734
DADOS DE LIGAR/DESLIGAR MOTOR….736
DADOS DE PROBLEMA, AVISO….737
DADOS DE CARGA ÚTIL TOTAL, NÚMERO GERAL DE CICLOS….738
OUTROS DADOS….738
UTILIZAÇÃO DOS INTERRUPTORES….739
EFECTUAR A CALIBRAÇÃO….740
VISOR FORÇADO DA CARGA ÚTIL TOTAL E DO NÚMERO GERAL DE CICLOS….742
MODO DE VERIFICAÇÃO DO OPERADOR….744
REGULAR A LUMINOSIDADE NO VISOR DO MONITOR….759
REGULAR O NÍVEL DE SOM DO ALARME….759
DEFINIR A UNIDADE DE MASSA (SELECCIONAR TONELADA MÉTRICA OU AMERICANA)….759
DEFINIÇÃO DE PROIBIÇÃO FORÇADA PARA INTERRUPTORES….760
MODO DE VERIFICAÇÃO DO SERVIÇO….760
VISOR DE PROBLEMAS E DE AVISO (CÓDIGO DE ERRO)….762
QUANDO É VISUALIZADO O CÓDIGO F-09 (PROCEDIMENTO PARA SUBSTITUIR A BATERIA)….769
SUBSTITUIR A BATERIA….769
PROCEDIMENTO APÓS A SUBSTITUIÇÃO DA BATERIA….771
OPERAÇÃO QUANDO É VISUALIZADO O CÓDIGO DE ERRO F.CAL OU O CONTROLADOR TIVER SIDO SUBSTITUÍDO….772
EFECTUAR INICIALIZAÇÃO FORÇADA….773
ARSC (CONTROLO AUTOMÁTICO DO RETARDADOR DA VELOCIDADE)….775
EXPLICAÇÃO DOS COMPONENTES….776
MÉTODO DE OPERAÇÃO….779
UTILIZAR O MONITOR DE VISÃO TRASEIRA….782
NOME E FUNÇÃO DE CADA PARTE DO MONITOR DE VISÃO TRASEIRA….782
UTILIZAR O MONITOR DE VISÃO TRASEIRA….786
CUIDADOS QUANDO UTILIZAR O MONITOR DE VISÃO TRASEIRA….787
MANUSEAMENTO DO CONTADOR DE DESCARGA….788
MÉTODO DE VISUALIZAÇÃO, REDEFINIR O CONTADOR DE DESCARGA….788
MANUSEAMENTO DE MÁQUINAS EQUIPADAS COM KOMTRAX….789
PRECAUÇÕES BÁSICAS….789
ÍNDICE….791
<A>….793
<B>….793
<C>….793
<D>….793
<E>….793
<F>….793
<I>….793
<L>….793
<M>….793
<O>….794
<P>….794
<R>….794
<S>….794
<T>….794
<U>….795
<V>….795
CÓLOFON….797
GEN00020-00 – Dump Truck HD325-6, HD405-6 Field Assembly Manual….799
COVER….799
CONTENTS….800
HD325-6/HD405-6….801
LIFTING UP CHASSIS ASSEMBLY….801
INSTALLING FRONT AXLE….803
INSTALLING FRONT TIRES….805
INSTALLING REAR TIRES….807
INSTALLING RIGHT FRONT LIGHT ASSEMBLY….809
INSTALLING GUARDS….811
INSTALLING CATWALK AND GUARD….813
ASSEMBLING RIGHT PLATFORM….815
INSTALLING MIRRORS….817
INSTALLING BODY PINS….819
ADJUSTING BODY SHIMS….821
INSTALLING BODY ACCESSORIES….825
INSTALLING BODY GUARDS….827
HD325-6….829
PREPARATION WORK….829
ASSEMBLY OF SPLIT BODY….831
WELDING BODY….833
WELDING BODY PROTECTOR….839
HD405-6….843
PREPARATION WORK….843
ASSEMBLY OF SPLIT BODY….845
WELDING BODY….847
WELDING BODY PROTECTOR….853
APPENDIX….858
FIELD ASSEMBLY INSPECTION REPORT….858
GEN00045-05 – Dump Truck HD325-7, HD405-7 Field Assembly Manual….866
COVER….866
CONTENTS….867
1. Outline of division (Only main components)….869
2. Dimensions of main components….870
3. Rough schedule of assembly and welding….871
4. List of equipments, tools, and consumables….874
5. Assembly process No….0
0010 Oil, grease, and coolant….878
0020 Levels of oil, grease, and coolant….879
0030 Slinging bare machine….880
0040 Positioning bare machine….881
0045 Assembly of tire and wheel assembly….882
0050 Installing tire and wheel assembly….883
0060 Installing rear tire valve extension….884
0065 Installing rear monitor….885
0080 Installing L.H platform….886
0090 Installing L.H handrail….887
0091 Installation of left handrail (Diagonal ladder specification)….888
0095 Installation of diagonal ladder (Diagonal ladder specification)….889
0096 Installation of diagonal ladder 1 (Diagonal ladder specification)….890
0097 Installation of diagonal ladder 2 (Diagonal ladder specification)….891
0098 Installation of diagonal ladder 3 (Diagonal ladder specification)….892
0100 Installing radio antenna and fixing its cable….893
0110 Installing side view mirrors….894
0120 Installing under view mirrors (For general overseas countries)….895
0121 Installing under view mirrors (For EU)….896
0122 Installation of under view mirror (Diagonal ladder specification)….897
0130 Installation of KOMTRAX antenna (If equipped)….898
0140 Installing left side mudguard….899
0150 Installing right side mudguard….900
0160 Preparation of installing body….901
0170 Welding body….902
0180 Installing 150-mm body spill guard (If equipped)….903
0181 Installing 250-mm body spill guard (If equipped)….904
0191 Installing platform guard….905
0200 Slinging body….906
0210 Installing body hinge pin….907
0220 Installing hoist cylinder….908
0230 Installing body shim….909
0240 Adjusting body shims….910
0250 Installing muffler flange….911
0260 Installing body accessories….912
0270 Connecting dump sensor….913
0280 Procedure for adjusting dump sensor….914
0290 Calibrating dump control….915
0300 Greasing….916
0310 Touching up….917
0320 Adjusting suspension….918
0330 Sticking body decal….919
0340 Adjustment of view range in mirror (For EU)….920
0341 Adjustment of view range in mirror (For general overseas countries)….921
0350 Check and addition of lubricants (1/2)….922
0360 Check and addition of lubricants (2/2)….923
C-0010 Preparation of welding body….924
C-0020 Assembly of split body….925
C-0030 Tack welding body….926
C-0040 Welding body….927
C-0050 Welding body instruction (1/2)….928
C-0060 Welding body instruction (2/2)….929
C-0070 Turn over the body….930
C-0080 Welding body protector (1/2)….931
C-0090 Welding body protector (2/2)….932
C-0100 Finishing and painting welded parts of body….933
Appendix : Field assembly inspection report….935
SEAM000802 – Dump Truck HD325-6 Operation & Maintenance Manual….943
COVER….943
FOREWORD….944
EXPLANATION OF SYMBOLS….945
BREAKING IN YOUR NEW MACHINE….945
CONTENTS….946
SAFETY HINTS….947
OPERATION….948
MAINTENANCE….959
POSITION FOR STICKING CAUTION AND NAME PLATES….964
OPERATION….967
GENERAL LOCATIONS AND SPECIFICATIONS….968
INSTRUMENTS AND CONTROLS….969
OPERATING YOUR MACHINE….1017
CHECKS BEFORE OPERATING THE MACHINE….1017
BEFORE STARTING THE ENGINE….1021
TO START THE ENGINE….1023
AFTER STARTING….1026
TO MOVE THE MACHINE OFF….1027
CHANGING GEAR SPEED….1029
TRAVEL….1030
REVERSING….1033
OPERATING DUMP BODY….1034
TO STOP THE MACHINE….1036
TO STOP THE ENGINE….1038
BRAKE PERFORMANCE GRAPH….1040
PRECAUTIONS REGARDING TYPE OF LOAD….1047
PRECAUTIONS FOR MACHINE OPERATION….1048
MAINTENANCE….1050
PRECAUTIONS FOR MAINTENANCE….1051
MAINTENANCE TABLE….1054
OIL FILLER AND LEVEL GAUGE POSITIONS….1059
CHECK BEFORE STARTING….1060
EVERY 50 HOURS SERVICE….1071
EVERY 250 HOURS SERVICE….1073
EVERY 500 HOURS SERVICE….1082
EVERY 1000 HOURS SERVICE….1087
EVERY 2000 HOURS SERVICE….1093
EVERY 4000 HOURS SERVICE….1098
WHEN REQUIRED….1099
ADJUSTMENT….1109
PERIODICAL REPLACEMENT OF SAFETY PARTS….1114
OPERATING INSTRUMENTS….1116
PLANNING AND CONSTRUCTION OF HAUL ROADS….1117
METHOD OF RELEASING PARKING BRAKE AND EMERGENCY BRAKE WHEN ACTUATED IN A EMERGENCY….1119
INSTRUCTIONS FOR TOWING THE MACHINE….1122
HANDLING THE TIRES….1123
OPERATING THE PAYLOAD METER….1127
OPERATING THE AIR CONDITIONER….1139
OPERATING THE CAR RADIO….1143
OPERATING THE CAR STEREO….1145
HANDLING OF BATTERY….1149
COLD WEATHER OPERATION….1153
STORAGE….1157
OPTIONAL PARTS,ATTACHMENT….1159
SELECTION OF DUMP BODY….1160
OPTIONAL PARTS,ATTACHMENTS….1161
TROUBLE SHOOTING GUIDE….1162
SERVICE METER,SERIAL NUMBERS,LUBRICANTS….1170
SERVICE METER….1171
MACHINE AND ENGINE SERIAL NUMBERS….1172
FUEL,COOLANT AND LUBRICANTS….1173
OPERATION AND MAINTENANCE (EQUIPPED WITH A CLUSTER GAUGE PANEL)….1177
INSTRUMENTS AND CONTROLS….1178
METERS AND LAMPS….1178
MACHINE WARNING DEVICE….1182
MECHATRONICS EQUIPMENT CONTROLLER….1186
FUSES….1187
TO MOVE THE MACHINE OFF….1189
m.CHECK MACHINE WARNING DEVICE….1190
SERVICE METER….1192
SEAM000803 – Dump Truck HD325-6 Operation & Maintenance Manual….1193
COVER….1193
1.FOREWORD….1194
2.SAFETY INFORMATION….1195
3.INTRODUCTION….1196
3.1 FEATURES….1196
3.2 BREAKING IN THE MACHINE….1196
4.LOCATION OF PLATES,TABLE TO ENTER SERIAL NUMBER AND DISTRIBUTOR….1197
4.1 MACHINE SERIAL NO. PLATE POSITION….1197
4.2 ENGINE SERIAL NO. PLATE POSITION….1197
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….1197
5.CONTENTS….1198
SAFETY….1201
6.GENERAL PRECAUTIONS….1202
7.PRECAUTIONS DURING OPERATION….1207
7.1 BEFORE STARTING ENGINE….1207
7.2 OPERATING MACHINE….1209
7.3 BATTERY….1213
7.4 TOWING….1214
8.PRECAUTIONS FOR MAINTENANCE….1215
8.1 BEFORE CARRYING OUT MAINTENANCE….1215
8.2 DURING MAINTENANCE….1217
8.3 TIRES….1221
9.POSITION FOR ATTACHING SAFETY LABELS….1223
9.1 POSITION FOR ATTACHING SAFETY LABELS….1223
OPERATION….1226
10.GENERAL VIEW….1227
10.1 GENERAL VIEW OF MACHINE….1227
10.2 GENERAL VIEW OF CONTROLS AND GAUGES….1228
11.EXPLANATION OF COMPONENTS….1229
11.1 MACHINE MONITOR….1229
11.2 SWITCHES….1248
11.3 CONTROL LEVERS AND PEDALS….1255
11.4 MECHATRONICS EQUIPMENT CONTROLLER….1259
11.5 SAFETY PIN….1259
11.6 FUSES….1260
11.7 CAR RADIO….1262
11.8 CAR STEREO….1266
11.9 AIR CONDITIONER….1269
12.OPERATION….1272
12.1 CHECK BEFORE STARTING ENGINE….1272
12.2 STARTING ENGINE….1289
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE….1291
12.4 MOVING MACHINE OFF….1292
12.5 SHIFTING GEAR….1294
12.6 TRAVELING DOWNHILL….1295
12.7 TRAVELING IN REVERSE….1301
12.8 STEERING THE MACHINE….1302
12.9 STOPPING THE MACHINE….1303
12.10 OPERATING DUMP BODY….1305
12.11 PRECAUTIONS FOR OPERATION….1307
12.12 PARKING MACHINE….1308
12.13 CHECKS AFTER COMPLETION WORK….1309
12.14 STOPPING ENGINE….1309
12.15 CHECK AFTER STOPPING ENGINE….1309
12.16 LOCKING….1310
12.17 HANDLING TIRES….1311
13.DETERMINING AND MAINTAINING TRAVEL ROAD….1314
13.1 DETERMINING TRAVEL ROAD….1314
13.2 MAINTAINING TRAVEL ROAD….1315
14.COLD WEATHER OPERATION….1316
14.1 PRECAUTIONS FOR LOW TEMPERATURE….1316
14.2 PRECAUTIONS AFTER COMPLETION OF WORK….1318
14.3 AFTER COLD WEATHER….1318
15.LONG-TERM STORAGE….1319
15.1 BEFORE STORAGE….1319
15.2 DURING STORAGE….1319
15.3 AFTER STORAGE….1320
15.4 PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE….1320
16.TROUBLESHOOTING….1321
16.1 AFTER RUNNING OUT OF FUEL….1321
16.2 TOWING MACHINE….1321
16.3 IF BATTERY IS DISCHARGED….1325
16.4 OTHER TROUBLE….1329
MAINTENANCE ….1339
17.GUIDES TO MAINTENANCE….1340
18.OUTLINES OF SERVICE….1343
18.1 OUTLINE OF OIL,FUEL,COOLANT….1343
18.2 OUTLINE OF ELECTRIC SYSTEM….1346
19.WEAR PARTS LIST….1347
20.USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….1348
21.STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….1352
21.1 INTRODUCTION OF NECESSARY TOOLS….1352
21.2 TORQUE LIST….1353
22.PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….1354
23.MAINTENANCE SCHEDULE CHART….1356
23.1 MAINTENANCE SCHEDULE CHART….1356
24.SERVICE PROCEDURE….1361
24.1 INITIAL 250 HOURS SERVICE….1361
24.2 WHEN REQUIRED….1362
24.3 CHECK BEFORE STARTING….1374
24.4 EVERY 50 HOURS SERVICE….1384
24.5 EVERY 250 HOURS SERVICE….1386
24.6 EVERY 500 HOURS SERVICE….1394
24.7 EVERY 1000 HOURS SERVICE….1401
24.8 EVERY 2000 HOURS SERVICE….1407
24.9 EVERY 4000 HOURS SERVICE….1411
SPECIFICATIONS….1412
25.SPECIFICATIONS….1413
OPTIONS,ATTACHMENTS….1415
26.HANDLING PAYLOAD METER….1416
26.1 NAME OF PARTS….1416
26.2 EXTERNAL DISPLAY LAMPS….1416
26.3 OPERATING PAYLOAD METER….1418
27.SELECTING DUMP BODY….1427
28.OPTIONS AND ATTACHMENTS….1428
SEAM000805 – Dump Truck HD325-6 Operation & Maintenance Manual….1429
COVER….1429
1.FOREWORD….1430
2.SAFETY INFORMATION….1431
3.INTRODUCTION….1432
3.1 FEATURES….1432
3.2 BREAKING IN THE MACHINE….1432
4.LOCATION OF PLATES,TABLE TO ENTER SERIAL NUMBER AND DISTRIBUTOR….1433
4.1 MACHINE SERIAL NO.PLATE POSITION….1433
4.2 ENGINE SERIAL NO.PLATE POSITION….1433
4.3 TABEL TO ENTER SERIAL NO.AND DISTRIBUTOR….1433
5.CONTENTS….1434
SAFETY….1438
6.GENERAL PRECAUTIONS….1439
7.PRECAUTIONS DURING OPERATION….1444
7.1 BEFORE STARTING ENGINE….1444
7.2 AFTER STARTING ENGINE….1446
7.3 SHIPPING….1453
7.4 BATTERY….1454
7.5 TOWING….1456
8.PRECAUTIONS FOR MAINTENANCE….1457
8.1 BEFORE CARRYING OUT MAINTENANCE….1457
8.2 DURING MAINTENANCE….1462
8.3 TIRES….1467
9.POSITION FOR ATTACHING SAFETY LABELS….1468
9.1 POSITION FOR ATTACHING SAFETY LABELS….1468
OPERATION….1471
10.GENERAL VIEW OF MACHINE….1472
10.1 GENERAL VIEW OF MACHINE….1472
10.2 GENERAL VIEW OF CONTROLS AND GAUGES….1473
11.EXPLANATION OF COMPONENTS….1474
11.1 MACHINE MONITOR….1474
11.2 SWITCHES….1493
11.3 CONTROL LEVERS AND PEDALS….1500
11.4 MECHATRONICS EQUIPMENT CONTROLLER….1504
11.5 SAFETY PIN….1504
11.6 DUST INDICATOR….1505
11.7 FUSES….1505
11.8 LOCATION OF MANUAL BOX….1506
11.9 CAR RADIO….1507
11.10 CAR STEREO….1511
11.11 AIR CONDITIONER….1514
12.OPERATION….1517
12.1 CHECK BEFORE STARTING ENGINE….1517
12.2 STARTING ENGINE….1534
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE….1536
12.4 MOVING MACHINE OFF….1537
12.5 SHIFTING GEAR….1539
12.6 TRAVELING DOWNHILL….1540
12.7 TRAVELING IN REVERSE….1546
12.8 STEERING THE MACHINE….1547
12.9 STOPPING THE MACHINE….1548
12.10 OPERATING DUMP BODY….1550
12.11 PRECAUTIONS FOR OPERATION….1552
12.12 PARKING MACHINE….1553
12.13 CHECKS AFTER COMPLETION OF WORK….1554
12.14 STOPPING ENGINE….1554
12.15 CHECKS AFTER STOPPING ENGINE….1554
12.16 LOCKING….1555
12.17 HANDLING TIRES….1556
13.DETERMINING AND MAINTAINING TRAVEL ROAD….1559
13.1 DETERMINING TRAVEL ROAD….1559
13.2 MAINTAINING TRAVEL ROAD….1560
14.COLD WEATHER OPERATION….1561
14.1 PRECAUTIONS FOR LOW TEMPERATURE….1561
14.2 PRECAUTIONS AFTER COMPLETION OF WORK….1563
14.3 AFTER COLD WEATHER….1563
15.LONG-TERM STORAGE….1564
15.1 BEFORE STORAGE….1564
15.2 DURING STORAGE….1564
15.3 AFTER STORAGE….1565
15.4 PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE….1565
16.TROUBLESHOOTING….1566
16.1 AFTER RUNNING OUT OF FUEL….1566
16.2 TOWING MACHINE….1566
16.3 IF BATTERY IS DISCHARGED….1570
16.4 OTHER TROUBLE….1574
MAINTENANCE ….1584
17.GUIDES TO MAINTENANCE….1585
18.OUTLINES OF SERVICE….1588
18.1 OUTLINE OF OIL,FUEL,COOLANT….1588
18.2 OUTLINE OF ELECTRIC SYSTEM….1591
19.WEAR PARTS LIST….1592
20.USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….1593
21.STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….1597
21.1 INTRODUCTION OF NECESSARY TOOLS….1597
21.2 TORQUE LIST….1598
22.PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….1599
23.MAINTENANCE SCHEDULE CHART….1601
24.SERVICE PROCEDURE….1606
24.1 INITIAL 250 HOURS SERVICE….1606
24.2 WHEN REQUIRED….1607
24.3 CHECK BEFORE STARTING….1619
24.4 EVERY 50 HOURS SERVICE….1629
24.5 EVERY 250 HOURS SERVICE….1631
24.6 EVERY 500 HOURS SERVICE….1639
24.7 EVERY 1000 HOURS SERVICE….1646
24.8 EVERY 2000 HOURS SERVICE….1652
24.9 EVERY 4000 HOURS SERVICE….1656
24.10 EVERY 3 YEARS SERVICE….1656
SPECIFICATIONS….1657
25.SPECIFICATIONS….1658
OPTIONS,ATTACHMENTS….1660
26.HANDLING PAYLOAD METER….1661
26.1 NAME OF PARTS….1661
26.2 EXTERNAL DISPLAY LAMPS….1661
26.3 OPERATING PAYLOAD METER….1663
27.SELECTING DUMP BODY….1672
28.OPTIONS AND ATTACHMENTS….1673
29.USING DIFFERENTIAL LOCK….1674
29.1 DIFFERENTIAL LOCK PEDAL….1674
29.2 PRECAUTIONS AND METHOD OF USE….1675
HIGH ALTITUDE SPECIFICATIONS….1676
30.EXPLANATION OF COMPONENTS….1677
30.1 MACHINE MONITOR….1677
30.2 HYDRAULIC TANK PRESSURIZING DEVICE….1679
31.OPERATION….1680
31.1 HANDLING TIRES….1680
32.SERVICE PROCEDURE….1681
32.1 CHECKING BEFORE STARTING….1681
32.2 EVERY 500 HOURS SERVICE….1683
32.3 EVERY 2000 HOURS SERVICE….1684
SEAM000806 – Dump Truck HD325-6 Operation & Maintenance Manual….1687
COVER….1687
1. FOREWORD….1688
2. SAFETY INFORMATION….1689
3. INTRODUCTION….1690
3.1 FEATURES….1690
3.2 BREAKING IN THE MACHINE….1690
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NUMBER AND DISTRIBUTOR….1691
4.1 MACHINE SERIAL NO. PLATE POSITION….1691
4.2 ENGINE SERIAL NO. PLATE POSITION….1691
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….1691
5. CONTENTS….1692
SAFETY….1696
6. GENERAL PRECAUTIONS….1697
7. PRECAUTIONS DURING OPERATION….1702
7.1 BEFORE STARTING ENGINE….1702
7.2 AFTER STARTING ENGINE….1704
7.3 SHIPPING….1711
7.4 BATTERY….1712
7.5 TOWING….1714
8. PRECAUTIONS FOR MAINTENANCE….1715
8.1 BEFORE CARRYING OUT MAINTENANCE….1715
8.2 DURING MAINTENANCE….1720
8.3 TIRES….1725
9. POSITION FOR ATTACHING SAFETY LABELS….1726
9.1 POSITION FOR ATTACHING SAFETY LABELS ….1726
OPERATION….1730
10. GENERAL VIEW….1731
10.1 GENERAL VIEW OF MACHINE….1731
10.2 GENERAL VIEW OF CONTROLS AND GAUGES….1732
11. EXPLANATION OF COMPONENTS….1733
11.1 MACHINE MONITOR….1733
11.2 SWITCHES….1747
11.3 CONTROL LEVERS AND PEDALS….1754
11.4 MECHATRONICS EQUIPMENT CONTROLLER ….1758
11.5 SAFETY PIN….1758
11.6 DUST INDICATOR….1759
11.7 FUSES….1759
11.8 LOCATION OF MANUAL BOX….1760
11.9 CAR RADIO….1761
11.10 CAR STEREO….1765
11.11 AIR CONDITIONER ….1768
11.12 CAR HEATER….1772
12. OPERATION….1773
12.1 CHECK BEFORE STARTING ENGINE….1773
12.2 STARTING ENGINE….1790
12.3 OPERATIONS AND CHECK AFTER STARTING ENGINE….1792
12.4 MOVING MACHINE OFF….1793
12.5 SHIFTING GEAR….1795
12.6 TRAVELING DOWNHILL….1796
12.7 TRAVELING IN REVERSE….1802
12.8 STEERING THE MACHINE….1803
12.9 STOPPING THE MACHINE….1804
12.10 OPERATING DUMP BODY….1806
12.11 PRECAUTIONS FOR OPERATION….1808
12.12 PARKING MACHINE….1809
12.13 CHECKS AFTER COMPLETION OF WORK….1810
12.14 STOPPING ENGINE….1810
12.15 CHECKS AFTER STOPPING ENGINE….1810
12.16 LOCKING….1811
12.17 HANDLING TIRES….1812
13. DETERMINING AND MAINTAINING TRAVEL ROAD….1815
13.1 DETERMINING TRAVEL ROAD….1815
13.2 MAINTAINING TRAVEL ROAD….1816
14. COLD WEATHER OPERATION….1817
14.1 PRECAUTIONS FOR LOW TEMPERATURE….1817
14.2 PRECAUTIONS AFTER COMPLETION OF WORK….1819
14.3 AFTER COLD WEATHER….1819
15. LONG-TERM STORAGE….1820
15.1 BEFORE STORAGE….1820
15.2 DURING STORAGE….1820
15.3 AFTER STORAGE….1821
15.4 PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE….1821
16. TROUBLESHOOTING….1822
16.1 AFTER RUNNING OUT OF FUEL….1822
16.2 TOWING MACHINE….1823
16.3 IF BATTERY IS DISCHARGED….1826
16.4 OTHER TROUBLE….1830
MAINTENANCE….1846
17. GUIDES TO MAINTENANCE….1847
18. OUTLINES OF SERVICE….1850
18.1 OUTLINE OF OIL, FUEL, COOLANT….1850
18.2 OUTLINE OF ELECTRIC SYSTEM….1853
19. WEAR PARTS LIST….1854
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….1855
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….1859
21.1 INTRODUCTION OF NECESSARY TOOLS….1859
21.2 TORQUE LIST….1860
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….1861
23. MAINTENANCE SCHEDULE CHART….1863
24. SERVICE PROCEDURE….1868
24.1 INITIAL 250 HOURS SERVICE….1868
24.2 WHEN REQUIRED….1869
24.3 CHECK BEFORE STARTING….1880
24.4 EVERY 50 HOURS SERVICE….1890
24.5 EVERY 250 HOURS SERVICE….1892
24.6 EVERY 500 HOURS SERVICE….1900
24.7 EVERY 1000 HOURS SERVICE….1907
24.8 EVERY 2000 HOURS SERVICE….1913
24.9 EVERY 4000 HOURS SERVICE….1917
24.10 EVERY 3 YEARS SERVICE….1918
SPECIFICATIONS….1920
25. SPECIFICATIONS….1921
OPTIONS, ATTACHMENTS….1924
26. HANDLING PAYLOAD METER….1925
26.1 NAME OF PARTS….1925
26.2 EXTERNAL DISPLAY LAMPS….1925
26.3 OPERATING PAYLOAD METER….1927
27. SELECTING DUMP BODY….1936
28. OPTIONS AND ATTACHMENTS….1937
29. TACHOGRAPH (TCO 15-6)….1938
29.1 EXPLAINATION OF COMPONENTS….1938
29.2 METHOD OF USING KEY….1940
29.3 METHOD OF USE….1941
30. REVO TACHOGRAPH (TCO 15-7)….1943
30.1 EXPLAINATION OF COMPONENTS….1943
30.2 METHOD OF USE….1946
31. USING DIFFERENTIAL LOCK….1948
31.1 DIFFERENTIAL LOCK PEDAL….1948
31.2 PRECAUTIONS AND METHOD OF USE….1949
32. OPERATION OF ABS AND ABS/ASR….1950
32.1 EXPLANATION OF COMPONENTS….1950
32.2 OPERATION METHOD….1951
32.3 PRECAUTIONS FOR USE….1952
32.4 TROUBLESHOOTING….1953
33. HANDLING AUTO-GREASING SYSTEM….1954
33.1 METHOD OF OPERATING AUTO-GREASING SYSTEM….1954
33.2 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM….1962
33.3 TROUBLESHOOTING….1963
33.4 SPECIFICATIONS….1963
34. ARSC (AUTOMATIC RETARD SPEED CONTROL)….1964
34.1 EXPLANATION OF COMPONENTS….1964
34.2 METHOD OF OPERATION….1966
34.3 TROUBLESHOOTING….1968
HIGH ALTITUDE SPECIFICATIONS….1972
35. EXPLANATION OF COMPONENTS….1973
35.1 MACHINE MONITOR….1973
35.2 HYDRAULIC TANK PRESSURIZING DEVICE….1975
36. OPERATION….1976
36.1 HANDLING TIRES….1976
37. SERVICE PROCEDURE….1977
37.1 CHECK BEFORE STARTING….1977
37.2 EVERY 500 HOURS SERVICE….1979
37.3 EVERY 2000 HOURS SERVICE….1980
SEAM000807 – Dump Truck HD325-6 Operation & Maintenance Manual….1985
COVER….1985
1. FOREWORD….1988
2. SAFETY INFORMATION….1989
3. INTRODUCTION….1990
3.1 FEATURES….1990
3.2 BREAKING IN THE MACHINE….1990
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NUBMER AND DISTRIBUTOR….1991
4.1 MACHINE SERIAL NO. PLATE POSITION….1991
4.2 ENGINE SERIAL NO. PLATE POSITION….1991
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….1991
5. CONTENTS….1992
SAFETY….1996
6. GENERAL PRECAUTIONS….1997
7. PRECAUTIONS DURING OPERATION….2002
7.1 BEFORE STARTING ENGINE….2002
7.2 AFTER STARTING ENGINE….2004
7.3 SHIPPING….2011
7.4 BATTERY….2012
7.5 TOWING….2014
8. PRECAUTIONS FOR MAINTENANCE….2015
8.1 BEFORE CARRYING OUT MAINTENANCE….2015
8.2 DURING MAINTENANCE….2020
8.3 TIRES….2025
9. POSITION FOR ATTACHING SAFETY LABELS….2026
9.1 POSTISION FOR ATTACHING SAFETY LABELS….2026
OPERATION….2030
10. GENERAL VIEW….2031
10.1 GENERAL VIEW OF MACHINE….2031
10.2 GENERAL VIEW OF CONTROLS AND GAUGES….2032
11. EXPLANATION OF COMPONENTS….2033
11.1 MACHINE MONITOR….2033
11.2 SWITCHES….2047
11.3 CONTROL LEVERS AND PEDALS….2054
11.4 MECHATRONICS EQUIPMENT CONTROLER….2058
11.5 SAFETY PIN….2058
11.6 DUST INDICATOR….2059
11.7 FUSES….2059
11.8 LOCATION OF MANUAL BOX….2060
11.9 CAR RADIO….2061
11.10 CAR STEREO….2065
11.11 AIR CONDITIONER….2068
11.12 CAR HEATER….2072
12. OPERATION….2073
12.1 CHECK BEFORE STARTING ENGINE….2073
12.2 STARTING ENGINE….2090
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE….2092
12.4 MOVING MACHINE OFF….2093
12.5 SHIFTING GEAR….2095
12.6 TRAVELING DOWNHILL….2096
12.7 TRAVELING IN REVERSE….2102
12.8 STEERING THE MACHINE….2103
12.9 STOPPING THE MACHINE….2104
12.10 OPERATING DUMP BODY….2106
12.11 PRECAUTIONS FOR OPERATION….2108
12.12 PARKING MACHINE….2109
12.13 CHECKS AFTER COMPLETION OF WORK….2110
12.14 STOPPING ENGINE….2110
12.15 CHECKS AFTER STOPPING ENGINE….2110
12.16 LOCKING….2111
12.17 HANDLING TIRES….2112
13. DETERMINING AND MAINTAINING TRAVEL ROAD….2115
13.1 DETERMINING TRAVEL ROAD….2115
13.2 MAINTAINING TRAVEL ROAD….2116
14. COLD WEATHER OPERATION….2117
14.1 PRECAUTIONS FOR LOW TEMPERATURE….2117
14.2 PRECAUTIONS AFTER COMPLETION OF WORK….2119
14.3 AFTER COLD WEATHER….2119
15. LONG-TERM STORAGE….2120
15.1 BEFORE STORAGE….2120
15.2 DURING STORAGE….2120
15.3 AFTER STORAGE….2121
15.4 PRECAUTION BEFORE TRAVELING AFTER LONG-TERM STORAGE….2121
16. TROUBLESHOOTING….2122
16.1 AFTER RUNNING OUT OF FUEL….2122
16.2 TOWING MACHINE….2123
16.3 IF BATTERY IS DISCHARGED….2126
16.4 OTHER TROUBLE….2130
MAINTENANCE….2146
17. GUIDES TO MAINTENANCE….2147
18. OUTLINES OF SERVICE….2150
18.1 OUTLINE OF OIL, FUEL, COOLANT….2150
18.2 OUTLINE OF ELECTRIC SYSTEM….2153
19. WEAR PARTS LIST….2154
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….2155
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….2159
21.1 INTRODUCTION OF NECESSARY TOOLS….2159
21.2 TORQUE LIST….2160
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….2161
23. MAINTENANCE SCHEDULE CHART….2163
24. SERVICE PROCEDURE….2168
24.1 INITIAL 250 HOURS SERVICE….2168
24.2 WHEN USED….2169
24.3 CHECK BEFORE STARTING ….2180
24.4 EVERY 50 HOURS SERVICE….2190
24.5 EVERY 250 HOURS SERVICE….2192
24.6 EVERY 500 HOURS SERVICE….2200
24.7 EVERY 1000 HOURS SERVICE….2207
24.8 EVERY 2000 HOURS SERVICE….2213
24.9 EVERY 4000 HOURS SERVICE….2217
24.10 EVERY 3 YEARS SERVICE….2218
SPECIFICATIONS….2220
25. SPECIFICATIONS….2221
OPTIONS, ATTACHEMENTS….2224
26. HANDLING PAYLOAD METER….2225
26.1 NAME OF PARTS….2225
26.2 EXTERNAL DISPLAY LAMPS….2225
26.3 OPERATING PAYLOAD METER….2227
27. SELECTING DUMP BODY….2236
28. OPTIONS AND ATTACHEMENTS….2237
29. TACHOGRAPH (TCO 15-6)….2238
29.1 EXPLANANTION OF COMPONENTS….2238
29.2 METHOD OF USING KEY….2240
29.3 METHOD OF USE….2241
30. REVO TACHOGRAPH (TCO 15-7)….2243
30.1 EXPLANATION OF COMPONENTS….2243
30.2 METHOD OF USE….2246
31. USING DIFFERENTIAL LOCK….2248
31.1 DIFFERENTIAL LOCK PEDAL….2248
31.2 PRECAUTIONS AND METHOD OF USE….2249
32. OPERATION OF ABS AND ABS/ASR….2250
32.1 EXPLANATION OF COMPONENTS….2250
32.2 OPERATION METHOD….2251
32.3 PRECAUTIONS FOR USE….2252
32.4 TROUBLESHOOTING….2253
33. HANDLING AUTO-GREASING SYSTEM….2254
33.1 METHOD OF OPERATING AUTO-GREASING SYSTEM….2254
33.2 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM….2262
33.3 TROUBLESHOOTING….2263
33.4 SPECIFICATIONS….2263
34. ARSC (AUTOMATIC RETARD SPEED CONTROL)….2264
34.1 EXPLANATION OF COMPONENTS….2264
34.2 METHOD OF OPERATION….2266
34.3 TROUBLESHOOTING….2268
HIGH ALTITUDE SPECIFICATIONS….2272
35. EXPLANATION OF COMPONENTS….2273
35.1 MACHINE MONITOR….2273
35.2 HYDRAULIC TANK PRESSURIZING DEVICE….2275
36. OPERATION….2276
36.1 HANDLING TIRES….2276
37. SERVICE PROCEDURE….2277
37.1 CHECK BEFORE STARTING….2277
37.2 EVERY 500 HOURS SERVICE….2279
37.3 EVERY 2000 HOURS SERVICE….2280
SEAM000808 – Dump Truck HD325-6 Operation & Maintenance Manual….2285
COVER….2285
1. FOREWARD….2286
2. SAFETY INFORMATION….2287
3. INTRODUCTION….2288
3.1 FEATURES….2288
3.2 BREAKING IN THE MACHINE….2288
4. LOCATION OF PLATES, TABLE TO ENTER ….2289
4.1 MACHINE SERIAL NO. PLATE POSITION….2289
4.2 ENGINE SERIAL NO. PLATE POSITION….2289
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….2289
5. CONTENTS….2290
SAFETY….2294
6. GENERAL PRECAUTIONS….2295
7. PRECAUTIONS DURING OPERATION….2300
7.1 BEFORE STARTING ENGINE….2300
7.2 AFTER STARTING ENGINE….2302
7.3 SHIPPING….2309
7.4 BATTERY….2310
7.5 TOWING….2312
8. PRECAUTIONS FOR MAINTENANCE….2313
8.1 BEFORE CARRYING OUT MAINTENANCE….2313
8.2 DURING MAINTENANCE….2318
8.3 TIRES….2323
9. POSITION FOR ATTACHING SAFETY LABELS….2324
9.1 POSITION FOR ATTACHING SAFETY LABELS….2324
OPERATION….2328
10. GENERAL VIEW….2329
10.1 GENERAL VIEW OF MACHINE….2329
10.2 GENERAL VIEW OF CONTROLS AND GAUGES….2330
11. EXPLANATION OF COMPONENTS….2331
11.1 MACHINE MONITOR….2331
11.2 SWITCHES….2345
11.3 CONTROL LEVERS AND PEDALS….2352
11.4 MECHATRONICS EQUIPMENT CONTROLLER….2356
11.5 SAFETY PIN….2356
11.6 DUST INDICATOR….2357
11.7 FUSES….2357
11.8 LOCATION OF MANUAL BOX….2358
11.9 CAR RADIO….2359
11.10 CAR STEREO….2363
11.11 AIR CONDITIONER….2366
11.12 CAR HEATER….2370
12. OPERATION….2371
12.1 CHECK BEFORE STARTING ENGINE….2371
12.2 STARTING ENGINE….2388
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE….2390
12.4 MOVING MACHINE OFF….2391
12.5 SHIFTING GEAR….2393
12.6 TRAVELING DOWNHILL….2394
12.7 TRAVELING IN REVERSE….2400
12.8 STEERING THE MACHINE….2401
12.9 STOPPING THE MACHINE….2402
12.10 OPERATING DUMP BODY….2404
12.11 PRECAUTIONS FOR OPERATION….2406
12.12 PARKING MACHINE….2407
12.13 CHECKS AFTER COMPLETION OF WORK….2408
12.14 STOPPING ENGINE….2408
12.15 CHECKS AFTER STOPPING ENGINE….2408
12.16 LOCKING….2409
12.17 HANDLING TIRES….2410
13. DETERMINING AND MAINTAINING TRAVEL ROAD….2413
13.1 DETERMINING TRAVEL ROAD….2413
13.2 MAINTAINING TRAVEL ROAD….2414
14. COLD WEATHER OPERATION….2415
14.1 PRECAUTIONS FOR LOW TEMPERATURE….2415
14.2 PRECAUTIONS AFTER COMPLETION OF WORK….2417
14.3 AFTER COLD WEATHER….2417
15. LONG TERM STORAGE….2418
15.1 BEFORE STORAGE….2418
15.2 DURING ST6ORAGE….2418
15.3 AFTER STORAGE….2419
15.4 PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE….2419
16. TROUBLESHOOTING….2420
16.1 AFTER RUNNING OUT OF FUEL….2420
16.2 TOWING MACHINE….2421
16.3 IF BATTERY IS DISCHARGED….2424
16.4 OTHER TROUBLE….2428
MAINTENANCE….2444
17. GUIDES TO MAINTENANCE….2445
18. OUTLINES OF SERVICE….2448
18.1 OUTLINE OF OIL, FUEL, COOLANT….2448
18.2 OUTLINE OF ELECTRIC SYSTEM….2451
19. WEAR PARTS LIST….2452
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….2453
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….2457
21.1 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….2457
21.2 TORQUE LIST….2458
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….2459
23. MAINTENANCE SCHEDULE CHART….2461
24. SERVICE PROCEDURE….2466
24.1 INITIAL 250 HOURS SERVICE….2466
24.2 WHEN REQUIRED ….2467
24.3 CHECK BEFORE STARTING….2478
24.4 EVERY 50 HOURS SERVICE….2488
24.5 EVERY 250 HOURS SERVICE….2490
24.6 EVERY 500 HOURS SERVICE….2498
24.7 EVERY 1000 HOURS SERVICE….2505
24.8 EVERY 2000 HOURS SERVICE….2511
24.9 EVERY 4000 HOURS SERVICE….2515
24.10 EVERY 3 YEARS SERVICE….2516
SPECIFICATIONS….2518
25. SPECIFICATIONS….2519
OPTIONS, ATTACHMENTS….2522
26. HANDLING PAYLOAD METER….2523
26.1 NAME OF PARTS….2523
26.2 EXTERNAL DISPLAY LAMPS….2523
26.3 OPERATING PAYLOAD METER….2525
27. SELECTING DUMP BODY….2534
28. OPTIONS AND ATTACHMENTS….2535
29. TACHOGRAPH….2536
29.1 EXPLANATION OF COMPONENTS….2536
29.2 METHOD OF USING KEY….2538
29.3 METHOD OF USE….2539
30. REVO TACHOGRAPH (TC015-7)….2541
30.1 EXPLANATION OF COMPONENTS….2541
30.2 METHOD OF USE….2544
31. USING DIFFERENTIAL LOCK….2546
31.1 DIFFERENTIAL LOCK PEDAL….2546
31.2 PRECAUTIONS AND METHOD OF USE….2547
32. OPERATION OF ABS AND ABS/ASR….2548
32.1 EXPLANATION OF COMPONENTS….2548
32.2 OPERATION METHOD….2549
32.3 PRECAUTIONS FOR USE….2550
32.4 TROUBLESHOOTING….2551
33. HANDLING AUTO-GREASING SYSTEM….2552
33.1 METHOD OF OPERATING AUTO-GREASING SYSTEM….2552
33.2 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM….2560
33.3 TROUBLESHOOTING….2561
33.4 SPECIFICATIONS….2561
34. ARSC (AUTOMATIC RETARD SPEED CONTROL)….2562
34.1 EXPLANATION OF COMPONENTS….2562
34.2 METHOD OF OPERATION….2564
34.3 TROUBLESHOOTING….2566
HIGH ALTITUDE SPECIFICATIONS….2570
35. EXPLANATION OF COMPONENTS….2571
35.1 MACHINE MONITOR….2571
35.2 HYDRAULIC TANK PRESSURIZING DEVICE….2571
36. OPERATION….2574
36.1 HANDLING TIRES….2574
37. SERVICE PROCEDURE….2575
37.1 CHECK BEFORE STARTING….2575
37.2 EVERY 500 HOURS SERVICE….2577
37.3 EVERY 2000 HOURS SERVICE….2578
SEAM000817T – Dump Truck HD325-6, HD405-6 Operation & Maintenance Manual….2582
COVER….2582
FOREWORD….2583
FOREWORD….2584
SAFETY INFORMATION….2587
INTENDED USE….2589
DIRECTIONS OF MACHINE….2589
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….2590
PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE….2590
ENGINE SERIAL NO. PLATE POSITION….2590
SERVICE METER POSITION….2591
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….2591
CONTENTS….2592
SAFETY….2595
SAFETY INFORMATION….2596
SAFETY LABLES….2598
POSITION FOR ATTACHING SAFETY LABELS….2598
SAFETY LABELS….2599
GENERAL PRECAUTIONS….2604
SAFETY RULES….2604
IF ABNORMALITIES ARE FOUND….2604
CLOTHING AND PERSONAL PROTECTIVE ITEMS….2604
FIRE EXTINGUISHER AND FIRST AID KIT….2604
SAFETY FEATURES….2605
KEEP MACHINE CLEAN….2605
INSIDE OPERATOR'S COMPARTMENT….2605
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT….2605
HANDRAILS AND STEPS….2606
MOUNTING AND DISMOUNTING….2606
CRUSHING OR CUTTING PREVENTION….2606
PREVENTION OF BURNS….2607
FIRE PREVENTION….2607
ACTION IF FIRE OCCURS….2608
WINDOW WASHER LIQUID….2608
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)….2609
PRECAUTIONS FOR ATTACHMENTS….2609
UNAUTHORIZED MODIFICATION….2609
SAFETY AT WORKSITE….2609
WORKING ON LOOSE GROUND….2610
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES….2610
ENSURE GOOD VISIBILITY….2610
PRECAUTIONS RELATED TO VENTILATION OF EXHAUST GAS….2611
CHECKING SIGNALMAN'S SIGNALS AND SIGNS….2611
EMERGENCY ESCAPE FROM OPERATOR'S CAB….2611
ASBESTOS DUST HAZARD PREVENTION….2611
PRECAUTIONS DURING OPERATION….2612
STARING ENGINE….2612
CHECKS BEFORE STARTING ENGINE, ADJUST….2612
PRECAUTIONS WHEN STARTING….2612
PRECAUTIONS IN COLD AREAS….2613
OPERATION….2614
CHECKS BEFORE STARTING OPERATION….2614
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE….2614
PRECAUTIONS WHEN TRAVELING….2614
PRECAUTIONS WHEN TRAVELING ON SLOPS….2615
PRECAUTIONS WHEN OPERATING DUMP BODY….2615
PRECAUTIONS WHEN OPERATING….2615
PRECAUTIONS FOR ACCUMULATED SNOW, ICE….2615
PARKING MACHINE….2616
TRANSPORTATION….2617
SHIPPING….2617
LOADING AND UNLOADING….2617
BATTERY….2618
BATTERY HAZARD PREVENTION….2618
STARTING WITH BOOSTER CABLES….2619
TOWING….2620
WHEN TOWING….2620
PRECAUTIONS FOR MAINTENANCE….2621
WARNING TAG….2621
KEEP WORK PLACE CLEAN AND TIDY….2621
APPOINT LEADER WHEN WORKING WITH OTHERS….2621
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE….2622
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….2623
PROPER TOOLS….2624
HANDLING SUSPENTION CYLINDER….2624
PERSONNEL….2624
WORK UNDER THE MACHINE….2624
NOISE….2624
PRECAUTIONS WHEN USING HAMMER….2625
REPAIR WELDING….2625
REMOVING BATTERY TERMINAL….2625
PRECAUTIONS WITH HIGH-PRESSURE OIL….2625
PRECAUTIONS FOR HIGH-PRESSURE FUEL….2625
HANDLING HIGH-PRESSURE HOSES, PIPING….2626
PRECAUTIONS FOR HIGH VOLTAGE….2626
WASTE MATERIALS….2626
MAINTENANCE OF AIR CONDITIONER….2626
COMPRESSED AIR….2626
PERIODIC REPLACEMENT OF SAFETY-CIRTICAL PARTS….2627
PRECAUTIONS WITH TIRES….2628
HANDLING TIRES….2628
PRECAUTIONS WHEN STORING TIRE….2628
OPERATION….2629
GENERAL VIEW….2630
GENERAL VIEW OF MACHINE….2630
GENERAL VIEW OF CONTROLS AND GAUGES….2631
EXPLANATION OF COMPONENTS….2633
MACHINE MONITOR….2633
SWITCHES….2650
CONTROL LEVERS AND PEDALS….2659
MECHATRONICS EQUIPMENT CONTROLLER….2663
SAFETY PIN….2664
DUST INDICATOR….2664
LOCATION OF FIRE EXTINGUISHER….2665
LOCATION OF FIRST AID KIT….2665
FUSES….2665
CAR RADIO….2668
CAR STEREO….2674
AIR CONDITIONER….2682
OPERATION….2687
CHECK BEFORE STARTING ENGINE….2687
STARTING ENGINE….2703
OPERATIONS, CHECKS AFTER STARTING ENGINE….2707
STOPPING ENGINE….2708
CHECKS AFTER STOPPING ENGINE….2708
MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING….2709
SHIFTING GEAR….2714
TRAVELING DOWNHILL….2715
STEERING THE MACHINE….2724
LOADING OPERATIONS….2724
DUMP OPERATIONS….2725
PRECAUTIONS FOR OPERATION….2726
PARKING MACHINE….2727
CHECKS AFTER COMPLETION OF WORK….2728
DRAIN WATER FROM AIR TANK….2728
LOCKING….2728
HANDLING TIRES….2729
DETERMINING AND MAINTAINING TRAVEL ROAD….2732
DETERMINING TRAVEL ROAD….2732
MAINTAINING TRAVEL ROAD….2732
TRANSPORTATION….2733
PRECAUTIONS WHEN TRANSPORTING….2733
STEPS FOR TRANSPORTATION….2733
COLD WEATHER OPERATION….2734
PRECAUTIONS FOR LOW TEMPERATURE….2734
PRECAUTIONS AFTER COMPLETION OF WORK….2735
AFTER COLD WEATHER….2736
LONG-TERM STORAGE….2737
BEFOR STORAGE….2737
DURING STORAGE….2737
AFTER STORAGE….2737
PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE….2737
TROUBLESHOOTING….2738
AFTER RUNNING OUT OF FUEL….2738
TOWING THE MACHINE….2740
IF BATTERY IS DISCHARGED….2743
OTHER TROUBLE….2746
MAINTENANCE….2754
GUIDES TO MAINTENANCE….2755
OUTLINES OF SERVICE….2757
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….2757
OUTLINE OF ELECTRIC SYSTEM….2759
WEAR PARTS….2760
WEAR PARTS LIST….2760
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….2761
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….2768
TORQUE LIST….2768
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….2769
SAFETY CRITICAL PARTS….2769
MAINTENANCE SCHEDULE CHART….2770
MAINTENANCE SCHEDULE CHART….2770
ADJUST INJECTOR….2773
SERVICE PROCEDURE….2774
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)….2774
WHEN REQUIRED….2775
CHECK, CLEAN OR REPLACE AIR CLEANER ….2775
CLEAN INSIDE OF COOLING SYSTEM….2777
CHECK LEVEL OF WINDOW WASHER FLUID, ADD FLUID….2780
CLEAN AIR CONDITIONER AIR FILTER….2780
CHECK REFRIGERANT (GAS) LEVEL….2781
CHECK DUMP BODY….2781
CHECK ELECTRIC INTAKE AIR HEATER….2781
CHECK LENGTH OF SUSPENSION CYLINDER, CHECK OIL LEVEL….2782
BLEED AIR FROM REAR BRAKE….2783
BLEED AIR FROM FRONT BRAKE….2784
ADJUSTING PARKING BRAKE….2785
BLEED AIR FROM HYDRAULIC CIRCUIT OF FRONT DRIVE….2786
ADJUST BODY POSITIONER….2787
CHECK PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT….2788
SELECTION AND INSPECTION OF TIRES….2789
DRAIN WATER FROM WATER SEPARETOR….2791
CHECK BEFORE STARTING….2792
EVERY 50 HOURS SERVICE….2793
LUBRICATION….2793
EVERY 100 HOURS SERVICE….2795
CHECK ALCOHOL LEVEL IN ALCOHOL INJECTOR, ADD ALCOHOL….2795
EVERY 250 HOURS SERVICE….2796
CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL ….2796
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL ….2796
LUBRICATE DRIVE SHAFT (5 POINTS)….2797
CHECK DRIVE SHAFT….2797
CHECK LEVEL OF BATTERY ELECTROLYTE….2798
CHECK ALTERNATOR BELT TENSION, ADJUST….2800
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST….2801
CLEAN BREATHERS….2802
CHECK FRAME….2803
CHECK BRAKING CAPACITY OF FOOT BRAKE….2803
CHECK BRAKING CAPACITY OF RETARDER BRAKE….2804
CHECK BRAKING CAPACITY OF PARKING BRAKE….2804
CHECK WEAR OF PARKING BRAKE PADS….2804
CHECK, CLEAN AUTOMATIC SUSPENSION….2805
CLEAN CENTRAL BREATHER BOX AND CENTRAL BREATHER AIR CLEANER….2806
EVERY 500 HOURS SERVICE….2807
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….2807
REPLACE FUEL FILTER CARTRIDGE ….2808
CLEAN FUEL TANK STRAINER….2810
REPLACE TRANSMISSION OIL FILTER ELEMENT ….2811
REPLACE ELEMENT OF FRONT DRIVE OIL FILTER….2812
CHECK WEAR OF FRONT DISK BRAKE PADS….2812
CLEAN, CHECK RADIATOR FINS AND AFTER COOLER FINS….2813
CHECK FAN BELT TENSION, ADJUST….2813
LUBRICATE TENSION PULLEY (1 POINT)….2814
REPLACE ADDITIONAL FUEL FILTER CARTRIDGE (IF EQUIPPED)….2815
EVERY 1000 HOURS SERVICE….2817
REPLACE CORROSION RESISTOR CARTRIDGE….2817
CHANGE OIL IN TRANSMISSION CASE, CLEAN TRANSMISSION CASE STRAINER….2818
CHANGE OIL IN FRONT FINAL DRIVE….2819
CHANGE OIL IN FRONT DRIVE OIL TANK, CLEAN FRONT DRIVE OIL TANK STRAINER….2820
REPLACE HYDRAULIC FILTER ELEMENT ….2821
LUBRICATION….2822
CHECK WEAR OF REAR BRAKE DISC….2823
CHECK TIGHTENING PARTS FOR TURBOCHARGER….2823
REPLACE FUEL FILTER CARTRIDGE….2823
EVERY 2000 HOURS SERVICE….2824
CHANGE OIL IN HYDRAULIC TANK….2824
CAHNGE OIL IN FINAL DRIVE CASE….2825
CHANGE OIL IN DIFFERENTIAL CASE….2825
CLEAN DIFFERENTIAL CASE BREATHER….2826
CLEAN ENGINE BREATHER ELEMENT ….2826
CLEAN AIR DRYER FILTER AND DEFLECTOR (IF EQUIPPED)….2827
CLEAN EMERGENCY RALAY VALVE….2827
CHECK ALTERNATOR, STARTING MOTOR….2827
CHECK, ADJUST ENGINE VALVE CLEARANCE….2827
CHECK INJECTOR….2827
CLEAN, CHECK TURBOCHARGER ….2828
CHECK PLAY OF TURBOCHARGER ROTOR….2828
EVERY 4000 HOURS SERVICE….2829
CHECK WATER PUMP….2829
CHECK AIR COMPRESSOR….2829
CHECK FAN PULLEY AND TENSION PULLEY….2829
CHECK VIBRATION DAMPER….2829
CHECK INJECTOR….2829
REPLACE INJECTOR ASSEMBLY….2829
CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HANDENING OF RUBBER….2829
CHEKCING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER….2830
EVERY 8000 HOURS SERVICE….2831
REPLACE INJECTOR NOZZLE TIP….2831
REPLACE HIGH-PRESSURE PIPING CLAMP….2831
REPLACE FUEL SPRAY PREVENTION CAP….2831
SPECIFICATIONS….2832
SPECIFICATIONS….2833
ATTACHMENTS, OPTIONS….2834
HANDLING PAYLOAD METER….2835
NAME OF PARTS….2835
EXTERNAL DISPLAY LAMPS….2836
OPERATING PAYLOAD METER….2839
SELECTING DUMP BODY….2847
TACHOGRAPH (TCO 15-6)….2848
EXPLANATION OF COMPONENTS….2848
METHOD OF USING KEY….2850
METHOD OF USE….2850
REVO TACHOGRAPH (TCO 15-7)….2852
EXPLANATION OF COMPONENTS….2852
METHOD OF USE….2854
USING DIFFERENTIAL LOCK….2856
DIFFERENTIAL LOCK PEDAL….2856
PRECAUTIONS AND METHOD OF USE….2857
OPERATION OF ABS AND ABS/ASR….2858
EXPLANATION OF COMPONENTS ….2858
OPERATION METHOD ….2860
PRECAUTIONS FOR USE….2861
TROUBLESHOOTING….2861
HANDLING AUTO-GREASING SYSTEM….2862
METHOD OF OPERATING AUTO-GREASING SYSTEM….2862
PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM….2868
TROUBLESHOOTING….2868
ARSC (AUTOMATIC RETARDER SPEED CONTROL)….2869
EXPLANATION OF COMPONENTS….2870
METHOD OF OPERATION….2872
TROUBLESHOOTING….2874
HANDLING OIL FILTER CUATION ….2877
METHOD OF USE….2877
INDEX….2879
SEAM000819T – Dump Truck HD325-6, HD405-6 Operation & Maintenance Manual….2882
COVER….2882
FOREWORD….2883
FOREWORD….2884
SAFETY INFORMATION….2887
INTENDED USE….2889
DIRECTIONS OF MACHINE….2889
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….2890
PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE….2890
ENGINE SERIAL NO. PLATE POSITION….2890
SERVICE METER POSITION….2891
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….2891
CONTENTS….2892
SAFETY….2895
SAFETY INFORMATION….2896
SAFETY LABLES….2898
POSITION FOR ATTACHING SAFETY LABELS….2898
SAFETY LABELS….2899
GENERAL PRECAUTIONS….2904
SAFETY RULES….2904
IF ABNORMALITIES ARE FOUND….2904
CLOTHING AND PERSONAL PROTECTIVE ITEMS….2904
FIRE EXTINGUISHER AND FIRST AID KIT….2904
SAFETY FEATURES….2905
KEEP MACHINE CLEAN….2905
INSIDE OPERATOR'S COMPARTMENT….2905
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT….2905
HANDRAILS AND STEPS….2906
MOUNTING AND DISMOUNTING….2906
CRUSHING OR CUTTING PREVENTION….2906
PREVENTION OF BURNS….2907
FIRE PREVENTION….2907
ACTION IF FIRE OCCURS….2908
WINDOW WASHER LIQUID….2908
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)….2909
PRECAUTIONS FOR ATTACHMENTS, OPTIONS….2909
UNAUTHORIZED MODIFICATION….2909
SAFETY AT WORKSITE….2909
WORKING ON LOOSE GROUND….2910
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES….2910
ENSURE GOOD VISIBILITY….2910
PRECAUTIONS RELATED TO VENTILATION OF EXHAUST GAS….2911
CHECKING SIGNALMAN'S SIGNALS AND SIGNS….2911
EMERGENCY ESCAPE FROM OPERATOR'S CAB….2911
ASBESTOS DUST HAZARD PREVENTION….2911
PRECAUTIONS DURING OPERATION….2912
STARING ENGINE….2912
CHECKS BEFORE STARTING ENGINE, ADJUST….2912
PRECAUTIONS WHEN STARTING….2912
PRECAUTIONS IN COLD AREAS….2913
OPERATION….2914
CHECKS BEFORE STARTING OPERATION….2914
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE….2914
PRECAUTIONS WHEN TRAVELING….2914
PRECAUTIONS WHEN TRAVELING ON SLOPS….2915
PRECAUTIONS WHEN OPERATING DUMP BODY….2915
PRECAUTIONS WHEN OPERATING….2915
PRECAUTIONS FOR ACCUMULATED SNOW, ICE….2915
PARKING MACHINE….2916
TRANSPORTATION….2917
LOADING AND UNLOADING….2917
SHIPPING….2917
BATTERY….2918
BATTERY HAZARD PREVENTION….2918
STARTING WITH BOOSTER CABLES….2919
TOWING….2920
WHEN TOWING….2920
PRECAUTIONS FOR MAINTENANCE….2921
WARNING TAG….2921
KEEP WORK PLACE CLEAN AND TIDY….2921
APPOINT LEADER WHEN WORKING WITH OTHERS….2921
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE….2922
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….2923
PROPER TOOLS….2924
HANDLING SUSPENTION CYLINDER….2924
PERSONNEL….2924
WORK UNDER THE MACHINE….2924
NOISE….2924
PRECAUTIONS WHEN USING HAMMER….2925
REPAIR WELDING….2925
REMOVING BATTERY TERMINAL….2925
PRECAUTIONS WITH HIGH-PRESSURE OIL….2925
PRECAUTIONS FOR HIGH-PRESSURE FUEL….2925
HANDLING HIGH-PRESSURE HOSES, PIPING….2926
PRECAUTIONS FOR HIGH VOLTAGE….2926
WASTE MATERIALS….2926
MAINTENANCE OF AIR CONDITIONER….2926
COMPRESSED AIR….2926
PERIODIC REPLACEMENT OF SAFETY-CIRTICAL PARTS….2927
PRECAUTIONS WITH TIRES….2928
HANDLING TIRES….2928
PRECAUTIONS WHEN STORING TIRE….2928
OPERATION….2929
GENERAL VIEW….2930
GENERAL VIEW OF MACHINE….2930
GENERAL VIEW OF CONTROLS AND GAUGES….2931
EXPLANATION OF COMPONENTS….2933
MACHINE MONITOR….2933
SWITCHES….2951
CONTROL LEVERS AND PEDALS….2960
MECHATRONICS EQUIPMENT CONTROLLER….2964
SAFETY PIN….2965
DUST INDICATOR….2965
LOCATION OF FIRE EXTINGUISHER….2966
LOCATION OF FIRST AID KIT….2966
FUSES….2966
CAR RADIO….2969
CAR STEREO….2975
AIR CONDITIONER….2983
OPERATION….2988
CHECK BEFORE STARTING ENGINE….2988
STARTING ENGINE….3004
OPERATIONS, CHECKS AFTER STARTING ENGINE….3008
STOPPING ENGINE….3009
CHECKS AFTER STOPPING ENGINE….3009
MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING….3010
SHIFTING GEAR….3015
TRAVELING DOWNHILL….3016
STEERING THE MACHINE….3025
LOADING OPERATIONS….3025
DUMP OPERATIONS….3026
PRECAUTIONS FOR OPERATION….3027
PARKING MACHINE….3028
CHECKS AFTER COMPLETION OF WORK….3029
DRAIN WATER FROM AIR TANK….3029
LOCKING….3029
HANDLING TIRES….3030
DETERMINING AND MAINTAINING TRAVEL ROAD….3034
DETERMINING TRAVEL ROAD….3034
MAINTAINING TRAVEL ROAD….3034
TRANSPORTATION….3035
PRECAUTIONS WHEN TRANSPORTING….3035
STEPS FOR TRANSPORTATION….3035
COLD WEATHER OPERATION….3036
PRECAUTIONS FOR LOW TEMPERATURE….3036
PRECAUTIONS AFTER COMPLETION OF WORK….3037
AFTER COLD WEATHER….3038
LONG-TERM STORAGE….3039
BEFOR STORAGE….3039
DURING STORAGE….3039
AFTER STORAGE….3039
PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE….3039
TROUBLESHOOTING….3040
AFTER RUNNING OUT OF FUEL….3040
TOWING THE MACHINE….3042
IF BATTERY IS DISCHARGED….3045
OTHER TROUBLE….3049
MAINTENANCE….3057
GUIDES TO MAINTENANCE….3058
OUTLINES OF SERVICE….3060
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….3060
OUTLINE OF ELECTRIC SYSTEM….3062
WEAR PARTS….3063
WEAR PARTS LIST….3063
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….3064
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….3071
TORQUE LIST….3071
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….3072
SAFETY CRITICAL PARTS….3072
MAINTENANCE SCHEDULE CHART….3073
MAINTENANCE SCHEDULE CHART….3073
ADJUST INJECTOR….3076
SERVICE PROCEDURE….3077
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)….3077
WHEN REQUIRED….3078
CHECK, CLEAN OR REPLACE AIR CLEANER ….3078
CLEAN INSIDE OF COOLING SYSTEM….3080
CHECK LEVEL OF WINDOW WASHER FLUID, ADD FLUID….3083
CLEAN AIR CONDITIONER AIR FILTER….3083
CHECK REFRIGERANT (GAS) LEVEL….3084
CHECK DUMP BODY….3084
CHECK ELECTRIC INTAKE AIR HEATER….3084
CHECK LENGTH OF SUSPENSION CYLINDER, CHECK OIL LEVEL….3085
BLEED AIR FROM REAR BRAKE….3086
BLEED AIR FROM FRONT BRAKE….3087
ADJUSTING PARKING BRAKE….3088
BLEED AIR FROM HYDRAULIC CIRCUIT OF FRONT DRIVE….3089
ADJUST BODY POSITIONER….3090
CHECK PLAY OF OUTPUT COUPLING OF OUTPUT SHAFT….3091
SELECTION AND INSPECTION OF TIRES….3092
DRAIN WATER FROM WATER SEPARETOR….3094
CHECK BEFORE STARTING….3095
EVERY 50 HOURS SERVICE….3096
LUBRICATION….3096
EVERY 100 HOURS SERVICE….3098
CHECK ALCOHOL LEVEL IN ALCOHOL INJECTOR, ADD ALCOHOL….3098
EVERY 250 HOURS SERVICE….3099
CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL ….3099
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL ….3099
LUBRICATE DRIVE SHAFT (5 PLACES)….3100
CHECK DRIVE SHAFT….3100
CHECK LEVEL OF BATTERY ELECTROLYTE….3101
CHECK ALTERNATOR BELT TENSION, ADJUST….3103
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST….3104
CLEAN BREATHERS….3105
CHECK FRAME….3106
CHECK BRAKING CAPACITY OF FOOT BRAKE….3106
CHECK BRAKING CAPACITY OF RETARDER BRAKE….3107
CHECK BRAKING CAPACITY OF PARKING BRAKE….3107
CHECK WEAR OF PARKING BRAKE PADS….3107
CHECK, CLEAN AUTOMATIC SUSPENSION….3108
CLEAN CENTRAL BREATHER BOX AND CENTRAL BREATHER AIR CLEANER….3109
EVERY 500 HOURS SERVICE….3110
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….3110
REPLACE FUEL FILTER CARTRIDGE ….3111
CLEAN FUEL TANK STRAINER….3113
REPLACE TRANSMISSION OIL FILTER ELEMENT ….3114
REPLACE ELEMENT OF FRONT DRIVE OIL FILTER….3115
CHECK WEAR OF FRONT DISK BRAKE PADS….3115
CLEAN, CHECK RADIATOR FINS AND AFTER COOLER FINS….3116
CHECK FAN BELT TENSION, ADJUST….3116
LUBRICATE TENSION PULLEY (1 PLACE)….3117
REPLACE ADDITIONAL FUEL FILTER CARTRIDGE (IF EQUIPPED)….3118
EVERY 1000 HOURS SERVICE….3120
REPLACE CORROSION RESISTOR CARTRIDGE….3120
CHANGE OIL IN TRANSMISSION CASE, CLEAN TRANSMISSION CASE STRAINER….3121
CHANGE OIL IN FRONT FINAL DRIVE….3122
CHANGE OIL IN FRONT DRIVE OIL TANK, CLEAN FRONT DRIVE OIL TANK STRAINER….3123
REPLACE HYDRAULIC FILTER ELEMENT ….3124
LUBRICATION….3125
CHECK WEAR OF REAR BRAKE DISC….3126
CHECK TIGHTENING PARTS FOR TURBOCHARGER….3126
REPLACE FUEL FILTER CARTRIDGE….3126
EVERY 2000 HOURS SERVICE….3127
CHANGE OIL IN HYDRAULIC TANK….3127
CAHNGE OIL IN FINAL DRIVE CASE….3128
CHANGE OIL IN DIFFERENTIAL CASE….3128
CLEAN DIFFERNTIAL CASE BREATHER….3129
CLEAN ENGINE BREATHER ELEMENT ….3129
CLEAN AIR DRYER FILTER AND DEFLECTOR (IF EQUIPPED)….3130
CLEAN EMERGENCY RALAY VALVE….3130
CHECK ALTERNATOR, STARTING MOTOR….3130
CHECK, ADJUST ENGINE VALVE CLEARANCE….3130
CHECK INJECTOR….3130
CLEAN, CHECK TURBOCHARGER ….3131
CHECK PLAY OF TURBOCHARGER ROTOR….3131
EVERY 4000 HOURS SERVICE….3132
CHECK WATER PUMP….3132
CHECK AIR COMPRESSOR….3132
CHECK FAN PULLEY AND TENSION PULLEY….3132
CHECK VIBRATION DAMPER….3132
CHECK INJECTOR….3132
REPLACE INJECTOR ASSEMBLY….3132
CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HANDENING OF RUBBER….3132
CHEKCING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER….3133
EVERY 8000 HOURS SERVICE….3134
REPLACE INJECTOR NOZZLE TIP….3134
REPLACE HIGH-PRESSURE PIPING CLAMP….3134
REPLACE FUEL SPRAY PREVENTION CAP….3134
SPECIFICATIONS….3135
SPECIFICATIONS….3136
ATTACHMENTS, OPTIONS….3137
HANDLING PAYLOAD METER….3138
NAME OF PARTS….3138
EXTERNAL DISPLAY LAMPS….3139
OPERATING PAYLOAD METER….3142
SELECTING DUMP BODY….3150
TACHOGRAPH (TCO 15-6)….3151
EXPLANATION OF COMPONENTS….3151
METHOD OF USING KEY….3153
METHOD OF USE….3153
REVO TACHOGRAPH (TCO 15-7)….3155
EXPLANATION OF COMPONENTS….3155
METHOD OF USE….3157
USING DIFFERENTIAL LOCK….3159
DIFFERENTIAL LOCK PEDAL….3159
PRECAUTIONS AND METHOD OF USE….3160
OPERATION OF ABS AND ABS/ASR….3161
EXPLANATION OF COMPONENTS ….3161
OPERATION METHOD ….3163
PRECAUTIONS FOR USE….3164
TROUBLESHOOTING….3164
HANDLING AUTO-GREASING SYSTEM….3165
METHOD OF OPERATING AUTO-GREASING SYSTEM….3165
PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM….3171
TROUBLESHOOTING….3171
ARSC (AUTOMATIC RETARDER SPEED CONTROL)….3172
EXPLANATION OF COMPONENTS….3172
METHOD OF OPERATION….3174
TROUBLESHOOTING….3176
HANDLING OIL FILTER CUATION ….3179
METHOD OF USE….3179
INDEX….3181
SEAM05660501 – Dump Truck HD325-5 Operation & Maintenance Manual….3184
COVER….3184
FOREWORD….3185
BREAKING IN YOUR NEW MACHINE….3186
CONTENTS….3187
SAFETY HINTS….3188
GENERAL LOCATIONS AND SPECIFICATIONS….3195
INSTRUMENTS AND CONTROLS….3196
AIR CONDITIONER….3220
CHECK BEFORE STARTING….3224
OPERATING YOUR MACHINE….3232
RELEASE OF PARKING BRAKE….3251
EMERGENCY BRAKE….3252
RELEASE OF EMERGENCY BRAKE….3254
INSTRUCTIONS FOR TOWING THE MACHINE….3255
DUMP BODY OPERATION….3256
HANDLING THE TIRES….3258
HANDLING OF BATTERY….3261
COLD WEATHER OPERATION….3264
PERIODIC MAINTENANCE….3269
PRECAUTIONS FOR MAINTENANCE….3270
PERIODIC REPLACEMENT OF COMPONENT PARTS FOR SAFETY….3273
MAINTENANCE TABLE….3274
EVERY 50 HOURS SERVICE….3278
INITIAL 250 HOURS SERVICE….3281
EVERY 250 HOURS SERVICE….3281
EVERY 500 HOURS SERVICE….3288
EVERY 1000 HOURS SERVICE….3291
EVERY 2000 HOURS SERVICE….3297
EVERY 4000 HOURS SERVICE….3299
WHEN REQUIRED….3300
ADJUSTMENT….3306
TROUBLE SHOOTING GUIDE….3313
STORAGE….3318
SERVICE METER….3320
MACHINE AND ENGINE SERIAL NUMBERS….3321
FUEL,COOLANT AND LUBRICANTS….3322
SEAM05660505 – Dump Truck HD325-5 Operation & Maintenance Manual….3325
COVER….3325
FOREWORD….3326
BREAKING IN YOUR NEW MACHINE….3327
CONTENTS….3328
GENERAL LOCATIONS AND SPECIFICATIONS….3329
INSTRUMENTS AND CONTROLS….3330
CHECK BEFORE STARTING….3354
OPERATING YOUR MACHINE….3365
METHOD OF RELEASING PARKING BRAKE AND EMERGENCY BRAKE WHEN ACTUATED IN A EMERGENCY….3384
INSTRUCTIONS FOR TOWING THE MACHINE….3386
DUMP BODY OPERATION….3387
HANDLING THE TIRES….3389
COLD WEATHER OPERATION….3392
PERIODIC MAINTENANCE….3396
PERIODICAL REPLACEMENT OF SAFETY PARTS….3397
MAINTENANCE TABLE….3398
OIL FILLER AND LEVEL GAUGE POSITIONS….3402
EVERY 50 HOURS SERVICE….3403
EVERY 250 HOURS SERVICE….3406
EVERY 500 HOURS SERVICE….3413
EVERY 1000 HOURS SERVICE….3418
EVERY 2000 HOURS SERVICE….3424
EVERY 4000 HOURS SERVICE….3426
WHEN REQUIRED….3427
ADJUSTMENT….3434
TROUBLE SHOOTING GUIDE….3439
SERVICE METER….3444
MACHINE AND ENGINE SERIAL NUMBERS….3445
FUEL,COOLANT AND LUBRICANTS….3446
OPERATION AND MAINTENANCE (EQUIPPED WITH A ELECTRONIC INSTRUMENT PANEL)….3448
INSTRUMENTS AND CONTROLS….3449
CHECK BEFORE STARTING….3458
TROUBLE SHOOTING GUIDE….3459
SAFETY AND OPERATION….3460
CONTENTS….3461
SAFETY HINTS….3462
PRECAUTIONS FOR MAINTENANCE….3474
AIR CONDITIONER….3481
HANDLING OF BATTERY….3485
OPERATING DIFFERENTIAL LOCK DEVICE….3488
STORAGE….3490
COOLANT AND LUBRICANTS….3492
SEAM566D01 – Dump Truck HD320-3, HD325-3 Operation & Maintenance Manual….3495
COVER….3495
FOREWORD….3496
BREAKING IN YOUR NEW MACHINE….3497
CONTENTS….3498
SAFETY HINTS….3499
GENERAL LOCATIONS….3510
OPERATOR'S COMPARTMENT….3512
INSTRUMENTS AND CONTROLS….3515
CHECK BEFORE STARTING….3535
OPERATING YOUR MACHINE….3543
INSTRUCTIONS FOR TOWING THE TRUCK….3563
PERIODIC MAINTENANCE….3572
PRECAUTIONS FOR MAINTENANCE….3573
MAINTENANCE TABLE….3579
EVERY 50 HOURS SERVICE….3589
EVERY 250 HOURS SERVICE….3592
EVERY 500 HOURS SERVICE….3604
EVERY 1000 HOURS SERVICE….3606
EVERY 2000 HOURS SERVICE….3611
EVERY 4000 HOURS SERVICE….3612
WHEN REQUIRED….3616
ADJUSTMENT….3623
WEAR PARTS….3631
TROUBLE SHOOTING GUIDE….3632
COLD WEATHER OPERATION….3635
STORAGE….3641
SERVICE METER….3643
MACHINE AND ENGINE SERIAL NUMBERS….3644
SPECIFICATIONS….3645
OPTIONAL PARTS….3649
FUEL AND LUBRICANTS….3651
SEAMW00500 – Dump Truck HD325-6 Operation & Maintenance Manual….3654
COVER….3654
1. FOREWORD….3656
2. SAFETY INFORMATION….3659
3. INTRODUCTION….3661
3.1 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE….3661
3.2 BREAKING IN THE MACHINE….3661
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NUMBER AND DISTRIBUTOR….3662
4.1 MACHINE SERIAL NO. PLATE POSITION….3662
4.2 ENGINE SERIAL NO. PLATE POSITION….3662
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….3662
5. CONTENTS….3663
SAFETY….3668
6. GENERAL PRECAUTIONS….3669
7. PRECAUTIONS DURING OPERATION….3678
7.1 BEFORE STARTING ENGINE….3678
7.2 AFTER STARTING ENGINE….3680
7.3 SHIPPING….3684
7.4 BATTERY….3685
7.5 TOWING….3687
8. PRECAUTIONS FOR MAINTENANCE….3688
8.1 BEFORE CARRYING OUT MAINTENANCE….3688
8.2 DURING MAINTENANCE….3689
8.3 TIRES….3693
9. POSITION FOR ATTACHING SAFETY LABELS….3694
9.1 POSITION FOR ATTACHING SAFETY LABELS….3694
OPERATION….3698
10. GENERAL VIEW….3699
10.1 GENERAL VIEW OF MACHINE….3699
10.2 GENERAL VIEW OF CONTROLS AND GAUGES….3700
11. EXPLANATION OF COMPONENTS….3701
11.1 MACHINE MONITOR….3701
11.2 SWITCHES….3715
11.3 CONTROL LEVERS AND PEDALS….3722
11.4 MECHATRONICS EQUIPMENT CONTROLLER….3726
11.5 SAFETY PIN….3726
11.6 DUST INDICATOR….3727
11.7 FUSES….3727
11.8 LOCATION OF MANUAL BOX….3728
11.9 CAR RADIO….3729
11.10 CAR STEREO….3733
11.11 AIR CONDITIONER….3736
11.12 CAR HEATER….3740
12. OPERATION….3741
12.1 CHECK BEFORE STARTING ENGINE….3741
12.2 STARTING ENGINE….3758
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE….3760
12.4 MOVING MACHINE OFF….3761
12.5 SHIFTING GEAR….3763
12.6 TRAVELING DOWNHILL….3764
12.7 TRAVELING IN REVERSE….3770
12.8 STEEERING THE MACHINE….3771
12.9 STOPPING THE MACHINE….3772
12.10 OPERATING DUMP BODY….3774
12.11 PRECAUTIONS FOR OPERATIONS….3776
12.12 PARKING MACHINE….3777
12.13 CHECKS AFTER COMPLETION OF WORK….3778
12.14 STOPPING ENGINE….3778
12.15 CHECKS AFTER STOPPING ENGINE….3778
12.16 LOCKING….3779
12.17 HANDLING TIRES….3780
13. DETERMINING AND MAINTAINING TRAVEL ROAD….3783
13.1 DETERMINING TRAVEL ROAD….3783
13.2 MAINTAINING TRAVEL ROAD….3784
14. COLD WEATHER OPERATION….3785
14.1 PRECAUTIONS FOR LOW TEMPERATURE….3785
14.2 PRECAUITIONS AFETR COMPLETION OF WORK….3787
14.3 AFTER COLD WEATHER….3787
15. LONG-TERM STORAGE….3788
15.1 BEFORE STORAGE….3788
15.2 DURING STORAGE….3788
15.3 AFTER STORAGE….3789
15.4 PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE….3789
16. TROUBLESHOOTING….3790
16.1 AFTER RUNNING OUT OF FUEL….3790
16.2 TOWING MACHINE….3791
16.3 IF BATTERY IS DISCHARGED….3794
16.4 OTHER TROUBLE….3798
MAINTENANCE….3814
17. GUIDES TO MAINTENANCE….3815
18. OUTLINE OF SERVICE….3818
18.1 OUTLINE OF OIL, FUEL, COOLANT….3818
18.2 OUTLINE OF ELECTRIC SYSTEM….3821
19. WEAR PARTS LIST….3822
20. USE OF FUEL, COOLANT, AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….3823
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….3827
21.1 INTRODUCTION OF NECESSARY TOOLS….3827
21.2 TORQUE LIST….3828
22. PERIODIC REPLACEMENT OF SAFETY CRTICAL PARTS….3829
23. MAINTENANCE SCHEDULE CHART….3831
24. SERVICE PROCEDURE….3836
24.1 INITIAL 250 HOURS SERVICE….3836
24.2 WHEN REQUIRED….3837
24.3 CHECK BEFORE STARTING….3848
24.4 EVERY 50 HOURS SERVICE….3858
24.5 EVERY 250 HOURS OF SERVICE….3860
24.6 EVERY 500 HOURS OF SERVICE….3868
24.7 EVERY 1000 HOURS OF SERVICE….3875
24.8 EVERY 2000 HOURS OF SERVICE….3881
24.9 EVERY 4000 HOURS OF SERVICE….3885
24.10 EVERY 3 YEARS OF SERVICE….3886
SPECIFICATIONS….3888
25. SPECIFICATIONS….3889
OPTIONS, ATTACHMENTS….3892
26. HANDLING PAYLOAD METER….3893
26.1 NAME OF PARTS….3893
26.2 EXTERNAL DISPLAY LAMPS….3893
26.3 OPERATING PAYLOAD METER….3895
27. SELECTING DUMP BODY….3904
28. OPTIONS AND ATTACHMENTS….3905
29. TACHOGRAPH (TCO15-6)….3906
29.1 EXPLANATION OF COMPONENTS….3906
29.2 METHOD OF USING KEY….3908
29.3 METHOD OF USE….3909
30. REVO TACHOGRAPH (TCO15-6)….3911
30.1 EXPLANATION OF COMPONENTS….3911
30.2 METHOD OF USE….3914
31. USING DIFFERENTIAL LOCK….3916
31.1 DIFFERENTIAL LOCK PEDAL….3916
31.2 PRECAUTIONS AND METHOD OF USE….3917
32. HANDLING AUTO-GREASING SYSTEM….3918
32.1 METHOD OF OPERATING AUTO-GREASING SYSTEM….3918
32.2 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM….3926
32.3 TROUBLESHOOTING….3927
32.4 SPECIFICATIONS….3927
HIGH ALTITUDE SPECIFICATIONS….3928
33. EXPLANATIONS OF COMPONENTS….3929
33.1 MACHINE MONITOR….3929
33.2 HYDRAULIC TANK PRESSURIZING DEVICE….3931
34. OPERATION….3932
34.1 HANDLING TIRES….3932
35. SERVICE PROCEDURE….3933
35.1 CHECK BEFORE STARTING….3933
35.2 EVERY 500 HOURS SERVICE….3935
35.3 EVERY 2000 HOURS SERVICE….3936
SEBM000704 – Dump Truck HD325-6, HD405-6 Shop Manual….3941
COVER….3941
CONTENTS….3942
01 GENERAL….3964
DIMENSIONS….3965
SPECIFICATIONS….3967
WEIGHT TABLE….3973
TABLE OF OIL COOLANT QUANTITIES….3975
10 STRUCTURE AND FUNCTION….3977
RADIATOR,TORQUE CONVERTER,BRAKE OIL COOLER,AFTER COOLER….3979
POWER TRAIN SKELETON….3980
OUTPUT SHAFT….3983
DRIVE SHAFT….3984
TORQUE CONVERTER,TRANSMISSION AND BRAKE COOLING HYDRAULIC PIPING….3985
HYDRAULIC CIRCUIT DIAGRAM FOR TORQUE CONVERTER,TRANSMISSION AND BRAKE COOLING….3986
TORQUE CONVERTER,TRANSMISSION AND BRAKE COOLING HYDRAULIC CIRCUIT SCHEMATICS….3987
TORQUE CONVERTER….3988
TORQUE CONVERTER VALVE….3991
LOCKUP SOLENOID VALVE….3996
TRANSMISSION….3997
TRANSMISSION VALVE….4000
ECMV(ELECTRONIC CONTROL MODULATION VALVE)….4001
FRONT AXLE….4006
REAR AXLE….4008
DIFFERENTIAL….4009
FINAL DRIVE….4013
FRONT BRAKE….4014
REAR BRAKE….4015
PARKING BRAKE….4016
WHEELS….4017
AXLE SUPPORT….4018
STEERING SYSTEM….4019
STEERING WHEEL….4020
STEERING LINKAGE….4021
SUSPENSION SYSTEM….4023
SUSPENSION CYLINDER….4025
AIR PIPING….4032
AIR CIRCUIT DIAGRAM….4036
AIR GOVERNOR….4040
AIR DRIER….4042
SAFETY VALVE….4044
CHECK VALVE….4044
DOUBLE-CHECK VALVE….4045
PROTECTION VALVE….4046
HAND BRAKE VALVE(RETARDER CONTROL VALVE)….4047
BRAKE VALVE….4049
2-WAY CONTROL VALVE(PARKING BRAKE VALVE,EMERGENCY BRAKE VALVE)….4052
EMERGENCY BRAKE CONTROL VALVE(VARIABLE CONTROL TYPE)….4054
RELAY VALVE(ACTS ALSO AS EMERGENCY RELAY)….4057
PARKING BRAKE RELAY VALVE….4060
FRONT BRAKE CHAMBER….4062
REAR BRAKE CHAMBER….4063
BRAKE CHAMBER….4063
PARKING BRAKE CHAMBER….4066
SLACK ADJUSTER….4067
HYDRAULIC CIRCUIT DIAGRAM(FRONT DRIVE)….4069
HYDRAULIC PIPING DIAGRAM(FRONT DRIVE)….4070
PISTON PUMP(FRONT DRIVE)….4072
PISTON MOTOR(FRONT DRIVE)….4074
CHARGE PUMP OIL FILTER….4076
HYDRAULIC PIPING(STEERING AND HOIST)….4077
HYDRAULIC CIRCUIT DIAGRAM(STEERING AND HOIST)….4078
HYDRAULIC CIRCUIT SCHEMATICS….4079
DUMP BODY CONTROL….4080
HYDRAULIC TANK,FILTER….4081
DEMAND VALVE….4082
STEERING CONTROL VALVE….4086
CROSS-OVER RELIEF VALVE….4090
HOIST VALVE….4091
ELECTRICAL CIRCUIT DIAGRAM….4092
FRONT BRAKE CUT-OFF VALVE….4100
AUTOMATIC RETARDER VALVE….4101
EXHAUST BRAKE VALVE….4101
HORN VALVE….4102
WIPER SWITCH….4102
WIPER RELAY….4103
AIR CONDITIONER….4104
PIPING DIAGRAM….4104
ELECTRICAL CIRCUIT DIAGRAM….4105
REFRIGERANT CIRCUIT DIAGRAM….4105
UNIT….4106
RECEIVER DRYER….4106
CONDENSER….4107
COMPRESSOR….4107
ENGINE CONTROL SYSTEM….4108
EXHAUST BRAKE….4109
SYSTEM DIAGRAM….4109
AUTOMATIC SHIFT CONTROL SYSTEM….4112
TRANSMISSION CONTROLLER….4114
SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES….4115
SHIFT LEVER SWITCH….4118
SENSORS,SWITCHES….4119
TRANSMISSION SPEED SENSOR….4119
TRANSMISSION OIL TEMPERATURE SENSOR….4119
FILL SWITCH….4120
ACCELERATOR SENSOR….4120
SHIFT LIMIT SWITCH….4121
MODE SELECTOR SWITCH….4121
AUTOMATIC EMERGENCY STEERING SYSTEM….4122
ELECTRICAL CIRCUIT DIAGRAM….4123
FLOW SWITCH….4124
RELAY TIMER….4126
AUTOMATIC SUSPENSION SYSTEM….4127
STRUCTURE OF SYSTEM….4127
AUTOMATIC SUSPENSION MODE SELECTION CONTROL….4129
SUSPENSION CONTROLLER….4130
SENSORS,SWITCHES….4131
STEERING ANGLE SENSOR….4131
PRESSURE SENSOR….4131
PAYLOAD METER….4132
STRUCTURE OF SYSTEM….4132
PRINCIPLE OF CALCULATION….4133
FEATURES OF EQUIPMENT….4135
ELECTRONIC MONITOR SYSTEM….4140
ELECTRONIC MONITOR PANEL….4141
ELECTRONIC MONITOR DISPLAYS,FUNCTIONS….4142
SENSORS,SWITCHES….4146
ENGINE SPEED SENSOR….4146
ENGINE OIL PRESSURE SENSOR….4146
ENGINE WATER TEMPERATURE SENSOR….4147
RETARDER OIL TEMPERATURE SENSOR….4147
TORQUE CONVERTER OIL TEMPERATURE SENSOR….4147
AIR PRESSURE SENSOR….4147
FUEL LEVEL SENSOR….4148
RADIATOR WATER LEVEL SENSOR….4149
TRANSMISSION OIL FILTER SENSOR….4149
TRANSMISSION FILTER OIL TEMPERATURE SWITCH….4150
BODY RAISE SWITCH,BODY FLOAT SWITCH….4150
STOP LAMP SWITCH….4151
EXHAUST BRAKE SWITCH….4151
TILT SWITCH….4151
PARKING BRAKE SWITCH….4152
BIMETAL TIMER….4152
DIODE….4153
LAMP….4154
LAMP CHECK SWITCH….4156
DIMMER SWITCH….4156
COMBINATION SWITCH….4157
RELAY SWITCH….4158
BUZZER….4159
MAINTENANCE MONITOR SYSTEM….4160
SYSTEM DIAGRAM….4160
MONITOR PANEL….4161
MAINTENACE MONITOR CIRCUIT DIAGRAM….4162
MONITOR DISPLAY,FUNCTIONS….4163
FUNCTIONS OF SWITCHES….4165
SENSORS,SWITCHES….4167
ENGINE OIL LEVEL SENSOR….4167
TRANSMISSION OIL LEVEL SENSOR….4167
HYDRAULIC OIL LEVEL SENSOR….4168
AIR FILTER CLOGGING SENSOR….4168
RETARDER BRAKE WEAR SENSOR….4169
HYDRAULIC FILTER SENSOR ….4169
TRANSMISSION OIL FILTER SENSOR….4169
BATTERY ELECTROLYTE LEVEL SENSOR….4170
FULL-FLOW FILTER SENSOR….4170
FRONT DRIVE SYSTEM….4171
SYSTEM DIAGRAM….4171
GERNERAL LOCATIONS FOR ELECTRICAL COMPONENTS….4172
ELECTRICAL CIRCUIT DIAGRAM….4173
4-WHEEL DRIVE CONTROLLER….4174
ECMV….4175
SENSORS,SWITCHES….4176
STEERING ANGLE SENSOR(POTENTIOMETER)….4176
HIGH-PRESSURE OIL PRESSURE SENSOR….4177
CLUTCH OIL PRESSURE SENSOR….4177
WHEEL SPEED SENSOR….4178
20 TESTING AND ADJUSTING….4179
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS….4180
STANDARD VALUE TABLE FOR CHASSIS….4182
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM….4190
TOOLS FOR TESTING,ADJUSTING AND TROUBLESHOOTING….4198
ADJUSTING VALVE CLEARANCE….4200
MEASURING COMPRESSION PRESSURE….4201
MEASURING BLOW-BY….4202
ADJUTING TENSION OF ALTERNATOR DRIVE BELT….4203
MEASURING ENGINE SPEED….4204
MEASURING ENGINE OIL PRESSURE….4205
MEASURING BOOST PRESSURE….4206
MEASURING EXHAUST TEMPERATURE….4207
MEASURING EXHAUST GAS COLOR….4208
TESTING AND ADJUSTING FUEL INJECTION TIMING….4209
AIR BLEEDING FROM FUEL SYSTEM….4212
ADJUSTING ENGINE STOP MOTOR CABLE….4213
ADJUSTING ACCELERATOR PEDAL….4214
ADJUSTING ENGINE SPEED SENSOR….4215
TESTING HYDRAULIC PRESSURE OF TORQUE CONVERTER VALVE….4216
MEASURING FRONT DRIVE CLUTCH OIL PRESSURE….4217
TESTING HYDRAULIC PRESSURE OF TRANSMISSION VALVE….4218
TESTING ECMV OIL PRESSURE….4219
TESTING TORQUE CONVERTER STALL SPEED….4221
TESTING BRAKE PRESSURE….4222
BLEEDING AIR FROM BRAKE CIRCUIT….4224
TESTING AND ADJUSTING PARKING BRAKE PERFORMANCE….4225
TESTING WEAR OF FRONT BRAKE PAD….4226
TESTING WEAR OF FRONT BRAKE DISC….4226
TESTING AND ADJUSTING SUSPENSION CYLINDER….4228
TESTING AND ADJUSTING SET PRESSURE OF AIR GOVERNOR….4240
ADJUSTING HOIST LEVER LINKAGE….4241
ADJUSTING BODY POSITIONER….4242
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING,HOIST CIRCUIT….4243
AIR BLEEDING FROM STEERING CYLINDER….4245
BLEEDING AIR FROM DRIVE HYDRAULIC CIRCUIT….4246
ADJUSTING ELECTRONIC MONITOR….4248
METHOD FOR EMERGENCY OPERATION OF TRUCK WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM OF TRANSMISSION CONTROL SYSTEM….4249
PROCEDURE FOR OPERATING SHIFT CHECKER AND MODULATION CHECKER….4251
TROUBLESHOOTING….4271
POINTS TO REMEMBER WHEN TROUBLESHOOTING….4272
SEQUENCE OF EVENTS IN TROUBLESHOOTING….4273
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE….4274
HANDLING CONNECTORS….4281
CHECKS BEFORE TROUBLESHOOTING….4282
METHOD OF USING TROUBLESHOOTING CHARTS AND TABLES….4284
METHOD OF USING JUDGEMENT TABLE….4292
EXPLANATION OF FUNCTIONS OF ELECTRIC SYSTEM(CONTROL MECHANISM)….4295
METHOD OF SELF-DIAGNOSTIC DISPLAY FOR MONITOR PANEL AND EACH CONTROLLER….4298
ACTION BY SELF-TESTER AND MACHINE SYMPTOMS(TRANSMISSION CONTROL SYSTEM)….4305
ACTION BY SELF-TESTER AND MACHINE SYMPTOMS(SUSPENSION CONTROLLER SYSTEM)….4311
ACTION BY SELF-TESTER AND MACHINE SYMPTOMS(FRONT DRIVE CONTROLLER SYSTEM)….4312
TYPE AND LOCATION OF CONNECTOR,SENSOR….4316
LOCATION OF CONNECTOR,SENSOR….4321
CONNECTION TABLE FOR CONNECTOR….4324
TROUBLESHOOTING OF CHASSIS RELATED PARTS….4335
D-1 STARTING PERFORMANCE IS POOR….4336
D-2 ENGINE DOES NOT START….4337
(1) ENGINE DOES NOT TURN….4337
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT(FUEL NOT BEING INJECTED)….4338
(3) EXHAUST SMOKE COMES OUT BUT ENGINE ENGINE DOES NOT START(FUEL IS BEING INJECTED)….4339
D-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR)….4340
D-4 ENGINE STOPS DURING OPERATIONS….4341
D-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)….4342
D-6 ENGINE LACKS OUTPUT(NO POWER)….4343
D-7 EXHAUST SMOKE IS BLACK(INCOMPLATE COMBUSTION)….4344
D-8 OIL CONSUMPTION IS EXCESSIVE(OR EXHAUST SMOKE IS BLUE)….4345
D-9 OIL BECOMES CONTAMINATED QUICKLY….4346
D-10 FUEL CONSUMPTION IS EXCESSIVE….4347
D-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN….4348
D-12 OIL PRESSURE LAMP LIGHTS UP(DROP IN OIL PRESSURE)….4349
D-13 OIL LEVEL RISES….4350
D-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING)….4351
D-15 ABNORMAL NOISE IS MADE….4352
D-16 VIBRATION IS EXCESSIVE….4353
TROUBLESHOOTING OF ENGINE ELECTRICAL SYSTEM FOR ENGINE START AND STOP….4354
G-1 ENGINE DOES NOT START(FUEL INJECTION PUMP STOP LEVER STAYS AT STOP POSITION)….4355
G-2 ENGINE DOES NOT STOP(FUEL INJECTION PUMP STOP LEVER STAYS AT FULL POSITION)….4356
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE START AND STOP….4357
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM….4358
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM….4360
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER,TRANSMISSION RELATED PARTS….4361
A-1 ABNORMALITY IN POWER SOURCE….4362
a) [OFF] SELF TESTING DISPLAY OF CONTROLLER DOES NOT LIGHT UP….4362
b) DROP IN VOLTAGE OF CONTROLLER POWER SOURCE DISPLAYED….4363
c) ABNORMALITY IN TRANSMISSION CUT RELAY POWER SOURCE DISPLAYED….4364
A-2 ABNORMALITY IN NEUTRAL SAFETY SYSTEM DISPLAYED….4365
A-3 ABNORMALITY IN CONTROLLER SYSTEM….4366
a) ONLY DOT LIGHT UP OR ABNORMALITY IN CONTROLLER DISPLAYED ABNORMALITY IN CONTROLLER DISPLAYED….4366
b) DOUBLE SYSTEM FOR CLUTCH DISPLAYED….4367
A-4 ABNORMALITY IN TRANSMISSION [CUT RELAY] SYSTEM DISPLAYED….4368
A-5 ABNORMALITY IN AUTO-RETARDER BRAKE SOLENOID SYSTEM DISPLAYED….4369
A-6 DISPLAYES ABNORMALITY IN EXHAUST BRAKE SOLENOID SYSTEM….4370
A-7 ABNORMALITY IN SPEED SENSOR SYSTEM….4371
a) ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM DISPLAYED….4371
b) ABNORMALITY IN INTERMEDIATE SHAFT SPEED SENSOR SYSTEM DISPLAYED….4372
c) DISCONNECTION IN TRAVEL SPEED SENSOR(TRANSMISSION OUTPUT SHAFT SPEED SENSOR)DISPLAYED….4373
A-8 SPEED SENSOR SYSTEM,CLUTCH SLIPPING….4374
a) INPUT SHAFT SENSOR OR H.L CLUTCH SYSTEM DISPLAYED….4374
b) TRAVEL SPEED SENSOR OR SPEED CLUTCH(1,2,3,4,R)SYSTEM DISPLAYED….4375
A-9 ABNORMALITY IN MODEL SELECTION DISPLAYED….4376
A-10 ABNORMALITY IN TRANSMISSION SHIFT LEVER SYSTEM….4377
a) SHORT CIRCUIT IN TRANSMISSION SHIFT LEVER ASSEMBLY POWER SOURCE DISPLAYED….4377
b) SHIFT LEVER POSITION SIGNAL DISPLAYS TWO OR MORE SYSTEMS….4378
c) TRANSMISSION SHIFT LEVER POSITION SIGNAL IS NOT INPUT….4381
A-11 ABNORMALITY IN ACCELERATOR SIGNAL DISPLAYED….4382
A-12 ABNORMALITY IN TRANSMISSION OIL TEMPERATURE SENSOR DISPLAYED….4384
A-13 ABNORMALITY IN PRESSURE CONTROL VALVE SYSTEM….4385
a) FILL SIGNAL DISPLAYES ON REGARDLESS OF COMMAND….4385
b) FILL SIGNAL IS NOT INPUT AND CLUTCH SLIPPING IS DISPLAYED….4386
b-1)INSPECTION OF FILL SIGNAL SYSTEM….4386
b-2)TRANSMISSION INPUT SHAFT REVOLUTION SIGNAL SYSTEM,CHECK OF HI-LO CLUTCH SYSTEM….4388
b-3)TRANSMISSION OUTPUT SHAFT REVOLUTION SIGNAL SYSTEM,CHECK OF F,R CLUTCH SYSTEM….4388
A-14 WHEN FILL SIGNAL IS NOT INPUT (FLOW DETEDTOR VALVE SYSTEM)….4389
A-15 SHORT CIRCUIT IN PRESSURE CONTROL VALVE SOLENOID SYSTEM DISPLAYED OR DISCONNECTION IN PRESSURE CONTROL VALVE SOLENOID SYSTEM DISPLAYED….4390
ELECTRICAL CIRCUIT DIAGRAM ….4392
TROUBLESHOOTING OF SUSPENSION CONTROLLER SYSTEM….4393
JUDGMENT TABLE FOR SUSPENSION CONTROLLER,SUSPENSION RELATED PARTS….4394
S-1 ABNORMALITY IN POWER SOURCE SYSTEM….4395
S-2 ABNORMALITY IN PRESSURE SENSOR [RIGHT] SYSTEM….4396
S-3 ABNORMALITY IN PRESSURE SENSOR [LEFT] SYSTEM….4397
S-4 ABNORMALITY IN TRAVEL SPEED SENSOR SYSTEM….4398
S-5 ABNORMALITY IN STEERING SENSOR SYSTEM….4399
S-6 ABNORMALITY IN MODEL SENSOR SYSTEM….4400
S-7 ABNORMALITY IN SOLENOID [I] SYSTEM….4401
S-8 ABNORMALITY IN SOLENOID [II] SYSTEM….4402
S-9 ABNORMALITY IN SOLENOID [III] SYSTEM….4403
S-10 ABNORMALITY IN CONTROLLER SYSTEM….4404
ELECTRICAL CIRCUIT DIAGRAM FOR SUSPENSION CONTROL SYSTEM….4405
TROUBLESHOOTING OF PAYLOAD METER SYSTEM….4406
L-1 WHEN THE STARTING SWITCH IS TURNED ON,NO DISPLAY APPEARS….4407
L-2 AFTER THE STARTING SWITCH IS TURNED ON,THE DEMAND FOR CALIBRATION(CAL FLASHES)CONTINUES TO BE GIVEN….4407
L-3 CALIBRATION CANNOT BE CARRIED OUT….4408
L-4 AFTER THE STARTING SWITCH IS TURNED ON,THE EXTERNAL DISPLAY LAMPS DO NOT ALL LIGHT UP….4410
L-5 EXTERNAL DISPLAY LAMPS LIGHT UP EVEN WHEN IT IS NOT THE CONDITION FOR LIGHTING UP….4410
L-6 THE LEVEL OF LIGHTING UP OF THE EXTERNAL DISPLAY LAMPS IS NOT CORRECT….4411
L-7 THERE IS ABNORMALITY IN THE DISPLAY LOGIC….4412
a) EVEN WHEN THE DUMP BODY IS OPERATED,THE DISPLAY DOES NOT BECOME 0 TON….4412
b) THE DISPLAY STAYS AT 0 TON AND DOES NTO CHANGE….4412
c) WHEN THE TRANSMISSION LEVER IS AT NEUTRAL,THE WEIGHT DISPLAY IS NOT GIVEN(TIME DISPLAY IS GIVEN)….4413
d) WHEN THE TRANSMISSION LEVER IS AT A POSITION OTHER THAN NEUTRAL,THE TIME DISPLAY IS NOT GIVEN….4415
L-8 E01-E04 IS DISPLAYED….4416
L-9 E11-E14 IS DISPLAYED….4417
L-10 E21-E28 IS DISPLAYED BY SENSOR CHECK….4417
L-11 E31 IS DISPLAYED….4418
L-12 E32 IS DISPLAYED….4420
L-13 E41 IS DISPLAYED….4420
L-14 E42 IS DISPLAYED….4421
L-15 THE PRINTER DOES NOT PRINT ANYTHING(ONLY BLANK PAPER COMES OUT)….4421
L-16 THE PRINTER ONLY PRINTS NO DATA….4422
L-17 EVEN WHEN THE [PRT]SWITCH IS PRESSED,NOTHING IS PRINTED OUT….4422
L-18 PAPE FLASHES….4423
L-19 THE TIME IS WRONG….4423
L-20 E33 IS DISPLAYED….4423
RELATED ELECTRICAL CIRCUIT DIAGRAMS….4424
ELECTRICAL CIRCUIT DIAGRAMS FOR PAYLOAD METER SYSTEM….4427
TROUBLESHOOTING OF MONITOR PANEL SYSTEM….4428
P-1 MONITOR PANEL DOES NOT WORK AT ALL….4430
P-2 PART OF MONITOR PANEL DOES NOT WORK….4431
a) SPEEDOMETER DISPLAY DOES NOT WORK….4431
b) SPEEDOMETER DISPLAY WORKS,BUT OTHER PARTS DO NOT WORK….4431
c) SUSPENSION DISPLAY DOES NOT WORK….4431
d) (MECHATRONICS)CAUTION,FUEL GAUGE DISPLAYS DO NOT WORK….4432
P-3 ENGINE(MECHATRONICS)DISPLAY FLASHES….4433
P-4 AUTOMATIC SHIFT DISPLAY (MECHATRONICS)FLASHES….4434
P-5 SUSPENSION(MECHATRONIC)DISPLAY FLASHES….4434
P-6 ABNORMALITY IN POWER MODE DISPLAY….4435
HIGH POWER DISPLAY LIGHTS UP….4435
P-7 ABNORMALITY IN SUSPENSION DISPLAY….4436
a) HARD DISPLAY DOES NOT LIGHT UP….4436
b) MEDIUM DISPLAY DOES NOT LIGHT UP….4436
c) SOFT DISPLAY DOES NOT LIGHT UP….4437
d) SUSPENSIO MODE DISPLAYS ALL LIGHT UP….4437
P-8 ABNORMALITY IN SHIFT POSITION DISPLAY….4438
a) R DISPLAY DOES NOT LIGHT UP….4438
b) N DISPLAY DOES NOT LIGHT UP….4438
c) D DISPLAY DOES NOT LIGHT UP….4439
d) 5 DISPLAY DOES NOT LIGHT UP….4439
e) 4 DISPLAY DOES NOT LIGHT UP….4440
f) 3 DISPLAY DOES NOT LIGHT UP….4440
g) L DISPLAY DOES NOT LIGHT UP….4441
P-9 SHIFT LIMITER DISPLAY DOES NOT LIGHT UP….4442
P-10 LOCK-UP DISPLAY DOES NOT LIGHT UP….4442
P-11 HI BEAM DISPLAY DOES NOT LIGHT UP….4443
P-12 ABNORMALITY IN TURN SIGNAL….4444
a) RIGHT TURN SIGNAL LAMP DOES NOT LIGHT UP….4444
b) LEFT TURN SIGNAL LAMP DOES NOT LIGHT UP….4444
P-13 ABNORMALITY IN SHIFT INDICATOR DISPLAY….4445
a) WHEN 1,2,4,6,R IS DISPLAYED,DISPLAY CHANGES TO E….4445
b) WHEN 3,5,7 IS DISPLAYED,DISPLAY CHANGES TO E….4445
c) WHEN 1 IS DISPLAYED,DISPLAY CHANGES TO E….4446
d) WHEN 2,3 IS DISPLAYED,DISPLAY CHANGES TO E….4446
e) WHEN 4,5 IS DISPLAYED,DISPLAY CHANGES TO E….4447
f) WHEN 6,7 IS DISPLAYED,DISPLAY CHANGES TO E….4447
g) WHEN R IS DISPLAYED,DISPLAY CHANGES TO E….4448
P-14 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY….4449
P-15 TACHOMETER DOES NOT WORK NORMALLY….4449
P-16 SERVICE METER DOES NOT WORK….4450
P-17 ODOMETER DOES NOT WORK….4450
P-18 ABNORMALITY IN ALARM BUZZER….4451
a) CAUTION DISPLAY IS FLASHING (LIGHTED UP),BUT ALARM BUZZER DOES NOT SOUND….4451
b) ALARM BUZZER CONTINUES TO SOUND….4451
P-19 ABNORMALITY IN WARNING LAMP….4452
a) CAUTION DISPLAY IS FLASHING(LIGHTED UP),BUT WARNING LAMP DOES NOT FLASH….4452
b) WARNING LAMP STAYS ON….4452
P-20 CAUTION DISPLAY DOES NOT FLASH(DOES NOT LIGHT UP),BUT WARNING LAMP FLASHES AND ALARM BUZZER SOUNDS….4453
a) WARNING LAMP FLASHES AND ALARM BUZZER SOUNDS….4453
b) WARNING LAMP FLASHES WHEN ENGINE STOPS….4453
c) WARNING LAMP FLASHES WHEN ENGINE IS RUNNIGN….4453
P-21 ABNORMALITY IN AIR PRESSURE GAUGE….4454
a) NO DISPLAY GIVEN IN DISPLAY AREA….4454
b) DISPLAY SHOWS HIGHEST LEVEL AND DOES NOT MOVE….4454
P-22 ABNORMALITY IN COOLANT TEMPERATURE GAUGE….4455
a) NO DISPLAY GIVEN IN DISPLAY AREA….4455
b) DISPLAY SHOWS LOWEST LEVEL AND DOES NOT MOVE….4455
P-23 ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE….4456
a) NO DISPLAY GIVEN IN DISPLAY AREA….4456
b) DISPLAY SHOWS LOWEST LEVEL AND DOES NOT MOVE….4456
P-24 ABNORMALITY IN RETARDER OIL TEMPERATURE GAUGE….4457
a) NO DISPLAY GIVEN IN DISPLAY AREA….4457
b) DISPLAY SHOWS LOWEST LEVEL AND DOES NOT MOVE….4457
P-25 ABNORMALITY IN FUEL GAUGE….4458
a) NO DISPLAY GIVEN IN DISPLAY AREA….4458
b) DISPLAY SHOWS FULL AND DOES NOT MOVE….4458
P-26 ABNORMALITY IN NIGHT LIGHTING….4459
a) NONE OF PANEL LAMPS LIGHT UP….4459
b) SERVICE METER AND ODOMETER LIGHT UP,BUT OTHER PARTS DO NOT LIGHT UP….4460
c) SERVICE METER AND ODOMETER DO NOT LIGHT UP….4460
RELATED ELECTRICAL CIRCUIT DIAGRAMS….4461
ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR PANEL SYSTEM….4469
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM….4470
M-1 MAINTENANACE MONITOR DOES NOT WOEK….4471
a) WHEN NOTHING WORKS….4471
b) WHEN CHECK DISPLAY DOES NOT WORK….4471
M-2 WHEN ENGINE IS STOPPED,ENGINE OIL LEVEL DISPLAY FLASHES….4472
M-3 WHEN ENGINE IS STOPPED,TRANSMISSION OIL LEVEL DISPLAY FLASHES….4473
M-4 WHEN ENGINE IS STOPPED,HYDRAULIC OIL LEVEL DISPLAY FLASHES….4474
M-5 WHEN ENGINE IS STOPPED,RETARDER OIL LEVEL DISPLAY FLASHES….4475
M-6 WHEN ENGINE IS STOPPED,BRAKE OIL LEVEL DISPLAY FLASHES….4476
M-7 WHEN ENGINE IS STOPPED,BATTERY ELECTROLYTE LEVEL DISPLAY FLASHES….4477
M-8 RETARDER WEAR DISPLAY FLASHES….4478
M-9 WHEN ENGINE IS RUNNIGN,AIR CLEANER CLOGGING DISPLAY FLASHES….4479
M-10 WHEN ENGINE IS RUNNING,FULL-FLOW FILTER CLOGGING DISPLAY FLASHES….4480
M-11 WHEN ENGINE IS RUNNIGN,TRANSMISSION FILTER CLOGGING DISPLAY FLASHES….4481
M-12 WHEN ENGINE IS RUNNIGN,HYDRAULIC FILTER CLOGGING DISPLAY FLASHES….4482
M-13 WHEN ENGINE IS RUNNIGN,RETARDER FILTER CLOGGING DISPLAY FLASHES….4483
M-14 MAINTENACE TIMER DOES NOT WORK….4484
M-15 ABNORMALITY IN SWITCH….4485
a) CONFIRMATION SWITCH FOR OIL OR FILTER REPLACEMENT TIME DOES NOT WORK….4485
b) REPLACEMENT SWITCH,MISOPERATION CANCEL SWITCH DO NOT WORK….4485
M-16 NIGHT LIGHTING DOES NOT LIGHT UP….4486
ELECTRICAL CIRCUIT DIAGRAM OF MAINTENACE MONITOR SYSTEM….4487
TROUBLESHOOTING OF PILOT LAMP SYSTEM….4488
F-1 ABNORMALITY IN LIGHTING UP OF REAR BRAKE LAMP….4489
a) BRAKE IS NOT BEING APPLIED,BUT PILOT LAMP LIGHTS UP….4489
b) PILOT LAMP DOES NOT LIGHT UP EVEN WHEN BRAKE IS APPLIED….4490
F-2 ABNORMALITY IN LIGHTING UP OF BODY FLOAT PILOT LAMP….4491
a) HOIST LEVER IS AT FLOAT POSITION,BUT PILOT LAMP LIGHTS UP….4491
b) PILOT LAMP DOES NOT LIGHT UP EVEN WHEN HOIST LEVER IS OPERATED….4492
F-3 ABNORMAL LIGHTING UP OF EXHAUST BRAKE PILOT LAMP….4493
a) PILOT LAMP LIGHTS UP EVEN WHEN EXHAUST BRAKE IS NOT BEING OPERATED….4493
b) PILOT LAMP DOES NOT LIGHT UP EVEN WHEN EXHAUST BRAKE IS BEING OPERATED….4494
F-4 ABNORMALITY IN LIGHTING UP OF PARKING BRAKE PILOT LAMP….4495
a) PARKING BRAKE IS NOT BEING APPLIED,BUT PILOT LAMP LIGHTS UP….4495
b) PILOT LAMP DOES NOT LIGHT UP EVEN WHEN PARKING BRAKE IS APPLIED….4496
ELECTRICAL CIRCUIT DIAGRAM FOR PILOT LAMP CIRCUIT….4497
TROUBLESHOOTING OF AIR SYSTEM ON MACHINE AIR COMPRESSOR….4498
BASIC AIR CIRCUIT OF AIR COMPRESSOR….4499
C-1 AIR PRESSURE DOES NOT RISE AT ALL….4500
C-2 AIR PRESSURE DOES NOT RISE TO SPECIFIED RANGE….4502
C-3 AIR PRESSURE RISE,BUT TAKES A LONG TIME TO CHARGE….4503
C-4 WHEN AIR PRESSURE REACHES TOP OF GREEN RANGE ON AIR GAUGE,AIR PRESSURE SUDDENLY DROPS TO BOTTOM OF GREEN RANGE ON AIR GAUGE EVEN WHEN NO AIR IS USED….4503
C-5 AIR BLOWS OUT FROM SAFETY VALVE….4504
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM….4505
H-1:MACHINE DOES NOT MOVE….4506
H-2:MACHINE DOES NOT TRAVEL SMOOTHLY….4508
H-3:LOCK-UP CLUTCH CANNOT BE DISENGAGED….4508
H-4:LARGE SHOCK WHEN STARTING OF SHIFTING….4509
H-5:TRANSMISSION DOES NOT SHIFT UP….4509
H-6:MACHINE LACKS POWER OR SPEED WHEN TRAVELING….4510
H-7:TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR….4516
H-8:TORQUE CONVERTER OIL TEMPERATURE IS HIGHT….4518
H-9:TORQUE CONVERTER OIL PRESSURE IS LOW….4519
H-10:FRONT BRAKE IS INEFFECTIVE OR EFFECTIVE ONE SIDE….4520
H-11:REAR BRAKE IS INEFFECTIVE OR EFFECTIVE ONE SIDE….4522
H-12:STEERING WHEEL IS HEAVY….4523
H-13:STEERING WHEEL DOES NOT FUNCTION….4524
H-14:STEERING WHEEL VIBRATES….4524
H-15:HOIST CYLINDER LACKS LIFTING FORCE(LIFTING SPEED)….4525
H-16:HOIST CYLINDER DOES NOT WORK….4526
H-17:EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY….4527
TROUBLESHOOTING OF FRONT DRIVE SYSTEM(HD325-6W)….4528
W-1 SELF-DIAGNOSTIC DISPLAY UNIT OF CONTROLLER DOES NOT LIGHT UP….4529
W-2 (DROP IN CONTROLLER INPUT VOLTAGE)IS DISPLAYED….4530
W-3 (ABNORMALITY IN ANALOG POWER SOURCE CUT RELAY)IS DISPLAYED….4531
W-4 (DISCONNECTION IN CLUTCH CONTROL VALVE OUTPUT WIRING)IS DISPLAYED (SHORT CIRCUIT IN CLUTCH CONTROL VALVE OUTPUT WIRING)IS DISPLAYED….4532
W-5 (DEFECTIVE CLUTCH CONTROL VALVE SYSTEM)IS DISPLAYED (DEFECTIVE FILL SIGNAL INPUT SYSTEM)IS DIAPLAYED….4533
W-6 (DISCONNECTION IN PUMP OUTPUT WIRING)IS DISPLAYED (SHORT CIRCUIT IN LEFT MOTOR OUTPUT WIRING)IS DISPLAYED….4534
W-7 (DISCONNECTION IN LEFT MOTOR OUTPUT WIRING)IS DISPLAYED (SHORT CIRCUIT IN LEFT MOTOR OUTPUT WIRING)IS DISPLAYED….4535
W-8 (DISCONNECTION IN RIGHT MOTOR OUTPUT WIRING)IS DISPLAYED (SHORT CIRCUTI IN RIGHT MOTOR OUTPUT WIRING)IS DISPLAYED….4536
W-9 (ABNORMALITY(DISCONNECTION)IN PRESSURE SENSOR[A])IS DISPLAYED (ABNORMALITY(DISCONNECTION)IN PRESSURE SENSOR[B])IS DISPLAYED….4537
W-10 (SHORT CIRCUIT IN PRESSURE SENSOR[A])IS DISPLAYED (SHORT CIRCUIT IN PRESSURE SENSOR[B])IS DISPLAYED….4538
W-11 (ABNORMALITY IN HST HYDRAULIC SYSTEM)IS DISPLAYED….4539
W-12 (DISCONNECTION IN STEERING ANGLE SENSOR)IS DISPLAYED (SHORT CIRCUIT IN STEERING ANGLE SENSOR)IS DISPLAYED (DEFECTIVE MOUNT OF STEERING ANGLE SENSOR)IS DISPLAYED….4540
W-13 (DISCONNECTION IN ENGINE SPEED SENSOR)IS DISPLAYED….4541
W-14 (DISCONNECTION IN TRANSMISSION INPUT SHAFT SPEED SENSOR)IS DISPLAYED….4542
W-15 (ABNORMALITY IN LEFT FRONT WHEEL SPEED SENSOR SYSTEM)IS DISPLAYED (ABNORMALITY IN RIGHT FRONT WHEEL SPEED SENSOR SYSTEM)IS DISPLAYED….4543
W-16 (ABNORMALITY IN FRONT WHEEL SPEED SENSOR SYSTEM)IS DISPLAYED….4543
W-17 (SHORT CIRCUIT IN 4-WHEEL DRIVE LAMP RELAY)IS DISPLAYED….4544
W-18 (CLOGGING OF FRONT DRIVE OIL FILTER)IS DISPLAYED….4545
W-19 (RISE IN TEMPERATURE OF FRONT DRIVE OIL)IS DISPLAYED….4546
W-20 (ABNORMALITY IN CLUTCH OIL PRESSURE SYSTEM)IS DISPLAYED….4547
ELECTRICAL CIRCUIT DIAGRAM FOR FRONT DRIVE SYSTEM….4548
30 DISASSEMBLY AND ASSEMBLY….4549
METHOD OF USING MANUAL….4551
PRECAUTIONS WHEN CARRYING OUT OPERATION….4552
SPECIAL TOOL LIST….4554
SKETCHES OF SPECIAL TOOLS….4558
STARTING MOTOR….4566
REMOVAL….4566
INSTALLATION….4566
ALTERNATOR….4567
REMOVAL….4567
INSTALLATION….4567
ENGINE OIL COOLER….4568
REMOVAL….4568
INSTALLATION….4568
FUEL INJECTION PUMP….4569
REMOVAL….4569
INSTALLATION….4571
AIR COMPRESSOR….4572
REMOVAL….4572
INSTALLATION….4572
AIR CONDITIONER COMPRESSOR….4573
REMOVAL….4573
INSTALLATION….4573
AIR CONDITIONER CONDENSER….4574
REMOVAL….4574
INSTALLATION….4574
WATER PUMP….4575
REMOVAL….4575
INSTALLATION….4575
AFTERCOOLER CORE….4576
REMOVAL….4576
INSTALLATION….4577
AFTERCOOLER….4578
REMOVAL….4578
INSTALLATION….4578
EXHAUST BRAKE CYLINDER….4579
REMOVAL….4579
INSTALLATION….4579
TURBOCHARGER….4580
REMOVAL….4580
INSTALLATION….4580
NOZZLE HOLDER….4582
REMOVAL….4582
INSTALLATION….4582
CYLINDER HEAD….4584
REMOVAL….4584
INSTALLATION….4589
ENGINE….4598
REMOVAL….4598
INSTALLATION….4601
RADIATOR,TORQUE CONVERTER OIL COOLER….4608
REMOVAL….4608
INSTALLATION….4611
RADIATOR,FRONT DRIVE COOLER….4616
REMOVAL….4616
INSTALLATION….4620
FRONT DRIVE OIL COOLER….4621
REMOVAL….4621
INSTALLATION….4621
OUTPUT SHAFT….4622
REMOVAL….4622
INSTALLATION….4624
DISASSEMBLY….4625
ASSEMBLY….4626
TORQUE CONVERTER,TRANSMISSION….4628
REMOVAL….4628
INSTALLATION….4630
TORQUE CONVERTER VALVE….4635
REMOVAL….4635
INSTALLATION….4635
DISASSEMBLY….4636
ASSEMBLY….4636
TORQUE CONVERTER,TRANSMISSION….4637
DISCONNECTION….4637
CONNECTION….4638
TORQUE CONVERTER….4639
DISASSEMBLY….4639
ASSEMBLY….4644
PTO….4649
DISASSEMBLY….4649
ASSEMBLY….4650
TRANSMISSION….4655
DISASSEMBLY….4655
ASSEMBLY….4673
TRANSMISSION CONTROL VALVE(ECMV ASSEMBLY)….4691
REMOVAL….4691
INSTALLATION….4691
DISASSEMBLY….4692
ASSEMBLY….4693
DIFFERENTIAL….4694
REMOVAL….4694
INSTALLATION….4694
DISASSEMBLY….4695
ASSEMBLY….4716
FRONT WHEEL….4760
REMOVAL….4760
INSTALLATION….4760
REAR WHEEL….4762
REMOVAL….4762
INSTALLATION….4763
FRONT BRAKE CALIPER PAD….4764
REMOVAL….4764
INSTALLATION….4764
FRONT BRAKE CALIPER….4765
REMOVAL….4765
INSTALLTION….4765
DISASSEMBLY….4766
ASSEMBLY….4766
FRONT WHEEL HUB….4767
DISASSEMBLY….4767
ASSEMBLY….4769
FRONT FINAL DRIVE CLUTCH CARRIER….4772
DISASSEMBLY….4772
ASSEMBLY….4776
FRONT FINAL DRIVE BRAKE….4781
DISASSEMBLY….4781
ASSEMBLY….4786
FRONT DRIVE SHAFT….4793
DISASSEMBLY….4793
ASSEMBLY….4797
REAR FINAL DRIVE CARRIER….4803
REMOVAL….4803
INSTALLTION….4804
DISASSEMBLY….4805
ASSEMBLY….4806
REAR FINAL DRIVE….4807
DISASSEMBLY….4807
ASSEMBLY….4809
REAR BRAKE….4811
REMOVAL….4811
INSTALLTION….4811
DISASSEMBLY….4812
ASSEMBLY….4813
PARKING BRAKE PAD….4815
REMOVAL….4815
INSTALLTION….4816
PARKING BRAKE CALIPER….4817
REMOVAL….4817
INSTALLTION….4817
DISASSEMBLY….4818
ASSEMBLY….4818
FRONT SUSPENSION CYLINDER….4819
REMOVAL….4819
INSTALLTION….4820
DISASSEMBLY….4823
ASSEMBLY….4824
VARIABLE DAMPING SELECTOR VALVE….4825
DISASSEMBLY….4825
ASSEMBLY….4826
REAR SUSPENSION CYLINDER….4827
REMOVAL….4827
INSTALLTION….4828
DISASSEMBLY….4829
ASSEMBLY….4830
AIR GOVERNOR….4833
REMOVAL….4833
INSTALLTION….4833
DISASSEMBLY….4834
ASSEMBLY….4834
BRAKE VALVE….4835
REMOVAL….4835
INSTALLTION….4835
DISASSEMBLY….4836
ASSEMBLY….4838
PARKING BRAKE CHAMBER….4840
REMOVAL….4840
INSTALLTION….4840
DISASSEMBLY….4841
ASSEMBLY….4842
FRONT BRAKE CHAMBER….4844
REMOVAL….4844
INSTALLTION….4844
REAR BRAKE CHAMBER….4847
REMOVAL….4847
INSTALLTION….4847
FRONT BRAKE CHAMBER….4848
DISASSEMBLY….4848
ASSEMBLY….4850
REAR BRAKE CHAMBER….4852
DISASSEMBLY….4852
ASSEMBLY….4854
SLACK ADJUSTER….4862
REMOVAL….4862
INSTALLTION….4862
DISASSEMBLY….4863
ASSEMBLY….4863
TRANSMISSION LUBRICATION,RETARDER BRAKE PUMP….4864
REMOVAL….4864
INSTALLTION….4864
BRAKE COOLING PUMP….4866
REMOVAL….4866
INSTALLTION….4866
HOIST,STEERING PUMP….4868
REMOVAL….4868
INSTALLTION….4868
FRONT DRIVE PUMP….4869
REMOVAL….4869
INSTALLTION….4870
DISASSEMBLY AND ASSEMBLY….4871
EMERGENCY STEERING MOTOR PUMP….4877
REMOVAL….4877
INSTALLTION….4877
TRAVEL MOTOR….4878
REMOVAL….4878
INSTALLTION….4879
DISASSEMBLY AND ASSEMBLY….4880
STEERING VALVE….4883
REMOVAL….4883
INSTALLTION….4883
DISASSEMBLY….4884
ASSEMBLY….4888
DEMAND VALVE….4894
REMOVAL….4894
INSTALLTION….4894
DISASSEMBLY….4895
ASSEMBLY….4895
RELIEF VALVE….4896
DISASSEMBLY….4896
ASSEMBLY….4896
HOIST VALVE….4897
REMOVAL….4897
INSTALLTION….4897
DISASSEMBLY….4898
ASSEMBLY….4899
STEERING CYLINDER….4900
REMOVAL….4900
INSTALLTION….4900
DISASSEMBLY….4901
ASSEMBLY….4903
HOIST CYLINDER….4905
REMOVAL….4905
INSTALLTION….4905
DISASSEMBLY….4906
ASSEMBLY….4908
BODY….4912
REMOVAL….4912
INSTALLTION….4913
TRANSMISSION CONTROLLER….4914
REMOVAL….4914
INSTALLTION….4914
SUSPENSION CONTROLLER….4914
REMOVAL….4914
INSTALLTION….4914
FRONT DRIVE CONTROLLER….4914
REMOVAL….4914
INSTALLTION….4914
40 MAINTENANCE STANDARD….4915
OUTPUT SHAFT….4916
TORQUE CONVERTER VALVE….4917
TORQUE CONVERTER….4918
TRANSMISSION….4920
ECMV(ELECTRONIC CONTROL MODULATION VALVE)….4924
FRONT AXLE ….4925
DIFFERENTIAL….4926
FINAL DRIVE….4930
FRONT BRAKE….4931
REAR BRAKE….4932
PARKING BRAKE….4933
REAR AXLE SUPPORT….4934
STEERING LINKAGE….4935
FRONT SUSPENSION CYLINDER….4937
REAR SUSPENSION CYLINDER….4938
PARKING BRAKE CHAMBER….4940
SLACK ADJUSTER….4941
HYDRAULIC PUMP….4942
DEMAND VALVE….4946
CROSS-OVER RELIEF VALVE….4946
HOIST VALVE….4947
STEERING CYLINDER….4948
HOIST CYLINDER….4949
SEBM015115 – Dump Truck HD325-6, HD405-6 Shop Manual….4950
COVER….4950
CONTENTS….4951
SAFETY….4958
FOREWARD….4960
GENERAL….4960
HOW TO READ THE SHOP MANUAL….4961
HOISTING INSTRUCTIONS….4962
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER….4963
COATING MATERIALS….4965
STANDARD TIGHTENING TORQUE….4967
ELECTRIC WIRE CODE….4970
CONVERSION TABLE….4971
UNITS….4977
01 GENERAL….4978
GENERAL ASSEMBLY DRAWING….4979
SPECIFICATIONS….4981
WEIGHT TABLE….4988
LIST OF LUBRICANT AND WATER….4991
10 STRUCTURE AND FUNCTION….4993
RADIATOR, TORQUE CONVERTER, OIL COOLER, AFTER COOLER….4995
POWER TRAIN SKELETON….4996
OUTPUT SHAFT….5000
DRIVE SHAFT….5001
TORQUE CONVERTER, TRANSMISSION AND BRAKE COOLING HYDRAULIC PIPING….5002
HYDRAULIC CIRCUIT DIAGRAM FOR TORQUE CONVERTER, TRANSMISSION AND BRAKE COOLING….5005
TORQUE CONVERTER, TRANSMISSION AND BRAKE COOLING HYRDAULIC CIRCUIT SCHEMATICS….5006
TORQUE CONVERTER….5007
TORQUE CONVERTER VALVE….5011
LOCKUP SOLENOID VALVE….5016
TRANSMISSION….5017
TRANSMISSION VALVE….5022
ECMV (ELECTRONIC CONTROL MODULATION VALVE)….5024
FRONT AXLE….5029
REAR AXLE….5033
DIFFERENTIAL….5034
FINAL DRIVE….5036
FRONT BRAKE….5037
REAR BRAKE….5038
PARKING BRAKE….5039
WHEELS….5040
REAR AXLE SUPPORT….5041
STEERING SYSTEM….5042
STEERING WHEEL….5043
STEERING LINKAGE….5044
SUSPENSION SYSTEM….5046
SUSPENSION CYLINDER….5048
AIR PIPING….5053
AIR CIRCUIT DIAGRAM….5055
AIR GOVERNOR….5057
AIR DRYER….5059
SAFETY VALVE….5062
CHECK VALVE….5062
DOUBLE CHECK VALVE….5063
HAND BRAKE VALVE….5064
BRAKE VALVE….5066
EMERGENCY BRAKE CONTROL VALVE….5069
PARKING BRAKE CONTROL VALVE….5072
RELAY VALVE….5074
PARKING BRAKE RELAY VALVE….5077
FRONT BRAKE CHAMBER….5079
REAR BRAKE CHAMBER….5080
PARKING BRAKE CHAMBER….5083
SLACK ADJUSTER….5084
FRONT DRIVE HYDRAULIC CIRCUIT DIAGRAM….5087
FRONT DRIVE PISTON PUMP….5090
FRONT DRIVE PISTON MOTOR….5092
CHARGE PUMP OIL FILTER….5094
HYDRAULIC PIPING….5096
HYDRAULIC CIRCUIT DIAGRAM….5099
HYDRAULIC CIRCUIT SCHEMATICS….5100
DUMP BODY CONTROL….5101
HYDRAULIC TANK, FILTER….5104
DEMAND VALVE….5107
STEERING CONTROL VALVE….5111
CROSS-OVER RELIEF VALVE….5115
HOIST VALVE….5116
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB….5117
DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB….5118
FRONT BRAKE CUT-OFF VALVE….5119
OVERRUN PREVENTION VALVE ….5120
EXHAUST BRAKE VALVE….5120
HORN VALVE….5121
WIPER SWITCH….5121
WIPER RELAY….5122
AIR CONDITIONER….5123
PIPING DIAGRAM….5123
ELECTRICAL CIRCUIT DIAGRAM….5125
REFRIGERANT CIRCUIT DIAGRAM….5127
UNIT….5128
RECEIVER DRYER….5128
CONDENSER….5129
COMPRESSOR….5129
ENGINE CONTROL SYSTEM….5130
EXHAUST BRAKE….5133
SYSTEM DIAGRAM….5133
AUTOMATIC RETARD SPEED CONTROL SYSTEM (OP)….5136
SYSTEM DRAWING….5136
STRUCTURE OF SYSTEM….5137
ELECTRICAL CIRCUIT DIAGRAM….5138
AIR CIRCUIT DIAGRAM….5139
AUTOMATIC RETARD SPEED CONTROL….5140
AUTOMATIC RETARD SPEED CONTROLLER….5141
AUTOMATIC SHIFT CONTROL SYSTEM….5142
SYSTEM DIAGRAM….5142
ELECTRICAL CIRCUIT DIAGRAM….5144
TRANSMISSION CONTROLLER….5145
CONNECTOR SIGNALS….5147
SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES….5148
AUTOMATIC GEAR SHIFT LINE GRAPH….5149
SHIFT LEVER SWITCH….5151
SENSORS, SWITCHES….5152
ENGINE SPEED SENSOR….5152
TRANSMISSION SPEED SENSOR….5152
TRANSMISSION OIL TEMPERATURE SENSORS….5152
FILL SWITCH….5153
ACCELERATOR SENSOR….5153
MODE SELECTOR SWITCH….5154
SELF-DIAGNOSTIC FUNCTION….5154
AUTOMATIC EMERGENCY STEERING SYTEM….5155
SYSTEM DIAGRAM….5155
ELECTRICAL CIRCUIT DIAGRAM….5156
FLOW SWITCH….5157
RELAY TIMER….5159
AUTOMATIC SUSPENSION SYSTEM….5160
STRUCTURE OF SYSTEM….5161
SYSTEM CIRCUIT DIAGRAM….5162
AUTOMATIC SUSPENSION MODE SELECTION CONTROL….5163
SUSPENSION CONTROLLER….5164
SENSORS, SWITCHES….5165
STEERING ANGLE SENSOR….5165
PRESSURE SENSOR….5165
SELF-DIAGNOSTIC FUNCTION….5166
PAYLOAD METER (PRINTER TYPE)….5167
STRUCTURE OF SYSTEM….5167
ELECTRICAL CIRCUIT DIAGRAM….5168
PRINCIPLE OF CALCULATION….5169
FEATURES OF EQUIPMENT….5171
1. PAYLOAD METER….5171
2. PRESSURE SENSOR….5174
3. CLINOMETER….5175
4. LAMP DRIVE RELAY….5175
SELF-DIAGNOSTIC FUNCTION….5176
PAYLOAD METER II (CARD TYPE)….5177
STRUCTURE OF SYSTEM….5177
ELECTRICAL CIRCUIT DIAGRAM….5178
PAYLOAD METER BLOCK DIAGRAM….5178
PRINCIPLE OF MEASUREMENT….5179
FEATURES OF EACH DEVICE….5180
1. PAYLOAD METER II….5180
LEFT FACE….5181
2. PRESSURE SENSOR….5208
3. CLINOMETER….5209
4. LAMP DRIVE RELAY….5209
5. SELF-DIAGNOSTIC FUNCTION….5211
MACHINE MONITOR SYSTEM….5217
SYSTEM DRAWING….5217
MONITOR PANEL DIAGRAM….5219
MACHINE MONITOR NORMAL DISPLAY FUNCTIONS….5220
SELF-DIAGNOSTIC FUNCTION WHEN STARTING SWITCH IS OPERATED….5227
TRAVEL SPEED COMPENSATION ROTARY SWITCH….5227
ENGINE OIL PRESSURE….5228
ENGINE WATER TEMPERATURE SENSOR….5229
RETARDER OIL TEMPERATURE SENSOR….5229
TORQUE CONVERTER OIL TEMPERATURE SENSOR….5229
AIR PRESSURE SENSOR….5229
FUEL LEVEL SENSOR….5230
TILT SWITCH….5231
TRANSMISSION OIL FILTER SENSOR….5232
RADIATOR WATER LEVEL SENSOR….5232
BODY SEATED SWITCH….5233
STEERING OIL TEMPERATURE SENSOR….5234
BRAKE STROKE SENSOR….5234
OIL FILTER CAUTION SYSTEM (IF EQUIPPED)….5235
SYSTEM DIAGRAM….5235
MONITOR PANEL….5236
CIRCUIT DIAGRAM OF OIL FILTER CAUTION MONITOR….5237
ITEMS DISPLAYED BY MONITOR AND FUNCTIONS….5238
FUNCTIONS OF SWITCHES….5240
HYDRAULIC OIL FILTER SENSOR….5242
FRONT DRIVE SYSTEM….5244
SYSTEM DIAGRAM….5244
4-WHEEL DRIVE CONTROLLER….5247
ECMV….5248
SENSORS, SWITCHES….5249
STEERING ANGLE SENSOR (POTENTIOMETER)….5249
HIGH-PRESSURE OIL PRESSURE SENSOR….5252
CLUTCH OIL PRESSURE SENSOR….5253
WHEEL SPEED SENSOR….5254
20 TESTING AND ADJUSTING….5256
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS….5259
STANDARD VALUE TABLE FOR CHASSIS….5261
STANDARD VALUE TABLE FOR ELECTRICAL PARTS….5266
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING….5284
ADJUSTING VALVE CLEARANCE….5288
MEASURING COMPRESSION PRESSURE….5291
MEASURING BLOW-BY….5292
ADJUSTING ALTERNATOR BELT TENSION….5293
ADJUSTING FAN BELT TENSION….5294
MEASURING ENGINE SPEED….5296
MEASURING ENGINE OIL PRESSURE….5297
MEASURING BOOST PRESSURE….5298
MEASURING EXHAUST TEMPERATURE….5299
MEASURING EXHAUST GAS COLOR….5300
TESTING AND ADJUSTING FUEL INJECTION TIMING….5301
AIR BLEEDING FROM FUEL SYSTEM….5305
CHECKING FOR LEAKAGE IN FUEL SYSTEM….5308
MEASURING FUEL PRESSURE….5309
REALEASING REMAINING PRESSURE IN FUEL SYSTEM….5309
HANDLING EQUIPMENT IN FUEL CIRCUIT….5310
REDUCED CYLINDER MODE OPERATION….5311
HANDLING OF ENGINE CONTROLLER HIGH CONTROLLER HIGH TENSION CIRCUIT….5312
ADJUSTING ENGINE STOP MOTOR CABLE….5314
ADJUSTING ACCELERATOR PEDAL….5315
ADJUSTING ENGINE SPEED SENSOR….5316
ADJUSTING TRANSMISSION SPEED SENSOR….5316
TESTING HYDRAULIC PRESSURE OF TORQUE CONVERTER VALVE….5317
TESTING ECMV OIL PRESSURE….5318
TESTING TORQUE CONVERTER STALL SPEED….5320
TESTING BRAKE PRESSURE….5321
BLEEDING AIR FROM BRAKE CIRCUIT….5322
TESTING AND ADJUSTING PARKING BRAKE PERFORMANCE….5323
TESTING WEAR OF FRONT BRAKE PAD….5324
TESTING WEAR OF FRONT BRAKE DISC….5324
TESTING WEAR OF REAR BRAKE DISC….5325
TESTING REAR BRAKE CAUTION SYSTEM….5326
TESTING AND ADJUSTING SUSPENSION CYLINDER….5328
TESTING AND ADJUSTING SET PRESSURE OF AIR GOVERNOR….5334
ADJUSTING HOIST LEVER LINKAGE….5335
ADJUSTING BODY POSITIONER….5338
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING, HOIST CIRCUIT….5339
AIR BLEEDING FROM STEERING CYLINDER….5341
BLEEDING AIR FROM FRONT DRIVE HYDAULIC CIRCUIT….5342
ADJUSTING ELECTRONIC MONITOR ….5344
SETTING ROTARY SWITCH….5345
METHOD OF DELETING DATA FROM TRANSMISSION CONTROLLER MEMORY….5346
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM….5349
PM CLINIC CHECK SHEET….5356
TROUBLESHOOTING….5360
POINTS TO REMEMBER WHEN TROUBLESHOOTING….5361
SEQUENCE OF EVENTS IN TROUBLESHOOTING….5362
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE….5363
CHECKS BEFORE TROUBLESHOOTING….5371
TYPE OF CONNECTOR AND POSITION OF INSTALLATION….5373
(HD325-6 SERIAL NO. 5680-6000, HD325-6W SERIAL NO. 5706-6000,HD405-6 SERIAL NO. 1055-2000)….5373
CONNECTOR PIN ALLOCATION CHART….5379
(HD325-6 SERIAL NO. 5680-6000, HD325-6W SERIAL NO. 5706-6000,HD405-6 SERIAL NO. 1055-2000)….5379
TYPE OF CONNECTOR AND POSITION OF INSTALLATION….5386
(HD325-6 SERIAL NO. 6001 AND UP, HD325-6W SERIAL NO. 6001 AND UP,HD405-6 SERIAL NO. 2001 AND UP)….5386
CONNECTOR PIN ALLOCATION CHART….5393
(HD325-6 SERIAL NO. 6001 AND UP, HD325-6W SERIAL NO. 6001 AND UP,HD405-6 SERIAL NO. 2001 AND UP)….5393
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS….5399
EXPLANATIONS OF FUNCTIONS (CONTROL MECHANISM)OF ELECTRICAL SYSTEM….5421
MONITOR PANEL USER CODES AND SERVICE MODE FUNCTION….5427
SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL AND CONTROLLERS….5447
TABLE OF SERVICE CODES AND USER CODES….5454
METHOD OF USING JUDGEMENT TABLES….5466
METHOD OF USING TROUBLESHOOTING CHARTS….5467
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)….5470
METHOD OF USING TROUBLESHOOTING CHARTS….5471
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)….5475
S-2 ENGINE DOES NOT START….5477
(1) ENGINE DOES NOT TURN….5477
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)….5478
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)….5479
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)….5480
S-4 ENGINE STOPS DURING OPERATIONS….5481
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)….5482
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)….5483
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)….5484
S-8 OIL CONSUMPTION IS EXCESSIV (OR EXHAUST SMOKE IS BLUE)….5485
S-9 OIL BECOMES CONTAMINATED QUICKLY….5486
S-10 FUEL CONSUMPTION IS EXCESSIVE….5487
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN….5488
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)….5489
S-13 OIL LEVEL RISES….5490
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)….5491
S-15 ABNORMAL NOISE IS MADE….5492
S-16 VIBRATION IS EXCESSIVE….5493
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A MODE)….5494
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM….5497
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE….5499
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS….5519
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM….5521
ABNORMALITY IN POWER SOURCE….5522
A-1 ….5522
A) [OFF] CONTROLLER SELF-DIAGNOSTIC DISPLAY LED DOES NOT LIGHT UP….5522
B) DROP IN VOLTAGE OF CONTROLLER POWER SOURCE IS DISPLAYED….5523
C) DROP IN VOLTAGE OF BATTERY DIRECT POWER SOURCE IS DISPLAYED….5524
D) DROP IN VOLTAGE OF MAIN POWER SOURCE IS DISPLAYED….5525
E) ABNORMALITY IN TRANSMISSION CUT RELAY POWER SOURCE IS DISPLAYED….5526
A-2 A) ABNORMALITY IN NEUTRAL SAFETY SYSTEM IS DISPLAYED….5527
ABNORMALITY IN CONTROLLER SYSTEM….5528
A-3 DOUBLE ENGAGEMENT FOR CLUTCH IS DISPLAYED….5528
A-4 ABNORMALITY IN TRANSMISSION [CUT RELAY] SYSTEM IS DISPLAYED….5529
A-5 ABNORMALITY IN REAR BRAKE SOLENOID SYSTEM IS DISPLAYED….5530
A-6 ABNORMALTIY IN EXHAUST BRAKE SOLENOID SYSTEM IS DISPLAYED….5531
ABNORMALITY IN SPEED SENSOR SYSTEM….5532
A-7 ….5532
A) DISCONNECTION IN ENGINE SPEED SENSOR [B]SYSTEM IS DISPLAYED OR FAILURE IN ENGINE SPEED SENSOR IS DISPLAYED….5532
B) DISCONNECTION IN INPUT SHAFT SPEED SENSOR SYSTEM IS DISPLAYED OR FAILURE OF INPUT SHAFT SPEED SENSOR IS DISPLAYED….5533
C) DISCONNECTION IN INTERMEDIATE SHAFT-SPEED SENSOR SYSTEM IS DISPLAYED OR FAILURE OF INTERMEDIATE SHAFT SPEED SENSOR IS DISP….5534
D) DISCONNECTION IN TRAVEL SPEED SENSOR (TRANSMISSION OUTPUT SHAFT SPEED SENSOR) SYSTEM IS DISPLAYED OR FAILURE OF OUTPUT SHA….5535
SPEED SENSOR SYSTEM, CLUTCH SLIPPING….5536
A-8….5536
A) INPUT SHAFT SPEED SENSOR OR H, L CLUTCH SYSTEM IS DISPLAYED….5536
B) TRAVEL SPEED SENSOR SYSTEM OR SPEED CLUTCH (1,2,3,4,R) SYSTEM IS DISPLAYED….5537
ABNORMALITY IN MODEL SELECTION SYSTEM….5538
A-9….5538
A) ABNORMALITY IN MODEL SELECTION (WIRING HARNESS) IS DISPLAYED….5538
B) ABNORMALITY IN MODEL SELECTION (ROTARY SWITCH) IS DISPLAYED….5539
ABNORMALITY IN SHIFT LEVER SYSTEM….5540
A-10 ….5540
A) SHORT CIRCUIT IN SHIFT LEVER ASSEMBLY POWER SOURCE IS DISPLAYED….5540
B) SHIFT LEVER POSITION SIGNAL INPUT FOR 2 OR MORE SYSTEMS IS DISPLAYED….5541
C) SHIFT LEVER POSITION IN NOT INPUT….5543
A-11 ABNORMALITY IN ACCELERATOR SIGNAL IS DISPLAYED….5545
A-12 ABNORMALITY IN TRANSMISSION OIL TEMPERATURE SENSOR IS DISPLAYED….5546
ABNORMALITY IN PRESSURE CONTROL VALVEDE418-1098….5547
A-13 ….5547
A) FILL SIGNAL (CLUTCH ON) IS DISPLAYED REGARDLESS OF COMMAND….5547
B) FILL SIGNAL IS NOT INPUT AND CLUTCH SLIPPING IS DISPLAYED….5549
B-1) INSPECTING FILL SIGNAL SYSTEM….5549
B-2) INSPECTING TRANMISSION INPUT SHAFT SPEED SIGNAL SYSTEM, H, L CLUTCH SYSTEM (INSPECTING CLUTCH SLIPPAGE)….5550
B-3) INSPECTING TRANSMISSION OUTPUT SHAFT SPEED SIGNAL SYSTEM, 1-4, R CLUTCH SYSTEM (INSPECTING CLUTCH SLIPPAGE)….5550
A-14 WHEN FILL SIGNAL IS NOT INPUT (FLOW DETECTOR VALVE SYSTEM)….5551
A-15 SHORT CIRCUIT IN PRESSURE CONTROL VALVE SOLENOID SYSTEM IS DISPLAYED….5552
DISCONNECTION IN PRESSURE CONTROL VLAVE SOLENOID SYSTEM IS DISPLAYED….5552
ABNORMALITY IN SENSOR SYSTEM….5554
A-16 ….5554
A) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM IS DISPLAYED….5554
B) ABNORMALITY IN FUEL LEVEL SENSOR SYSTEM IS DISPLAYED….5555
C) ABNORMALITY IN COOLING WATER TEMPERATURE SENSOR SYTEM IS DISPLAYED….5556
D) ABNORMALITY IN AIR PRESSURE SENSOR SYSTEM IS DISPLAYED….5557
E) ABNORMALITIY IN RETARD BRAKE OIL TEMPERATURE SENSOR SYSTEM IS DISPLAYED….5558
WARNING DISPLAY….5559
A-17….5559
A) TRANSMISSION FILTER CLOGGED WARNING IS DISPLAYED….5559
B) TILT WARNING IS DISPLAYED….5560
C) DROP IN RADIATOR WATER LEVEL WARNING IS DISPLAYED….5561
D) BATTERY CHARGE LEVEL WARNING IS DISPLAYED….5562
E) STEERING OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED….5563
F) DROP IN ENGINE OIL PRESSURE WARNING IS DISPLAYED….5564
G) REAR BRAKE OIL PRESSURE WARNING IS DISPLAYED….5565
A-18 ABNORMALITY IN ENGINE OIL PRESSURE SENSOR SYSTEM IS DISPLAYED….5566
A-19 ABNORMALITY IN CONNECTOR CONNECTION IS DISPLAYED….5567
A-20 ….5568
A) TORQUE CONVERTER OIL TEMPERATUER OVERHEAT WARNING IS DISPLAYED….5568
B) ENGINE WATER TEMPERATURE OVERHEAT WARNING IS DISPLAYED….5568
C) AIR PRESSURE DROP WARNING IS DISPLAYED….5568
D) RETARDER BRAKE OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED….5568
E) ENGINE OVERRUN ACUTATED IS DISPLAYED….5569
F) ENGINE OVERSHOOTI ACTUATED IS DISPLAYED….5569
TROUBLESHOOTING OF SUSPENSION CONTROLLER SYSTEM (SP MODE)….5570
JUDGEMENT TABLE FOR SUSPENSION CONTROLLER, SUSPENSION RELATED PARTS….5571
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE….5573
ELECTRICAL CIRCUIT DIAGRAM OF SUSPENSION CONTROLLER SYSTEM….5577
SP-1 ABNORMALITY IN POWER SOURCE IS DISPLAYED….5581
SP-2 ABNORMALITY IN PRESSURE SENSOR [RIGHT] SYSTEM IS DISPLAYED….5582
SP-3 ABNORMALITY IN PRESSURE SENSOR [LEFT] SYSTEM IS DISPLAYED….5584
SP-4 ABNORMALITY IN TRAVEL SPEED SENSOR SYSTEM IS DISPLAYED….5586
SP-5 ABNORMALITY IN STEERING SENSOR SYSTEM IS DISPLAYED….5587
SP-6 DEFECTIVE MODEL SELECTION DATA IS DISPLAYED….5588
SP-7 ABNORMALITY IN SOLENOID [1] SYSTEM IS DISPLAYED….5589
SP-8 ABNORMALITY IN SOLENOID [2] SYSTEM IS DISPLAYED….5590
SP-9 ABNORMALITY IN SOLENOID….5591
SP-10 DISCONNECTION IN NETWORK IS DISPLAYED….5592
SP-11 DEFECTIVE TRAVEL SPEED COMPENSATION DATA IS DISPLAYED….5593
TROUBLESHOOTING OF PAYLOAD METER (PRINTER TYPE) SYSTEM (LP MODE)….5594
(HD325-6 SERIAL NO. 5680-6000, HD325-6W SERIAL NO. 5706-6000, HD405-6 SERIAL NO. 1055-2000)….5594
SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER (PRINTER TYPE)….5595
ELECTRICAL CIRCUIT DIAGRAM FOR PAYLOAD METER (PRINTER TYPE) SYSTEM….5597
LP-1 NO DISPLAY APPEARS WHEN STARTING SWITCH IS TURNED ON ….5599
LP-2 CALIBRATION DEMAND (CAL FLASHES) IS SHOWN CONTINUOUSLY AFTER STARTING SWITCH IS TURNED ON….5600
LP-3 CALIBRATION CANNOT BE CARRIED OUT….5601
LP-4 AFTER STARTING SWITCH IS TURNED ON, ALL EXTERNAL DISPLAY LAMPS DO NOT LIGHT UP….5604
LP-5 CONDITION DOES NOT EXIST FOR LAMPS TO LIGHT UP, BUT EXTERNAL DISPLAY LAMPS LIGHT UP….5606
LP-6 LEVEL OF LIGHTING UP OF EXTERNAL DISPLAY LAMPS IS NOT CORRECT….5607
LP-7 ABNORMALITY IN DISPLAY LOGIC….5609
LP-8 E01-E04 IS DISPLAYED….5614
LP-9 E11-E14 IS DISPLAYED….5615
LP-10 E21-E28 IS DISPLAYED BY SENSOR CHECK….5616
LP-11 E31 IS DISPLAYED….5617
LP-12 E32 IS DISPLAYED….5619
LP-13 E41 IS DISPLAYED….5621
LP-14 E42 IS DISPLAYED….5622
LP-15 PRINTER DOES NOT PRINT ANYTHING (BLANK PAPER COMES OUT)….5623
LP-16 PRINTER PRINTS ONLY "NO DATA"….5623
LP-17 PRINTER DOES NOT PRINT OUT WHE PRT SWITCH IS PRESSED….5623
LP-18 "PAPE" FLASHES….5624
LP-19 TIME IS WRONG….5624
LP-20 E33 IS DISPLAYED….5624
TROUBLESHOOTING OF PAYLOAD METER (PRINTER TYPE) SYSTEM (LP MODE)….5626
(HD325-6 SERIAL NO. 6001 AND UP, HD325-6W SERIAL NO. 6001 AND UP, HD405-6 SERIAL NO. 2001 AND UP)….5626
SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER (PRINTER TYPE)….5627
ELECTRICAL CIRCUIT DIAGRAM FOR PAYLOAD METER (PRINTER TYPE) SYSTEM….5629
LP-1 NO DISPLAY APPEARS WHEN STARTING SWITCH IS TURNED ON ….5631
LP-2 CALIBRATION DEMAND (CAL FLASHES) IS SHOWN CONTINUOUSLY AFTER STARTING SWITCH IS TURNED ON….5632
LP-3 CALIBRATION CANNOT BE CARRIED OUT….5633
LP-4 AFTER STARTING SWITCH IS TURNED ON, ALL EXTERNAL DISPLAY LAMPS DO NOT LIGHT UP….5636
LP-5 CONDITION DOES NOT EXIST FOR LAMPS TO LIGHT UP, BUT EXTERNAL DISPLAY LAMPS LIGHT UP….5638
LP-6 LEVEL OF LIGHTING UP OF EXTERNAL DISPLAY LAMPS IS NOT CORRECT….5639
LP-7 ABNORMALITY IN DISPLAY LOGIC….5641
A) EVEN WHEN DUMP BODY IS OPERATED, DISPLAY DOES NOT SHOW 0 TON….5641
B) DISPLAY STAYS AT 0 TON AND DOES NOT CHANGE….5642
C) WHEN TRANSMISSION IS AT N, WEIGHT DISPLAY IS NOT GIVEN (STAYS AT TIME DISPLAY)….5643
D) WHEN TRANSMISSION LEVER IS AT POSITION OTHER THAN N, DISPLAY DOES NOT CHANGE TIME DISPLAY….5645
LP-8 E01-E04 IS DISPLAYED….5646
LP-9 E11-E14 IS DISPLAYED….5647
LP-10 E21-E28 IS DISPLAYED BY SENSOR CHECK….5648
LP-11 E31 IS DISPLAYED….5649
LP-12 E32 IS DISPLAYED….5651
LP-13 E41 IS DISPLAYED….5653
LP-14 E42 IS DISPLAYED….5654
LP-15 PRINTER DOES NOT PRINT ANYTHING (BLANK PAPER COMES OUT)….5655
LP-16 PRINTER PRINTS ONLY "NO DATA"….5655
LP-17 PRINTER DOES NOT PRINT OUT WHE PRT SWITCH IS PRESSED….5655
LP-18 "PAPE" FLASHES….5656
LP-19 TIME IS WRONG….5656
LP-20 E33 IS DISPLAYED….5656
TROUBLESHOOTING OF PAYLOAD METER II (CARD TYPE) SYSTEM (LC MODE)….5658
SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER II (CARD TYPE)….5659
ELECTRICAL CIRCUIT DIAGRAM FOR PAYLOAD METER II (CARD TYPE) SYSTEM….5663
LC-1 NO DISPLAY APPEARS WHEN STARTING SWITCH IS TURNED ON….5667
LC-2 AFTER STARTING SWITCH IS TURNED ON, ALL EXTERNAL DISPLAY LAMPS DO NOT LIGHT UP….5669
LC-3 CONDITION DOES NOT EXIST FOR LAMPS TO LIGHT UP, BUT EXTERNAL DISPLAY LAMPS LIGHT UP….5671
LC-4 LEVEL OF LIGHTING UP OF EXTERNAL DISPLAY LAMPS IS NOT CORRECT….5674
LC-5 CYCLE DATA IS NOT RECORDED, ON/OFF DATA IS NOT RECORDED: BATTERY CHARGE SIGNAL SYSTEM: ENGINE NOT STARTED IS DETECTED….5678
LC-6 CALIBRATION CANNOT BE CARRIED OUT, TIME DISPLAY DOES NOT MATCH CONDITIONS: SHIFT LEVER N POSITION SIGNAL SYSTEM….5679
LC-7 ABNORMAITY IN DISPLAY LOGIC….5682
LC-8 B-FL REMAINS DISPLAYED AND DOES NOT CHANGE: BODY FLOAT RELAY SYSTEMS: WHEN NOT DUMPING AND WHEN DUMP LEVER IS NOT AT ….5684
LC-9 F-09 IS DISPLAYED: DROP IN VOLTAGE OF BACK-UP BATTERY BUILT INTO PAYLOAD METER….5685
LC-10 FULL DISPLAY APPEARS….5685
LC-11 F-20 IS DISPLAYED: SENSOR POWER SOURCE VOLTAGE SYSTEM ….5686
LC-12 F-21-F-24 IS DISPLAYED: DISCONNECTION, SHORT CIRCUIT WITH GROUND IN SUSPENSION PRESSURE SENSOR SYSTEM….5689
LC-13 F-25-F-28 IS DISPLAYED: SHORT CIRCUIT IN SUSPENSION PRESSURE SENSOR SYSTEM POWER SOURCE….5691
LC-14 ECAL IS DISPLAYED: CALIBRATION NOT CARRIED OUT, DAMAGED DATA INSIDE PAYLOAD METER….5693
LC-15 F-41 – F-45 IS DISPLAYED: SHORT CIRCUIT IN EXTERNAL DISPLAY LAMP SYSTEM POWER SOURCE….5693
LC-16 L-BAD IS DISPLAYED: CYCLE DATA SAVED WHEN MACHINE WAS SWAYING….5697
LC-17 MACHINE IS NOT LOADING BUT EXTERNAL DISPLAY LAMPS GIVE LOAD ESTIMATE DISPLAY. AFTER LOADING, DISPLAY SWITCHES TO TIME….5699
LC-18 F-31 IS DISPLAYED: DISCONNECTION, SHORT CIRCUIT WITH GROUND IN CLINOMETER SYSTEM….5699
LC-19 F-32 IS DISPLAYED: SHORT CIRCUIT WITH CLINOMETER SYSTEM POWER SOURCE….5702
LC-20 F-18 IS DISPLAYED: DISCONNECTION IN BATTERY CHARGE SIGNAL….5705
TROUBLESHOOTING OF ARSC (AUTOMATIC RETARDER SPEED CONTROLLER) SYSTEM (R MODE)….5706
OUTLINE….5707
ELECTRICAL CIRCUIT DIAGRAM FOR ARSC (AUTOMATIC RETARDER SPEED CONTROLLER) SYSTEM….5711
R-1 0.1 (ABNORMALITY IN POWER SOURCE VOLTAGE) IS DISPLAYED….5713
R-2 1.0 (DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED….5714
R-3 1.3 (DISCONNECTION IN TRANSMISSION OUTPUT SHAFT SPEED SENSOR SYSTEM) IS DISPLAYED….5715
R-4 1.5 (FAILURE IN RETARDER OIL TEMPERATURE SENSOR SYSTEM) IS DISPLAYED….5716
R-5 1.7 (FAILURE IN ACCELERATOR SIGNAL SYSTEM) IS DISPLAYED….5717
R-6 1.8 (FAILURE IN SUSPENSION PRESSURE SENSOR "LEFT" SYSTEM) IS DISPLAYED….5718
R-7 1.9 (FAILURE IN SUSPENSION PRESSURE SENSOR "RIGHT" SYSTEM) IS DISPLAYED….5719
R-8 4.2 (DISCONNECTION IN EXHAUST BRAKE SELECTOR SIGNAL SYSTEM) IS DISPLAYED….5720
R-9 4.3 (DISCONNECTION IN ARSC CAUTION LAMP SYSTEM) IS DISPLAYED….5721
R-10 4.4 (DISCONNECTION IN READY LAMP SYSTEM) IS DISPLAYED….5722
R-11 4.5 (DISCONNECTION IN PANEL CAUTION AND BUZZER SYSTEM) IS DISPLAYED….5723
R-12 5.2 (SHORT CIRCUIT WITH GROUND IN EXHAUST BRAKE SELECTOR SIGNAL OUTPUT SYSTEM) IS DISPLAYED….5724
R-13 5.3 (SHORT CIRCUIT WITH GROUND IN ARSC CAUTION LAMP SYSTEM) IS DISPLAYED….5725
R-14 5.4 (SHORT CIRCUIT WITH GROUND IN READY OUTPUT CIRCUIT SYSTEM) IS DISPLAYED….5726
R-15 5.5 (SHORT CIRCUIT WITH GROUND IN PANEL CAUTION LAMP AND BUZZER OUTPUT SYSTEM) IS DISPLAYED….5727
R-16 6.0 (FAILURE IN ENGINE SPEED SYSTEM) IS DISPLAYED….5728
R-17 7.0 (DISCONNECTION IN TRAVEL SPEED DISPLAY UP OUTPUT SYSTEM) IS DISPLAYED….5729
R-18 7.1 (DISCONNECTION IN TRAVEL SPEED DISPLAY DOWN OUTPUT SYSTEM) IS DISPLAYED….5730
R-19 7.2 (DISCONNECTION IN TRAVEL SPEED DISPLAY CLEAR OUTPUT SYSTEM) IS DISPLAYED….5731
R-20 7.3 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY UP OUTPUT SYSTEM) IS DISPLAYED….5732
R-21 7.4 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY DOWN OUTPUT SYSTEM) IS DISPLAYED….5733
R-22 7.5 (SHORT CIRCUIT WITH GROUD IN TRAVEL SPEED DISPLAY CLEAR OUTPUT SYSTEM) IS DISPLAYED….5734
R-23 8.1 (SHORT CIRCUIT WITH GROUND IN PRESSURE CONTROL VALVE SYSTEM) IS DISPLAYED….5735
R-24 8.3 (DISCONNECTION IN PRESSURE CONTROL VALVE SYSTEM) IS DISPLAYED….5736
R-25 8.5 (FAILURE IN PRESSURE CONTROL VALVE (PRESSURE CONTROL VALVE REMAINS OPEN) IS DISPLAYED….5737
R-26 8.7 (FAILURE IN PRESSURE CONTROL VALVE (PRESSURE CONTROL VALVE DOES NOT OPEN) IS DISPLAYED….5738
R-27 8.9 (SHORT CIRCUIT WITH GROUND IN PRESSURE SWITCH VALVE SYSTEM) IS DISPLAYED….5739
R-28 9.0 (DISCONNECTION IN PRESSURE SWITCH VALVE SYSTEM) IS DISPLAYED….5740
R-29 9.1 (FAILURE IN PRESSURE SWITCH VALVE SYSTEM (REMAINS OPEN)) IS DISPLAYED….5741
R-30 9.2 (FAILURE IN PRESSURE SWITCH VALVE SYSTEM (DOES NOT OPEN)) IS DISPLAYED….5742
R-31 9.3 (DISCONNECTION IN SYSTEM SWITCH SYSTEM) IS DISPLAYED….5743
R-32 9.4 (SHORT CIRCUIT WITH GROUND IN SYSTEM SWITCH SYSTEM) IS DISPLAYED….5744
R-33 9.5 (DISCONNECTION, SHORT CIRCUIT WTH GROUND IN TRAVEL SPEED SETTING SWITCH SYSTEM) IS DISPLAYED….5745
R-101 SET SPEED CANNOT BE SET….5746
R-102 FAILURE CODE IS ALWAYS CLEARED (CONTROLLER DISPLAY WINDOW ALWAYS SHOWS '–") OR FAILURE CODE CANNOT BE CLEARED….5749
R-103 EFFECT OF RETARDER IS TOO STRONG WHEN MACHINE IS EMPTY, OR TOO WEAK WHEN MACHINE IS LOADED (DOES NOT JUDGE LOADED/UNLOA….5750
R-104 ABNORMALITY APPEARS IN OTHER CONTROLLER….5750
R-105 WHEN TRAVELING DOWNHILL, EVEN WHEN SET SPEED IS EXCEEDED, NO CONTROL IS CARRIED OUT….5751
R-106 MONITOR LAMP (BUZZER) STAY ON (OR OFF)….5752
R-107 READY LAMP DOES NOT LIGHT UP (OR STAY LIT UP)….5753
R-108 EXHAUST BRAKE DOES NOT WORK PROPERLY ….5755
[EXHAUST BRAKE IS ACTUATED WHEN EXHAUST BRAKE SWITCH IS OFF; OR EXHAUST BRAKE IS NOT ACTUATED WHEN EXHAUST BRAKE SWITCH IS ON….5755
R-109 THERE IS DIFFERENCE BETWEEN TRAVEL SPEED ROD VALUE AND ACTUAL MACHINE VALUE….5757
R-110 RETARDER LAMP DOES NOT LIGHT UP, OR STAY LIT UP….5759
R-111 TRAVEL SPEED DISPLAY ALWAYS GIVES DISPLAY (OR DOES NOT GIVE ANY DISPLAY)….5760
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)….5762
H-1 MACHINE DOES NOT START….5763
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE JERKS)….5765
H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED (ENGINE STALLS)….5765
H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING….5766
H-5 TRANSMISSION DOES NOT SHIFT UP….5766
H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING….5767
H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR….5771
H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH….5773
H-9 TORQUE CONVERTER OIL PRESSURE IS LOW….5774
H-10 FRONT BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE….5775
H-11 REAR BRAKE IS INEFFECTIVE, OR EFFECTIVE ON ONE SIDE….5778
H-12 STEERING WHEEL IS HEAVY….5779
H-13 STEERING WHEEL DOES NOT WORK….5780
H-14 STEERING WHEEL VIBRATES….5780
H-15 HOIST CYLINDER LACKS LIFTING FORCE (LIFTING SPEED)….5781
H-16 HOIST CYLINDER DOES NOT WORK….5782
H-17 EXCESSIVE HYRDRAULIC DRIFT OF DUMP BODY….5783
H-18 AIR PRESSURE DOES NOT RISE ….5784
TROUBLESHOOTING OF MONITOR PANEL SYSTEM (P MODE)….5786
METHOD OF SELF-DIAGNOSTIC DISPLAY FOR MONITOR PANEL AND CONTROLLERS….5788
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE (MONITOR PANEL SYSTEM)….5789
ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR PANEL SYSTEM….5793
P-1 CHECK PATTERN FOR WIRING HARNESSES BETWEEN MODULES….5795
P-2 NOTHING ON MONITOR PANEL WORKS….5799
P-3 LH, RH MODULE AND FUEL GAUGE DO NOT WORK….5800
P-4 LH, RH MODULE AND FUEL GAUGE DO NOT WORK….5801
P-5 RH MODULE DOES NOT WORK….5802
P-6 LH MODULE DOES NOT WORK….5803
P-7 TRAVEL CALCULATOR DOES NOT WORK….5804
P-8 SERVICE METER DISPLAY DOES NOT WORK CORRECTLY….5805
P-9 CENTRAL WARNING LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS FAILURE CODE (MONITOR PANEL DISPLAY)[A002]….5806
P-10 CENTRAL WARNING LAMP STAYS LIT UP….5807
P-11 ALARM BUZZER DOES NOT WORK, OR MONITOR PANEL DETECTS FAILURE CODE [A003]….5808
P-12 ALARM BUZZER CONTINUES TO SOUND….5809
P-13 ALL DATA FROM SHIFT CONTROLLER (SPPEDOMETER, TACHOMETER, SHIFT INDICATOR, ETC.) ARE ABNORMAL (NOTHING IS DISPLAYED, OR D….5810
P-14 SUSPENSION MODE, POWER/ECONOMY MODE DISPLAYS ARE ABNORMAL (NOTHIND IS DISPLAYED, OR DISPLAY DOES NOT CHANGE), OR MONITOR….5811
P-15 GAUGE DISPLAYS ARE ABNORMAL (NOTHING IS DISPLAYED, OR DISPLAY DOES NOT CHANGE)….5812
P-16 COOLING WATER LEVEL DROP CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]….5813
P-17 COOLING WATER LEVEL DROP CAUTION LAMP STAY LIT UP….5814
P-18 EMERGENCY STEERING PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]….5815
P-19 EMERGENCY STEERING PILOT LAMP STAYS LIT UP….5816
P-20 ENGINE OIL PRESSURE DROP CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]….5817
P-21 ENGINE OIL PRESSURE DROP CAUTION LAMP STAYS LIT UP….5818
P-22 EXHAUST BRAKE PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]….5819
P-23 EXHAUST BRAKE PILOT LAMP STAYS LIT UP….5820
P-24 CHARGING CIRCUIT ABNORMALITY CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]….5821
P-25 CHARGING CIRCUIT ABNORMALTIY CAUTION LAMP STAY LIT UP….5822
P-26 TRANSMISSION FILTER CLOGGING CAUTION LAMP DOES NOT WORK OR MONITOR PANEL DETECTS SERVICE CODE [A001]….5823
P-27 TRANSMISSION FILTER CLOGGING CAUTION LAMP STAYS LIT UP….5824
P-28 BRAKE STROKE CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]….5825
P-29 BRAKE STROKE CAUTION LAMP STAY LIT UP….5826
P-30 PREHEATING SWITCH PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]….5827
P-31 PREHEATING SWITCH PILOT LAMP STAYS LIT UP….5828
P-32 TILT WARNING LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]….5829
P-33 TILT WARNING LAMP STAYS LIT UP….5830
P-34 BODY FLOAT (EXCEPT FLOAT) PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]….5831
P-35 BODY FLOAT (EXCEPT FLOAT) PILOT LAMP STAYS LIGHTED UP….5832
P-36 REAR BRAKE PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE….5833
P-37 REAR BRAKE PILOT LAMP STAYS LIT UP….5834
P-38 PARKING BRAKE PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]….5835
P-39 PARKING BRAKE PILOT LAMP STAYS LIT UP….5836
P-40 MAINTENANCE CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]….5837
P-41 MAINTENANCE CAUTION LAMP STAYS LIT UP ….5838
P-42 STEERING OIL TEMPERATURE CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]….5839
P-43 STEERING OIL TEMPERATURE CAUTION LAMP STAYS LIT UP….5840
P-44 DIFFERENTIAL LOCK PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]….5841
P-45 DIFFERENTIAL LOCK PILOT LAMP STAYS LIT UP….5842
P-46 HIGH BEAM DISPLAY DOES NOT LIGHT UP….5843
P-47 TURN SIGNAL LAMP (RIGHT) DOES NOT LIGHT UP….5845
P-48 TURN SIGNAL LAMP (LEFT) DOES NOT LIGHT UP….5846
P-49 LAMP CHEK SWITCH DOES NOT WORK….5847
P-50 EXHAUST BRAKE SWITCH DOES NOT WORK….5848
P-51 MODE CHANGE SWITCH (1) DOES NOT WORK….5849
P-52 MODE CHANGE SWITCH (2) DOES NOT WORK….5850
P-53 KPH/MPH SPEEDOMETER UNIT SELECTOR DOES NOT WORK….5851
P-54 DEFECTIVE OPERATION OF ALL SWITCH INPUTS….5852
P-55 MONITOR PANEL DETECTS SERVICE CODES [A014] OR [A019]….5853
P-56 MONITOR PANEL DETECTS SERVICE CODE [A015]….5854
P-57 MONITOR PANEL DETECTS SERVICE CODE [A011]….5855
P-58 MONITOR PANEL DETECTS SERVICE CODE [A012]….5855
P-59 MONITOR PANEL DETECTS SERVICE CODE [A000]….5855
TROUBLESHOOTING OF ABS/ASR SYSTEM (OP)….5856
TROUBLESHOOTING FLOWCHART….5857
FOR MACHINES WITH ABS INSTALLED INDEPENDENTLY….5857
FOR MACHINES WITH ABS/ASR INSTALLED….5858
METHOD OF DELETING ECU TROUBLE DATA FROM MEMORY….5859
PROCEDURE FOR DELETING TROUBLE DATA FROM MEMORY….5859
METHOD OF TROUBLESHOOTING USING SELF-DIAGNOSTIC FUNCTION OF ECU….5860
INDEX (TROUBLESHOOTING CODE)….5861
SYSTEM CHECK SHEET FOR USING SYSTEM CHECKER….5863
TROUBLESHOOTING….5871
W-1 WARNING LAMP DOES NOT LIGHT UP….5871
I-1 ASR INFORMATION SWITCH DOES NOT GO OUT….5872
ASR-1 FAILURE IN ASR CONTROL VALVE (ONLY MACHINES WITH ABS/ASR INSTALLED)….5873
ASR-2….5874
ABS-1 FAILURE INSIDE ECU….5875
ABS-2 FAILURE IN FRONT RIGHT PRESSURE CONTROL VALVE….5876
ABS-3 FAILURE IN FRONT LEFT PRESSURE CONTROL VALVE….5877
ABS-4 FAILURE IN REAR LEFT PRESSURE CONTROL VALVE….5878
ABS-5 FAILURE IN REAR RIGHT PRESSURE CONTROL VALVE….5879
ABS-6 FAILURE IN FRONT RIGHT WHEEL SPEED SENSOR….5880
ABS-10 ABNORMALITY IN FRONT RIGHT WHEEL SPEED SENSOR OUTPUT….5880
ABS-7 FAILURE IN FRONT LEFT WHEEL SPEED SENSOR….5881
ABS-11 ABNORMALITY IN FRONT LEFT WHEEL SPEED SENSOR OUTPUT….5881
ABS-8 FAILURE IN REAR LEFT WHEEL SPEED SENSOR….5882
ABS-12 ABNORMALITY IN REAR LEFT WHEEL SPEED SENSOR OUTPUT….5882
ABS-9 FAILURE IN REAR RIGHT WHEEL SPEED SENSOR….5883
ABS-13 ABNORMALITY IN REAR RIGHT WHEEL SPEED SENSOR OUTPUT….5883
ABS-14 FAILURE IN VALVE RELAY (VR2)….5884
ABS-15 FAILURE IN VALVE RELAY (VR1)….5885
ABS-16 FAILURE IN VALVE RELAY (VR2)….5886
ABS-17 FAILURE IN VALVE RELAY (VR1)….5887
ABS-18 ABNORMALITY IN POWER SOURCE VOLTAGE….5888
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (G MODE)….5890
(HD325-6 SERIAL NO. 6001 AND UP, HD325-6W SERIAL NO. 6001 AND UP, HD405-6 SERIAL NO. 2001 AND UP)….5890
ERROR CODE DISPLAYS AND POINTS TO REMEMBER WHEN TROUBLESHOOTING….5892
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED….5895
ENGINE CONTROLLER RELATED JUDGEMENT TABLE….5903
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE CONTROLLER SYSTEM….5905
G-1 ERROR CODE [C01B] [ABNORMALITY IN NE REVOLUTION SENSOR SYSTEM]….5907
G-2 ERROR CODE [C01C] [ABNORMALITY IN G REVOLUTION SENSOR SYSTEM]….5908
G-3 ERROR CODE [C020] [ABNORMALITY IN MODEL SELECTION SYSTEM]….5909
G-4 ERROR CODE [C022] [OVERRUN]….5910
G-5 ERROR CODE [C022] [OVERHEAT]….5910
G-6 ERROR CODE [C024] [DROP IN OIL PRESSURE]….5911
G-7 ERROR CODE [C030] [ABNORMALITY IN IDLING VALIDATION SIGNAL SYSTEM]….5912
G-8 ERROR CODE [C031] [ABNORMALITY IN ACCELERATOR SENSOR SYSTEM]….5914
G-9 ERROR CODE [C034] [ABNORMALITY IN HIGH WATER TEMPERATURE SENSOR SYSTEM]….5916
G-10 ERROR CODE [C036] [ABNORMALITY IN OIL PRESSURESWITCH SYSTEM] ….5917
G-11 ERROR CODE [C03C] [ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM]….5919
G-12 ERROR CODE [C03D] [ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM….5920
G-13 ERROR CODE [C050] [ABNORMALITY IN PREHEATING RELAY CONNECTING POINT SYSTEM….5921
G-14 ERROR CODE [C051] [ABNORMALITY IN PREHEATING RELAY COIL SYSTEM]….5922
G-15 ERROR CODE [C054] [SHORT CIRCUIT IN STARTING SWITCH C SYSTEM]….5923
G-16 ERROR CODE [C055] [ABNORMALITY IN NETWORK]….5924
G-17 ERROR CODE [C056] [POWER SOURCE SYSTEM ABNORMALITY 1]….5925
G-18 ERROR CODE [C057] [POWER SOURCE SYSTEM ABNORMALITY 2]….5927
G-19 ERROR CODE [C06A] [ABNORMALITY IN FUEL INJECTION QUANITY CONTROL SWITCH SYSTEM]….5928
G-20 ERROR CODE [ABNORMALITY IN HIGH ENGINE WATER TEMPERATURE SENSOR SYSTEM]….5928
G-21 ERROR CODE [C070] EXCESS CURRENT IN FUEL SUPPLY PUMP PCV1 SYSTEM]….5929
G-22 ERROR CODE [C071] EXCESS CURRENT IN FUEL SUPPLY PUMP PCV2 SYSTEM]….5930
G-23 ERROR CODE [C074] [DISCONNECTION IN FUEL SUPPLY PUMP PCV1 SYSTEM]….5931
G-24 ERROR CODE [C075] [DISCONNECTION IN FUEL SUPPLY PUMP PCV2 SYSTEM]….5932
G-25 ERROR CODE [C077] ABNORMALITY IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM]….5933
G-26 ERROR CODE [C079] [COMMON RAIL HIGH FUEL PRESSURE ABNORMALITY 1]….5934
ERROR CODE [E-7A] [COMMON RAIL HIGH FUEL PRESSURE ABNORMALITY 2]….5934
G-27 ERROR CODE [C07B] [FUEL SUPPLY PUMP NON-FORCE FEED 1] ….5935
ERROR CODE [C07C] [FUEL SUPPLY PUMP NON-FORCE FEED 2] ….5935
G-28 ERROR CODE [C07D] [ABNORMALITY IN COMMON RAIL FUEL PRESSURE]….5937
G-29 ERROR CODE [CO80] [DEFECTIVE CONTROLLER]….5937
G-30 ERROR CODE [C081] [DISCONNECTION IN N0. FUEL INJECTOR <A> SYSTEM]….5938
G-31 ERROR CODE [C082] [DISCONNECTION IN N0.2 FUEL INJECTOR <E> SYSTEM]….5939
G-32 ERROR CODE [C083] [DISCONNECTION IN N0.3 FUEL INJECTOR <C> SYSTEM]….5940
G-33 ERROR CODE [C084] [DISCONNECTION IN N0.4 FUEL INJECTOR <F> SYSTEM]….5941
G-34 ERROR CODE [C085] [DISCONNECTION IN N0.5 FUEL INJECTOR <B> SYSTEM]….5942
G-35 ERROR CODE [C086] [DISCONNECTION IN N0.6 FUEL INJECTOR <D> SYSTEM]….5943
G-36 ERROR CODE [CO8A] [SHORT CIRCUIT IN NO. 1 ,<A>, NO. 2 <E>, NO.3 <C> FUEL INJECTOR SYSTEM]….5944
G-37 ERROR CODE [CO8A] [SHORT CIRCUIT IN NO. 4 ,<F>, NO. 5 <B>, NO.6 <D> FUEL INJECTOR SYSTEM]….5947
TROUBLESHOOTING OF FRONT DRIVE SYSTEM (W MODE) SERIAL NO. 5706-6000….5950
ELECTRICAL CIRCUIT DIAGRAM FOR FRONT DRIVE SYSTEM….5951
W-1 SELF-DIAGNOSTIC DISPLAY UNIT OF CONTROLLER DOES NOT LIGHT UP….5953
W-2 E-0.1 (DROP IN CONTROLLER POWER SUPPLY VOLTAGE) IS DISPLAYED….5954
W-3 E-0.4 (ABNORMALITY IN ANALOG POWER SOURCE RELAY) IS DISPLAYED….5955
W-4 E-1.1 (DISCONNECTION IN CLUTCH CONTROL VALVE OUTPUT WIRING) IS DISPLAYED….5956
W-4 E-1.2 (SHORT CIRCUIT IN CLUTCH CONTROL VALVE OUTPUT WIRING) IS DIPLAYED….5956
W-5 E-1.3 (DEFECTIVE CLUTCH CONTROL VALVE SYSTEM) IS DISPLAYED….5957
W-5 E-1.4 (DEFECTIVE FILL SIGNAL INPUT SYSTEM) IS DISPLAYED….5957
W-6 E-2.0 (DISCONNECTION IN PUMP OUTPUT WIRING) IS DISPLAYED….5958
W-6 E-2.1 (SHORT CIRCUIT IN PUMP OUTPUT WIRING) IS DISPLAYED….5958
W-7 E-2.2 (DISCONNECTION IN LEFT MOTOR OUPUT WIRING) IS DISPLAYED….5959
W-7 E-2.3 (SHORT CIRCUIT IN LEFT MOTOR OUTPUT WIRING) IS DISPLAYED….5959
W-8 E-2.4 (DISCONNECTION IN RIGHT MOTOR OUTPUT WIRING) IS DISPLAYED….5960
W-8 E-2.5 (SHORT CIRCUIT IN RIGHT MOTOR OUTPUT WIRING) IS DISPLAYED….5960
W-9 E-5.0 (ABNORMALITY (DISCONNECTION) IN PRESSURE SENSOR [A] IS DISPLAYED….5961
W-9 E-5.2 (ABNORMALITY (DISCONNECTION) IN PRESSURE SENSOR [B]) IS DISPLAYED….5961
W-10 E-5.1 (SHORT CIRCUIT IN PRESSOR SENSOR [A]) IS DISPLAYED….5962
W-10 E-5.3 (SHORT CIRCUIT IN PRESSURE SENSOR [B]) IS DISPLAYED….5962
W-11 E-5.4, E-5.5, E-5.6 (ABNORMALITY IN HST HYDRAULIC SYSTEM) IS DISPLAYED….5963
W-12 E-6.1 (DISCONNECTION IN STEERING ANGLE SENSOR) IS DISPLAYED….5964
W-12 E-6.2 (SHORT CIRCUIT IN STEERING ANGLE SENSOR) IS DISPLAYED….5964
W-12 E-6.3 (DEFECTIVE MOUNT OF STEERING ANGLE SENSOR) IS DISPLAYED….5964
W-13 E-7.1 (DISCONNECTION IN ENGINE SPEED SENSOR) IS DISPLAYED….5965
W-14 E-7.2 (DISCONNECTION IN TRANSMISSION INPUT SHAFT SPEED SENSOR) IS DISPLAYED….5966
W-15 E-7.3 (ABNORMALITY IN LEFT FRONT WHEEL SPEED SENSOR SYSTEM) IS DISPLAYED….5967
W-15 E-7.4 (ABNORMALITY IN RIGHT FRONT WHEEL SPEED SENSOR SYSTEM) IS DISPLAYED….5967
W-16 E-7.5 (ABNORMALITY IN FRONT WHEEL SPEED SENSOR SYSTEM) IS DISPLAYED….5967
W-17 E-8.2 (SHORT CIRCUIT IN 4-WHEEL DRIVE LAMP RELAY) IS DISPLAYED….5968
W-18 E-9.0 (CLOGGING OF FRONT DRIVE OIL FILTER) IS DISPLAYED….5969
W-19 E-9.1 (RISE IN TEMPERATURE OF FRONT DRIVE OIL) IS DISPLAYED….5970
W-20 E-9.3 (ABNORMALITY IN CLUTCH OIL PRESSURE SYSTEM) IS DISPLAYED….5971
TROUBLESHOOTING OF FRONT DRIVE SYSTEM (W MODE) SERIAL NO. 6001 AND UP….5972
ELECTRICAL CIRCUIT DIAGRAM FOR FRONT DRIVE SYSTEM….5973
W-1 SELF-DIAGNOSTIC DISPLAY UNIT OF CONTROLLER DOES NOT LIGHT UP….5975
W-2 E-0.1 (DROP IN CONTROLLER POWER SUPPLY VOLTAGE) IS DISPLAYED….5976
W-3 E-0.4 (ABNORMALITY IN CLUTCH POWER SUPPLY CUT RELAY) IS DISPLAYED….5977
W-4 E-1.1 (DISCONNECTION IN CLUTCH CONTROL VALVE OUTPUT WIRING) IS DISPLAYED….5978
W-4 E-1.2 (SHORT CIRCUIT IN CLUTCH VALVE OUTPUT WIRING) IS DISPLAYED….5978
W-5 E-1.3 (DEFECTIVE CLUTCH CONTROL VALVE SYSTEM) IS DISPLAYED….5979
W-5 E-1.4 (DEFECTIVE FILL SIGNAL INPUT SYSTEM) IS DISPLAYED….5979
W-6 E-2.0 (DISCONNECTION IN PUMP OUTPUT WIRING) IS DISPLAYED….5980
W-6 E-2.1 (SHORT CIRCUIT IN PUMP OUTPUT WIRING) IS DISPLAYED….5980
W-7 E-2.2 (DISCONNECTION IN LEFT MOTOR OUTPUT WIRING) IS DISPLAYED….5981
W-7 E-2.3 (SHORT CIRCUIT IN LEFT MOTOR OUTPUT WIRING) IS DISPLAYED….5981
W-8 E-2.4 (DISCONNECTION IN RIGHT MOTOR OUTPUT WIRING) IS DISPLAYED….5982
W-8 E-2.5 (SHORT CIRCUIT IN RIGHT MOTOR OUTPUT WIRING) IS DISPLAYED….5982
W-9 E-5.0 (ABNORMALITY (DISCONNECTION) IN PRESSURE SENSOR [A]) IS DISPLAYED….5983
W-9 E-5.2 (ABNORMALITY (DISCONNECTION) IN PRESSURE SENSOR [B]) IS DISPLAYED….5983
W-10 E-5.1 (SHORT CIRCUIT IN PRESSURE SENSOR [A]) IS DISPLAYED….5984
W-10 E-5.3 (SHORT CIRCUIT IN PRESSURE SENSOR [B]) IS DISPLAYED….5984
W-11 E-5.4, E-5.5, E-5.6 (ABNORMALITY IN HST HYDRAULIC SYSTEM) IS DISPLAYED….5985
W-12 E-6.1 (DISCONNECTION IN STEERING ANGLE SENSOR) IS DISPLAYED….5986
W-12 E-6.2 (SHORT CIRCUIT IN STEERING ANGLE SENSOR) IS DISPLAYED….5986
W-12 E-6.3 (DEFECTIVE MOUNT OF STEERING ANGLE SENSOR) IS DISPLAYED….5986
W-13 E-7.1 (DISCONNECTION IN ENGINE SPEED SENSOR) IS DISPLAYED….5987
W-14 E-7.2 (DISCONNECTION IN TRANSMISSION INPUT SHAFT SPEED SENSOR) IS DISPLAYED….5988
W-15 E-7.3 (ABNORMALITY IN LEFT FRONT WHEEL SPEED SENSOR SYSTEM) IS DISPLAYED….5989
W-15 E-7.4 (ABNORMALITY IN RIGHT FRONT WHEEL SPEED SENSOR SYSTEM) IS DISPLAYED….5989
W-16 E-7.5 (ABNORMALITY IN FRONT WHEEL SPEED SENSOR SYSTEM) IS DISPLAYED….5989
W-17 E-8.2 (SHORT CIRCUIT IN 4-WHEEL DRIVE LAMP RELAY) IS DISPLAYED….5990
W-18 E-9.0 (CLOGGING OF FRONT DRIVE OIL FILTER) IS DISPLAYED….5991
W-19 E-9.1 (RISE IN TEMPERATURE OF FRONT DRIVE OIL) IS DISPLAYED ….5992
W-20 E-9.3 (ABNORMALITY IN CLUTCH OIL PRESSURE SYSTEM) IS DISPLAYED….5993
30 DISASSEMBLY AND ASSEMBLY….5994
METHOD OF USING MANUAL….5998
PRECAUTIONS WHEN CARRYING OUT OPERATION….5999
SPECIAL TOOL LIST….6002
SKETCHES OF SPECIAL TOOLS….6005
STARTING MOTOR….6013
REMOVAL AND INSTALLATION….6013
ALTERNATOR ….6014
REMOVAL AND INSTALLATION….6014
ENGINE OIL COOLER ….6015
REMOVAL ….6015
INSTALLATION….6016
FUEL INJECTION PUMP ASSEMBLY….6018
REMOVAL ….6018
INSTALLATION….6019
FUEL SUPPLY PUMP….6020
REMOVAL….6020
INSTALLATION….6022
AIR COMPRESSOR….6023
REMOVAL….6023
INSTALLATION….6024
AIR CONDITIONER COMPRESSOR ….6026
REMOVAL….6026
INSTALLATION….6027
AIR CONDITIONER CONDENSER ….6028
REMOVAL AND INSTALLATION….6028
WATER PUMP….6029
REMOVAL….6029
INSTALLATION….6030
AFTERCOOLER….6032
REMOVAL….6032
INSTALLATION….6034
EXHAUST BRAKE CYLINDER ….6035
REMOVAL AND INSTALLATION….6035
TURBOCHARGER ….6036
REMOVAL ….6036
INSTALLATION….6037
NOZZLE HOLDER….6039
REMOVAL AND INSTALLATION….6039
FUEL INJECTOR….6040
REMOVAL ….6040
INSTALLATION….6041
CYLINDER HEAD….6044
REMOVAL….6044
INSTALLATION….6052
ENGINE ….6059
REMOVAL….6059
INSTALLATION….6067
RADIATOR, TORQUE CONVERTER OIL COOLER….6070
REMOVAL….6070
INSTALLATION….6077
RADIATOR, FRONT DRIVE COOLER (HD325-6W)….6080
REMOVAL….6080
INSTALLATION….6081
FRONT DRIVE OIL COOLER (HD325-6W)….6082
REMOVAL AND INSTALLATION….6082
OUTPUT SHAFT….6084
REMOVAL….6084
INSTALLATION….6087
DISASSEMBLY….6088
ASSEMBLY….6089
TORQUE CONVERTER, TRANSMISSION (HD325-6, 405-6)….6091
REMOVAL….6091
INSTALLATION….6093
TORQUE CONVERTER, TRANSMISSION (HD325-6W)….6095
REMOVAL….6095
INSTALLATION….6097
TORQUE CONVERTER VALVE….6099
REMOVAL AND ASSEMBLY….6099
DISASSEMBLY AND ASSEMBLY….6100
TORQUE CONVERTER, TRANSMISSION….6101
DISCONNECTION….6101
CONNECTION….6102
TORQUE CONVERTER….6103
DISASSEMBLY….6103
ASSEMBLY….6108
PTO (HD325, 405-6)….6113
DISASSEMBLY….6113
ASSEMBLY….6114
PTO (HD325-6W)….6116
DISASSEMBLY….6116
ASSEMBLY….6117
TRANSMISSION….6118
DISASSEMBLY….6118
ASSEMBLY….6136
TRANSMISSION CONTROL VALVE (ECMV ASSEMBLY)….6154
REMOVAL AND INSTALLATION….6154
DISASSEMBLY….6155
ASSEMBLY….6156
DIFFERENTIAL….6157
REMOVAL AND INSTALLATION….6157
DISASSEMBLY (STANDARD)….6158
DISASSEMBLY (WITH DIFFERENTIAL LOCK)….6163
DIFFERENTIAL GEAR….6168
ASSEMBLY (STANDARD)….6168
ASSEMBLY (WITH DIFFERENTIAL LOCK)….6178
FRONT WHEEL (HD325, 405-6)….6190
REMOVAL AND INSTALLATION….6190
FRONT WHEEL (HD325-6W)….6191
REMOVAL AND INSTALLATION….6191
REAR WHEEL….6193
REMOVAL….6193
INSTALLATION….6194
FRONT BRAKE CALIPER PAD….6195
REMOVAL AND INSTALLATION….6195
FRONT BRAKE CALIPER ….6196
REMOVAL AND INSTALLATION….6196
DISASSEMBLY….6197
ASSEMBLY….6198
FRONT WHEEL HUB….6200
DISASSEMBLY….6200
ASSEMBLY….6202
FRONT FINAL DRIVE CLUTCH, CARRIER (HD325-6W)….6205
DISASSEMBLY….6205
ASSEMBLY….6209
FRONT FINAL DRIVE, BRAKE (HD325-6W)….6214
DISASSEMBLY….6214
ASSEMBLY….6219
FRONT DRIVE SHAFT (HD325-6W)….6226
DISASSEMBLY….6226
ASSEMBLY….6230
REAR FINAL DRIVE CARRIER….6237
REMOVAL….6237
INSTALLATION….6238
DISASSEMBLY….6239
ASSEMBLY….6240
REAR FINAL DRIVE….6241
DISASSEMBLY….6241
ASSEMBLY….6243
REAR BRAKE ….6245
REMOVAL AND INSTALLATION….6245
DISASSEMBLY….6246
ASSEMBLY….6247
PARKING BRAKE PAD….6249
REMOVAL….6249
INSTALLATION….6250
PARKING BRAKE CALIPER….6251
REMOVAL AND INSTALLATION….6251
DISASSEMBLY AND ASSEMBLY….6252
FRONT SUSPENSION CYLINDER (HD325, 405-6)….6253
REMOVAL….6253
INSTALLATION….6254
FRONT SUSPENSION CYLINDER (HD325-6W)….6255
REMOVAL….6255
INSTALLATION….6256
DISASSEMBLY….6257
ASSEMBLY….6258
VARIABLE DAMPING SELECTOR VALVE….6261
DISASSEMBLY….6261
ASSEMBLY….6262
REAR SUSPENSION….6263
REMOVAL AND INSTALLATION….6263
DISASSEMBLY….6264
ASSEMBLY….6265
AIR GOVERNOR….6266
REMOVAL AND INSTALLATION….6266
DISASSEMBLY AND ASSEMBLY….6267
BRAKE VALVE….6268
REMOVAL AND INSTALLATION….6268
DISASSEMBLY….6269
ASSEMBLY….6271
PARKING BRAKE CHAMBER….6273
REMOVAL AND INSTALLATION….6273
DISASSEMBLY….6274
ASSEMBLY….6275
FRONT BRAKE CHAMBER (HD325, 405-60….6277
REMOVAL AND INSTALLATION….6277
REAR BRAKE CHAMBER….6278
REMOVAL AND INSTALLATION….6278
FRONT BRAKE CHAMBER ….6279
DISASSEMBLY….6279
ASSEMBLY….6281
REAR BRAKE CHAMBER….6283
DISASSEMBLY….6283
ASSEMBLY….6287
SLACK ADJUSTER….6290
REMOVAL AND INSTALLATION….6290
DISASSEMBLY AND ASSEMBLY….6291
TRANSMISSION LUBRICATION, RETARDER BRAKE PUMP (HD325, 405-6) ….6292
TRANSMISSION LUBRICATION, RETARDER BRAKE PUMP (HD325-6W)….6293
REMOVAL AND INSTALLATION….6293
BRAKE COOLING PUMP (HD325, HD405-6)….6294
REMOVAL AND INSTALLATION….6294
BRAKE COOLING PUMP (HD325-6W)….6295
REMOVAL AND INSTALLATION….6295
HOIST, STEERING PUMP….6296
REMOVAL AND INSTALLATION….6296
FRONT DRIVE PUMP (HD325-6W)….6297
REMOVAL….6297
INSTALLATION….6298
EMERGENCY STEERING MOTOR PUMP….6299
REMOVAL AND INSTALLATION….6299
TRAVEL DRIVE MOTOR (HD325-6W)….6300
REMOVAL….6300
INSTALLATION….6301
TRAVEL MOTOR (HD325-6W)….6302
DISASSEMBLY AND ASSEMBLY….6302
STEERING VALVE….6306
REMOVAL AND INSTALLATION….6306
DISASSEMBLY….6307
ASSEMBLY….6311
DEMAND VALVE….6317
REMOVAL AND INSTALLATION….6317
DISASSEMBLY AND ASSEMBLY….6318
RELIEF VALVE….6319
HOIST VALVE….6320
REMOVAL AND INSTALLATION….6320
DISASSEMBLY….6321
ASSSEMBLY….6322
STEERING CYLINDER….6323
REMOVAL AND INSTALLATION….6323
DISASSEMBLY….6324
ASSEMBLY….6326
HOIST CYLINDER….6328
REMOVAL AND INSTALLATION….6328
DISASSEMBLY….6329
ASSEMBLY….6331
BODY ASSEMBLY….6335
REMOVAL ….6335
INSTALLATION….6336
TRANSMISSION CONTROLLER….6337
REMOVAL AND INSTALLATION….6337
SUSPENSION CONTROLLER….6337
REMOVAL AND INSTALLATION….6337
FRONT DRIVE CONTROLLER….6337
REMOVAL AND INSTALLATION….6337
40 MAINTENANCE STANDARD….6338
OUTPUT SHAFT….6339
TORQUE CONVERTER VALVE….6340
TORQUE CONVERTER….6341
TRANSMISSION….6343
ECMV (ELECTRONIC CONTROL MODULATION VALVE)….6347
FRONT AXLE….6348
DIFFERENTIAL….6349
FINAL DRIVE (REAR)….6351
FINAL DRIVE (FRONT) HD325-6W….6352
FRONT BRAKE (HD325-6, 405-6)….6354
FRONT BRAKE (HD325-6W)….6355
REAR BRAKE….6357
PARKING BRAKE….6358
REAR AXLE SUPPORT….6359
STEERING LINKAGE….6360
FRONT SUSPENSION CYLINDER….6362
REAR SUSPENSION CYLINDER….6363
PARKING BRAKE CHAMBER….6364
SLACK ADJUSTER….6365
HYDRAULIC PUMP….6366
DEMAND VALVE….6369
CROSS-OVER RELIEF VALVE….6369
HOIST VALVE….6370
STEERING CYLINDER….6371
HOIST CYLINDER….6372
90 OTHER….6374
AIR PIPING DIAGRAM (HD325-6, 6W: 6001 AND UP, HD405-6: 2001 AND UP)….6376
AIR PIPING DIAGRAM (HD325-6W: 5485 – 6000)….6377
AIR PIPING DIAGRAM (HD325-6W: 6001 AND UP)….6378
AIR CIRCUIT DIAGRAM (HD325-6W: 5485 – 6000)….6379
AIR CIRCUIT DIAGRAM (HD325-6, 6W: 6001 AND UP, HD405-6: 2001 AND UP)….6380
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (1/3 – 3/3) (HD325-6: 5680-6000, HD325-6W: 5706-6000, HD405-6: 1055-2000)….6381
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (1/4-4/4) (HD325-6, 6W: 6001 AND UP, HD405-6: 2001 AND UP)….6384
DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (1/2-2/2) (HD325-6: 5680-6000, HD325-6W: 5706-6000, HD405-6: 1055-2000)….6388
DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (1/2-2/2) (HD325-6, 6W: 6001-6613, HD405-6: 2001 -2229)….6390
DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (1/2-2/2) (HD325-6, 6W: 6614 AND UP, HD405-6: 2230 AND UP)….6392
AUTOMATIC RETARD SPEED CONTROL SYSTEM ELECTRICAL CIRCUIT DIAGRAM….6394
AUTOMATIC SHIFT CONTROLLER (HD325-6: 5680-6000, HD325-6W: 5706-6000, HD405-6: 1055-2000)….6395
AUTOMATIC SHIFT CONTROLLER (HD325-6, 6W: 6001 AND UP, HD405-6: 2001 AND UP)….6396
AUTOMATIC SUSPENSION SYSTEM….6397
SYSTEM CIRCUIT DIAGRAM (1/2-2/2) (HD325-6: 5680-6000, HD325-6W: 5706-6000, HD405-6: 1055-2000)….6397
SYSTEM CIRCUIT DIAGRAM (HD325-6, 6W: 6001 AND UP, HD405-6: 2001 AND UP)….6399
PAYLOAD METER (PRINTER TYPE)….6400
ELECTRICAL CIRCUIT DIAGRAM (HD325-6: 5680-6000, HD325-6W: 5706-6000, HD405-6: 1055-2000)….6400
PAYLOAD METER II (CARD TYPE)….6402
ELECTRICAL CIRCUIT DIAGRAM (HD325-6: 5680-6000, HD325-6W: 5706-6000, HD405-6: 1055-2000)….6402
PAYLOAD METER II (PRINTER – CARD TYPE)….0
ELECTRICAL CIRCUIT DIAGRAM (HD325-6, 6W: 6001 AND UP, HD405-6: 2001 AND UP)….6401
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM (HD325-6, 6W: 6001 AND UP, HD405-6: 2001 AND UP)….6403
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM (1/2-2/2) (HD325-6, 6W: 6001 AND UP, HD405-6: 2001 AND UP)….6404
OIL FILTER CAUTION SYSTEM….6406
FRONT DRIVE SYSTEM- ELECTRICAL COMPONENT LAYOUT….6407
SEBM05660510 – Dump Truck HD325-5 Shop Manual….6411
COVER….6411
CONTENTS….6412
10 ENGINE….6433
12 TESTING AND ADJUSTING….6433
STANDARD VALUE TABLE….6434
TOO LIST FOR TESTING AND ADJUSTING….6435
ADJUSTING VALVE CLEARANCE….6436
MEASURING COMPRESSION PRESSURE….6437
MEASURING BLOW-BY PRESSURE….6438
ADJUSTING FUEL INJECTION TIMING….6439
AIR BLEEDING FROM FUEL SYSTEM….6440
ADJUSTING CABLE FOR ENGINE STOP MOTOR….6440
MEASURING EXHAUST GAS COLOR….6441
ADJUSTING TENSION OF ALTERNATOR DRIVE BELT….6443
MEASURING ENGINE OIL TEMPERATURE AND PRESSURE….6444
13 DISASSEMBLY AND ASSEMBLY….6445
STARTING MOTOR….6446
REMOVAL….6446
INSTALLATION….6446
ALTERNATOR….6447
REMOVAL….6447
INSTALLATION….6447
OIL COOLER….6448
REMOVAL….6448
INSTALLATION….6448
FUEL INJECTION PUMP….6449
REMOVAL….6449
INSTALLATION….6449
AIR COMPRESSOR….6450
REMOVAL….6450
INSTALLATION….6450
AIR CONDITIONER COMPRESSOR….6451
REMOVAL….6451
INSTALLATION….6451
WATER PUMP….6452
REMOVAL….6452
INSTALLATION….6452
TURBOCHARGER….6453
REMOVAL….6453
INSTALLATION….6453
NOZZLE HOLDER….6454
REMOVAL….6454
INSTALLATION….6454
AFTERCOOLER….6455
REMOVAL….6455
INSTALLATION….6457
CYLINDER HEAD….6459
REMOVAL….6459
INSTALLATION….6463
RADIATOR….6468
REMOVAL….6468
INSTALLATION….6471
ENGINE….6474
REMOVAL….6474
INSTALLATION….6478
20 POWER TRAIN….6483
21 STRUCTURE AND FUNCTION….6483
GENERAL….6484
OUTPUT SHAFT….6485
POWER TRAIN HYDRAULIC PIPING….6486
POWER TRAIN HYDRAULIC SYSTEM….6488
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM….6489
TORQUE CONVERTER….6492
TORQUE CONVERTER VALVE….6494
TRANSMISSION MOUNT….6500
TRANSMISSION….6501
TRANSMISSION CONTROL VALVE….6505
TRANSMISSION OIL TANK….6517
TORQUE CONVERTER AND TRANSMISSION PUMP….6518
RETARDER COOLING PUMP….6519
REAR AXLE….6520
DIFFERENTIAL….6521
FRONT AXLE….6524
FINAL DRIVE SYSTEM….6526
DRIVE SHAFT….6527
FRONT BRAKE….6528
REAR BRAKE….6530
REAR BRAKE COMPONENT PARTS….6531
PARKING BRAKE….6532
FRONT WHEEL….6533
REAR WHEEL….6534
22 TESTING AND ADJUSTING….6535
TABLE OF JUDGEMENT STANDARD….6536
TOOL LIST FOR TESTING AND ADJUSTING….6538
TESTING AND ADJUSTING OF ACCELERATOR PEDAL (AUTOMATIC TRANSMISSION)….6539
PROCEDURE FOR ADJUSTING MANUAL SHIFT CONSOLE….6541
MEASURING OF TRANSMISSION SHIFT LEVER OPERATING FORCE (AUTOMATIC TRANSMISSION)….6544
MEASURING OF TRANSMISSION OIL TEMPERATURE….6544
MEASURING OF TORQUE CONVERTER OIL PRESSURE….6545
MEASURING OF TRANSMISSION OIL PRESSURE….6546
ADJUSTING OF TRANSMISSION MODULATION OIL PRESSURE (CLUTCH CIRCUIT OIL PRESSURE)….6548
MEASURING OF TORQUE CONVERTER STALL….6549
TESTING OF SERVICE BRAKE PERFORMANCE….6550
TESTING OF BRAKING DISTANCE….6550
ADJUSTING OF FRONT BRAKE….6551
BLEEDING AIR FROM REAR BRAKE….6551
BLEEDING AIR FROM FRONT BRAKE….6552
MEASURING OF REAR BRAKE OIL PRESSURE….6553
MEASURING OF WEAR OF BRAKE DISC….6553
TESTING FRONT WHEEL BEARING ….6554
TESTING AND ADJUSTING OF PARKING BRAKE….6556
23 DISASSEMBLY AND ASSEMBLY….6557
OUTPUT SHAFT….6558
REMOVAL….6558
INSTALLATION….6559
DISASSEMBLY….6560
ASSEMBLY….6560
TORQUE CONVERTER AND TRANSMISSION….6561
REMOVAL….6561
INSTALLATION….6564
DISASSEMBLY….6567
CONNECTION….6568
TRANSMISSION PUMP….6569
REMOVAL….6569
INSTALLATION….6569
TORQUE CONVERTER….6570
DISASSEMBLY….6570
ASSEMBLY….6575
PTO….6580
DISASSEMBLY….6580
ASSEMBLY….6581
TORQUE CONVERTER CONTROL VALVE….6582
REMOVAL….6582
INSTALLATION….6582
DISASSEMBLY….6583
ASSEMBLY….6583
TRANSMISSION….6584
DISASSEMBLY….6584
ASSEMBLY….6597
TRANSMISSION CONTROL VALVE….6614
REMOVAL….6614
INSTALLATION….6614
DISASSEMBLY AND ASSEMBLY….6616
ACCUMULATOR VALVE….6615
REMOVAL….6615
INSTALLATION….6615
PARKING BRAKE SHOE….6621
REMOVAL….6621
INSTALLATION….6622
DIFFERENTIAL GEAR….6623
REMOVAL….6623
INSTALLATION….6626
DISASSEMBLY….6628
ASSEMBLY….6639
PLANETARY CARRIER (FINAL DRIVE)….6666
REMOVAL….6666
INSTALLATION….6667
FINAL DRIVE….6668
DISASSEMBLY….6668
ASSEMBLY….6671
REAR WHEEL BRAKE….6675
REMOVAL….6675
INSTALLATION….6677
DISASSEMBLY….6679
ASSEMBLY….6681
FRONT WHEEL….6683
REMOVAL….6683
INSTALLATION….6684
REAR WHEEL….6685
REMOVAL….6685
INSTALLATION….6686
FRONT BRAKE SHOE….6688
REMOVAL….6688
INSTALLATION….6689
FRONT CALIPER….6691
REMOVAL….6691
INSTALLATION….6691
CALIPER….6692
DISASSEMBLY….6692
ASSEMBLY….6692
FRONT WHEEL HUB….6693
DISASSEMBLY….6693
ASSEMBLY….6695
24 MAINTENANCE STANDARD….6698
OUTPUT SHAFT….6699
TORQUE CONVERTER VALVE….6700
TORQUE CONVERTER….6701
TRANSMISSION CONTROL VALVE….6703
TRANSMISSION….6705
TORQUE CONVERTER AND TRANSMISSION PUMP….6708
RETARDER COOLING PUMP….6709
DIFFERENTIAL….6710
FRONT BRAKE….6713
FINAL DRIVE….6715
REAR BRAKE….6716
PARKING BRAKE….6717
WHEEL….6718
40 STEERING AND SUSPENSION SYSTEM….6719
41 STRUCTURE AND FUNCTION….6719
STEERING SYSTEM….6720
STEERING WHEEL….6721
STEERING LINKAGE….6722
CHASSIS SUSPENSION SYSTEM….6723
FUNCTIONS OF CHASSIS SUSPENSION SYSTEM….6724
REAR AXLE SUPPORT….6726
FRONT SUSPENSION CYLINDER….6727
REAR SUSPENSION CYLINDER….6728
42 TESTING AND ADJUSTING….6729
TABLE OF JUDGEMENT STANDARD….6730
MEASURING OF STEERING WHEEL….6731
TESTING AND ADJUSTING OF SUSPENSION CYLINDER….6732
43 DISASSEMBLY AND ASSEMBLY….6737
STEERING VALVE….6738
REMOVAL….6738
INSTALLATION….6738
DISASSEMBLY….6740
ASSEMBLY….6744
FRONT SUSPENSION CYLINDER….6750
REMOVAL….6750
INSTALLATION….6752
REAR SUSPENSION CYLINDER….6754
REMOVAL….6754
INSTALLATION….6755
SUSPENSION CYLINDER….6756
DISASSEMBLY….6756
ASSEMBLY….6757
44 MAINTENANCE STANDARD….6758
SUSPENSION CYLINDER….6759
STEERING LINKAGE….6760
50 AIR SYSTEM….6761
51 STRUCTURE AND FUNCTION….6761
AIR PIPING….6762
AIR CIRCUIT DIAGRAM….6764
AIR CIRCUIT SCHEMATICS….6768
RELAY VALVE (ACTS ALSO AS EMERGENCY RELAY)….6769
PROTECTION VALVE….6773
FRONT BRAKE CONTROL….6774
FRONT BRAKE CHAMBER….6775
REAR BRAKE CHAMBER….6777
SLACK ADJUSTER….6780
PARKING BRAKE VALVE….6783
PARKING BRAKE REALY VALVE….6785
PARKING BRAKE CONTROL….6787
SPRING CYLINDER….6788
RETARDER BRAKE VALVE….6789
AUTO-RETARDER VALVE….6792
STOP LAMP SWITCH….6793
HORN VALVE….6793
LOW-PRESSURE BUZZER SWITCH….6794
SAFETY VALVE….6795
AIR GOVERNOR….6796
CHECK VALVE….6798
DOUBLE-CHECK VALVE….6799
BRAKE VALVES….6800
BRAKE CIRCUIT….6805
52 TESTING AND ADJUSTING….6808
TABLE OF JUDGEMENT STANDARD….6809
MEASURING OF BRAKE PEDAL….6810
MEASURING OF RETARDER CONTROL LEVER….6810
TESTING AND ADJUSTING OF AIR PRESSURE….6811
53 DISASSEMBLY AND ASSEMBLY….6812
SLACK ADJUSTER ASSEMBLY….6813
REMOVAL….6813
INSTALLATION….6813
DISASSEMBLY….6814
ASSEMBLY….6814
PARKING BRAKE SPRING CYLINDER….6815
REMOVAL….6815
INSTALLATION….6815
DISASSEMBLY….6816
ASSEMBLY….6817
BRAKE VALVE….6818
REMOVAL….6818
INSTALLATION….6818
DISASSEMBLY….6819
ASSEMBLY….6821
FRONT BRAKE CHAMBER ….6823
REMOVAL….6823
INSTALLATION….6823
DISASSEMBLY….6824
ASSEMBLY….6824
REAR BRAKE CHAMBER ….6829
REMOVAL….6829
INSTALLATION….6829
DISASSEMBLY….6830
ASSEMBLY….6831
AIR GOVERNOR ….6836
REMOVAL….6836
INSTALLATION….6836
DISASSEMBLY….6837
ASSEMBLY….6837
54 MAINTENANCE STANDARD….6838
AIR GOVERNOR….6839
SLACK ADJUSTER….6840
60 HYDRAULIC SYSTEM….6841
61 STRUCTURE AND FUNCTION….6841
HYDRAULIC PIPING….6842
HYDRAULIC SYSTEM….6844
HYDRAULIC CIRCUIT DIAGRAM….6845
HYDRAULIC TANK WITH FILTER….6846
HYDRAULIC TANK STEERING PUMP….6847
DEMAND VALVE….6848
HOIST CONTROL VALVE….6852
HOIST CONTROL SYSTEM….6856
STEERING CONTROL VALVE….6857
CROSSOVER RELIEF VALVE….6861
STEERING CYLINDER….6862
HOIST CYLINDER….6863
SLOW RETURN VALVE….6864
62 TESTING AND ADJUSTING….6866
TABLE OF JUDGEMENT STANDARD….6867
TESTING AND ADJUSTING OF HOIST LEVER….6868
MEASURING OF HYDRAULIC OIL TEMPERATURE….6869
TESTING AND ADJUSTING OF OIL PRESSURE IN STEERING AND HOIST CIRCUIT….6870
MEASURING OF RAISING SPEED OF DUMP BODY….6872
MEASURING OF HYDRAULIC DRIFT OF HOIST CYLINDER….6872
MEASURING OF HYDRAULIC PUMP PERFORMANCE….6873
BLEEDING AIR FROM STEERING CYLINDER….6875
63 DISASSEMBLY AND ASSEMBLY….6876
TANDEM PUMP (BRAKE COOLING)….6877
REMOVAL….6877
INSTALLATION….6877
TANDEM PUMP (HOIST, STEERING)….6878
REMOVAL….6878
INSTALLATION….6878
EMERGENCY STEERING MOTOR・PUMP….6879
REMOVAL….6879
INSTALLATION….6879
HOIST VALVE….6880
REMOVAL….6880
INSTALLATION….6880
DISASSEMBLY….6881
ASSEMBLY….6882
DEMAND VALVE….6883
REMOVAL….6883
INSTALLATION….6883
STEERING CYLINDER….6884
REMOVAL….6884
INSTALLATION….6884
DISASSEMBLY….6885
ASSEMBLY….6887
HOIST CYLINDER….6889
REMOVAL….6889
INSTALLATION….6890
DISASSEMBLY….6891
ASSEMBLY….6892
64 MAINTENANCE STANDARD….6893
HYDRAULIC AND STEERING PUMP….6894
DEMAND VALVE….6895
HOIST VALVE….6896
CROSSOVER RELIEF VALVE….6897
STEERING CYLINDER….6898
HOIST CYLINDER….6899
HOIST CONTROL SYSTEM….6900
70 WORK EQUIPMENT….6901
71 STRUCTURE AND FUNCTION….6901
MAIN FRAME, DUMP BODY….6902
73 DISASSEMBLY AND ASSEMBLY….6903
DUMP BODY ….6904
REMOVAL….6904
INSTALLATION….6904
74 MAINTENANCE STANDARD….6905
MAIN FRAME….6906
REPAIR OF DUMP BODY BY WELDING….6908
80 ELECTRICAL AND ELECTRONIC SYSTEM….6909
81 STRUCTURE AND FUNCTION….6909
ELECTRICAL CIRCUIT DIAGRAM….6910
FILTER CLOGGING CAUTION SENSOR….6915
RADIATOR WATER LEVEL SENSOR….6916
CENTER WARNING LAMP (RED)….6918
ELECTRONIC VEHICLE MONITORING SYSTEM (E.V.M.S.) (IF EQUIPPED)….6919
TRANSMISSION SHIFT CONTROL SYSTEM (MANUAL SHIFT)….6922
TRANSMISSION SELECTOR SWITCH….6925
DIODE MATRIX….6925
AUTO-LOCK-UP CONTROL CIRCUIT….6926
AUTO-LOCK-UP CONTROLLER….6926
AUTOMATIC SHIFT CONTROL SYSTEM (IF EQUIPPED)….6927
SHIFT INDICATOR….6938
82 TESTING AND ADJUSTING….6941
LOCATION DIAGRAM FOR CONNECTOR PINS….6942
CONNECTION TABLE FOR CONNECTOR PINS….6943
MS CONNECTORS….6945
TESTING OF SENSORS….6948
CHECKING PROCEDURE FOR AUTOMATIC SHIFT CONTROLLER (A.E.S.C.) WITH A-TYPE CHECKER….6952
CHECKING PROCEDURE FOR AUTOMATIC SHIFT CONTROLLER (A.E.S.C.) WITH B-TYPE CHECKER….6957
TROUBLESHOOTING….6962
TROUBLESHOOTING PROCEDURE….6962
CHECK BEFORE TROUBLESHOOTING….6963
TROUBLESHOOTING….6965
JUDGEMENT TABLE….6969
TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM FOR AUTOMATIC SHIFT TRANSMISSION (E-1.TO E-11.)….6972
E-1. ENGINE DOES NOT START….6973
E-2. ENGINE DOES NOT START….6982
E-3. MACHINE DOES NOT START….6984
E-4. ABNORMALITY IN OPERATION OF MACHINE WHEN STARTING….6996
E-5. GEAR SHIFT ABNORMALLY….6996
E-6. ABNORMALITY IN OPERATION OF MACHINE DURING TRAVEL….6997
E-7. TRANSMISSION SUDDENLY SHIFTS TO NEUTRAL WHEN TRAVELING….7005
E-8. LONG TIME TAKEN TO SHIFT UP….7015
E-9. SKIP SHIFT OPERATES ABNORMALLY….7022
E-10. KICK-DOWN OPERATES ABNORMALLY….7028
E-11. ABNORMALITY IN MACHINE OPERATION WHEN RETARDER IS OPERATED….7032
TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM FOR MANUAL SHIFT TRANSMISSION (E-1.TO E-7.)….7033
MANUAL SHIFT RELATED WIRING DIAGRAM….7034
CONNECTOR AND CONNECTOR POSITION….7035
E-1. ENGINE DOES NOT START….7039
E-2. ENGINE DOES NOT START….7040
E-3. MACHINE DOES NOT MOVE OR TRANSMISSION SUDDENLY RETURNS TO NEUTRAL….7042
E-4. ABNORMALITY GEAR SHIFTING WHEN MACHINE START….7043
E-5. GEAR SHIFTING IS ABNORMAL….7044
E-6. ACTION OF MACHINE ABNORMAL WHEN TRAVELING….7044
E-7. ACTION OF MACHINE ABNORMAL WHEN TRAVELING….7045
TROUBLESHOOTING TABLE (H-1. TO H-18.)….7046
H-1. MACHINE DOES NOT MOVE….7047
H-2. MACHINE DOES NOT TRAVEL SMOOTHLY….7049
H-3. CAN NOT DISENGAGE LOCK-UP CLUTCH (ENGINE STALL)….7049
H-4. LARGE SHOCK WHEN STARTING OR SHIFTING….7050
H-5. DOES NOT SHIFT UP OR SHIFT UP SPEED IS HIGH….7050
H-6. MACHINE TRAVELS SLOWLY OR LACKS POWER….7051
H-7. LARGE TIME LAG WHEN STARTING AND GEARSHIFTING….7056
H-8. TORQUE CONVERTER OIL TEMPERATURE IS HIGH….7057
H-9. TORQUE CONVERTER OIL PRESSURE IS LOW….7058
H-10. FRONT BRAKE IS INEFFECTIVE OR EFFECTIVE ONLY ONE SIDE….7059
H-11. REAR BRAKE IS INEFFECTIVE OR EFFECTIVE ONLY ONE SIDE….7060
H-12. STEERING WHEEL DRAGS….7061
H-13. STEERING WHEEL DOES NOT FUNCTION….7062
H-14. STEERING WHEEL VIBRATES….7062
H-15. HOIST CYLINDER LACKS LIFTING FORCE (LIFTING SPEED)….7063
H-16. HOIST CYLINDER DOES NOT WORK….7064
H-17. EXCESSIVE HYDRAULIC DRIFT OF THE DUMP BODY….7065
H-18. AIR PRESSURE DOES NOT RISE….7066
TROUBLESHOOTING CHART FOR STANDARD PANEL (M-1. TO M-5.)….7067
ELECTRICAL CIRCUIT DIAGRAM FOR STANDARD PANEL….7068
M-1. ENGINE WATER TEMPERATURE GAUGE DOES NOT DISPLAY OR DISPLAY ABNORMALLY….7069
M-2. TORQUE CONVERTER OIL TEMPERATURE GAUGE DOES NOT DISPLAY OR DISPLAYS ABNORMALLY….7070
M-3. RETARDER OIL TEMPERATURE DOES NOT DISPLAY OR DISPLAYS ABNORMALLY….7071
M-4. ENGINE OIL PRESSURE DOES NOT DISPLAY OR DISPLAYS ABNORMALLY….7072
M-5. SERVICE METER DOES NOT OPERATE….7073
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM (OPTION) (M-6. TO M-32.)….7074
HOW TO CONNECT CHECKER FOR EVMS….7074
TROUBLESHOOTING TABLE (EVMS)….7076
ELECTRICAL CIRCUIT DIAGRAM FOR EVMS….7078
M-6. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR….7079
M-7. ENGINE SPEED DISPLAY DOES NOT APPEAR….7081
M-8. MACHINE SPEED DISPLAY DOES NOT APPEAR….7083
M-9. RETARDER OIL TEMPERATURE GAUGE DOES NOT OPERATE….7085
M-10. SERVICE METER DOES NOT OPERATE….7087
M-11. ODOMETER DOES NOT OPERATE….7088
M-12. ENGINE OIL LEVEL IS CORRECT, BUT CHECK BEFORE STARTING ITEM LAMP FLASHES….7089
M-13. COOLANT LEVEL IS CORRECT, BUT CHECK BEFORE STARTING ITEM LAMP FLASHES….7091
M-14. FUEL LEVEL IS CORRECT, BUT WARNING ITEM LAMP FLASHES….7092
M-15. BATTERY CHARGING IS NORMAL, BUT WARNING ITEM LAMP FLASHES….7093
M-16. DUMP BODY IS NORMAL, BUT WARNING ITEM LAMP FLASHES….7094
M-17. RETARDER OIL TEMPERATURE IS NORMAL, BUT DANGER ITEM LAMP FLASHES….7095
M-18. ENGINE OIL PRESSURE IS NORMAL, BUT DANGER ITEM LAMP FLASHES….7095
M-19. COOLANT LEVEL IS CORRECT, BUT DANGER ITEM LAMP FLASHES….7097
M-20. AIR PRESSURE IS NORMAL, BUT DANGER ITEM LAMP FLASHES….7099
M-21. TORQUE CONVERTER OIL TEMPERATURE IS NORMAL, BUT DANGER ITEM LAMP FLASHES….7100
M-22. PARKING BRAKE IS NORMAL, BUT DANGER ITEM LAMP FLASHES….7101
M-23. ENGINE WATER TEMPERATURE IS NORMAL, BUT DANGER ITEM LAMP FLASHES….7102
M-24. WHEN RETARDER OIL TEMPERATURE GAUGE REACHES RED RANGE, WARNING LAMP FOR RETARDER OIL TEMPERATURE IN DANGER MONITOR DOES NOT FLASH; WARNING LAMP FLASHES WHEN RETARDER OIL TEMPERATURE GAUGE IS IN GREEN RANGE….7103
M-25. WHEN DANGER ITEM LAMP LIGHTS UP, THE BUZZER DOES NOT SOUND OR THE CENTRAL WARNING LAMP DOES NOT LIGHT UP….7104
M-26 NIGHT LIGHTING DOES NOT LIGHT UP….7106
M-27. PILOT LAMP FOR RETARDER DOES NOT LIGHT UP….7108
M-28. PILOT LAMP FOR TURN SIGNAL LAMP (LEFT) DOES NOT LIGHT UP….7110
M-29. PILOT LAMP FOR TURN SIGNAL LAMP (RIGHT) DOES NOT LIGHT UP….7112
M-30. PILOT LAMP FOR HIGH BEAM DOES NOT LIGHT UP….7114
M-31. PILOT LAMP FOR KICK-DOWN DOES NOT LIGHT UP….7116
M-32. PILOT LAMP FOR PARKING BRAKE DOES NOT LIGHT UP….7118
TROUBLESHOOTING OF SHIFT INDICATOR (S-1. TO S-7.)….7120
SHIFT INDICATOR RELATED CIRCUIT DIAGRAM….7121
SHIFT INDICATOR RELATED CONNECTORS….7122
S-1 NO DISPLAY IS GIVEN FOR ANY GEAR SPEED….7123
S-2 N IS DISPLAYED FOR EVERY GEAR SPEED….7124
S-3 E IS DISPLAYED FOR SOME GEAR SPEEDS ONLY….7125
S-4 SPEED SENSOR SIGNAL DISPLAY LED DOES NOT LIGHT UP….7126
S-5 LOCK-UP OPERATION DISPLAY LED DOES NOT LIGHT UP….7126
S-6 DISPLAY IS GIVEN BUT IT IS NOT CORRECT….7127
S-7 PART OF GEAR SPEED DISPLAY LED DOES NOT LIGHT UP, SO INCOMPLETE NUMBER OR LETTER IS DISPLAYED….7128
SEBMW00401 – Dump Truck HD325-6, HD405-6, HD465-5, HD605-5, HD785-5 Shop Manual….7129
COVER….7129
CONTENTS….7130
10 STRUCTURE AND FUNCTION….7131
AUTOMATIC SHIFT CONTROL SYSTEM….7132
SYSTEM DIAGRAM….7132
ELECTRICAL CIRCUIT DIAGRAM ….7134
TRANSMISSION CONTROLLER….7135
CONNECTOR SIGNALS….7136
SELF-DIAGNOSTIC FUNCTION….7136
SHIFT LEVER POSITION AND AUTOMATIC GEAR SHIFTING RANGES….7137
AUTOMATIC GEAR SHIFTING LINE GRAPH….7138
SHIFT LEVER SWITCH….7140
SENSORS,SWITCHES….7141
ENGINE SPEED SENSOR….7141
TRANSMISSION SPEED SENSOR….7141
TRANSMISSION OIL TEMPERATURE SENSOR….7141
FILL SWITCH….7142
ACCELERATOR SENSOR….7143
SHIFT LIMIT SWITCH….7144
MODE SELECTOR SWITCH….7144
20 TESTING AND ADJUSTING….7145
TESTING AND ADJUSTING PARKING BRAKE PARFORMANCE….7146
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM….7147
TROUBLESHOOTING….7153
SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL AND CONTROLLERS….7154
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ELECTRONIC GOVERNOR SPECIFICATION G MODE) HD465-5:4626 AND UP,HD605-5:1013 AND UP….7161
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE….7162
JUDGMENT TABLE FOR TRANSMISSION CONTROLLER,TRANSMISSION RELATED PARTS….7170
G-1 [0.0] (OFF) OR C010 [E. <–>1.0] ABNORMALITY IN POWER SOURCE….7173
G-2 C011 [E. <–>1.1] ABNORMALITY IN CONTROLLER….7173
G-3 C012 [E. <–>1.2] ABNORMALITY IN RACK SENSOR SYSTEM….7174
G-4 C014 [E. <–>1.4] ABNORMALITY IN GOVERNOR SOLENOID SYSTEM….7175
G-5 C016 [E. <–>1.6] ABNORMALITY IN GOVERNOR CUT RELAY SYSTEM….7176
G-6 C018 [E. <–>1.8] ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM….7177
G-7 C019 [E. <–>1.9] ABNORMALITY IN GOVERNOR SERVO SYSTEM BANK….7178
G-8 C01b [E. <–>1.b] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM A….7179
G-9 C01C [E. <–>1.C] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM B….7180
G-10 C01d [E. <–>1.d] ABNORMALITY IN PRE-STROKE SOLENOID SYSTEM….7181
G-11 C021 [E. <–>2.1] MISTAKEN CONNECTION OF CONNECTOR….7182
G-12 C022 [E. <–>2.2] ENGINE OVERRUN….7183
G-13 C023 [E. <–>2.3] ENGINE OVERHEATING….7183
G-14 C024 [E. <–>2.4] DROP IN ENGING OIL PRESSURE….7183
G-15 C031 [E. <–>3.1] ABNORMALITY IN ACCELERATION SENSOR SYSTEM….7184
G-16 C034 [E. <–>3.4] ABNORMALITY IN ENGINE WATER TEMPERATURE SYSTEM….7187
G-17 C036 [E. <–>3.6] ABNORMALITY IN ENGINE OIL PRESSURE SENSOR….7188
G-18 C055 [E. <–>5.5] ABNORMALITY IN NETWORK….7189
G-19 C056 [E. <–>5.6] ABNORMALITY IN SOLENOID POWER SOURCE SYSTEM RIGHT….7190
G-20 C058 [E. <–>5.8] ABNORMALITY IN BACKUP POWER SOURCE SYSTEM….7191
G-21 C059 [E. <–>5.9] ABNORMALITY IN BACKUP POWER SOURCE SYSTEM….7192
G-22 C0C2 [E. <–>C.2] DEFECTIVE MODEL SELECTION DATA….7193
G-23 C0C5 [E. <–>C.5] ABNORMALITY IN IDLING VALIDATION….7194
G-24 ENGINE DOES NOT START….7196
G-25 DEFECTIVE ACTUATION OF APS….7199
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM(G MODE) HD325-6:SERIAL NO.6001 AND UP,HD405-6:SERIAL NO.2001 AND UP….7207
ERROR CODE DISPLAYS AND POINTS TO REMEMBER WHEN TROUBLESHOOTING….7209
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED….7212
ENGINE CONTROLLER RELATED JUDGEMENT TABLE….7220
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE CONTROLLER SYSTEM….7222
G-1 ERROR CODE [C01b][ABNORMALITY IN NE REVOLUTION SENSOR SYSTEM]….7226
G-2 ERROR CODE [C01C][ABNORMALITY IN G REVOLUTION SENSOR SYSTEM]….7227
G-3 ERROR CODE [C020][ABNORMALITY IN MODEL SELECTION SYSTEM]….7228
G-4 ERROR CODE [C022][OVERRUN]….7229
G-5 ERROR CODE [C023][OVERHEAT]….7229
G-6 ERROR CODE [C024][DROP IN OIL PRESSURE]….7230
G-7 ERROR CODE [C030][ABNORMALITY IN IDLING VALIDATION SIGNAL SYSTEM]….7231
G-8 ERROR CODE [C031][ABNORMALITY IN ACCELERATOR SENSOR SYSTEM]….7233
G-9 ERROR CODE [C034][ABNORMALITY IN HIGH WATER TEMPERATURE SENSOR SYSTEM]….7235
G-10 ERROR CODE [C036][ABNORMALITY IN OIL PRESSURE SWITCH SYSTEM]….7236
G-11 ERROR CODE [C03C][ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM]….7238
G-12 ERROR CODE [C03d][ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM]….7239
G-13 ERROR CODE [C050][ABNORMALITY IN PREHEATING RELAY CONNECTING POINT SYSTEM]….7240
G-14 ERROR CODE [C051][ABNORMALITY IN PREHEATING RELAY COIL SYSTEM]….7241
G-15 ERROR CODE [C054][SHORT CIRCUIT IN STARTING SWITCH C SYSTEM]….7242
G-16 ERROR CODE [C055][ABNORMALITY IN NETWORK]….7243
G-17 ERROR CODE [C056][POWER SOURCE SYSTEM ABNORMALITY 1]….7244
G-18 ERROR CODE [C057][POWER SOURCE SYSTEM ABNORMALITY 2]….7246
G-19 ERROR CODE [C05A][ABNORMALITY IN FUEL INJECTION QUANTITY CONTROL SWITCH SIGNAL]….7248
G-20 ERROR CODE [C06A][ABNORMALITY IN HIGH ENGINE WATER TEMPERATURE SENSOR SYSTEM]….7249
G-21 ERROR CODE [C070][EXCESS CURRENT IN FUEL SUPPLY PUMP PCV1 SYSTEM]….7250
G-22 ERROR CODE [C071][EXCESS CURRENT IN FUEL SUPPLY PUMP PCV2 SYSTEM]….7251
G-23 ERROR CODE [C074][DISCONNECTION IN FUEL SUPPLY PUMP PCV1 SYSTEM]….7252
G-24 ERROR CODE [C075][DISCONNECTION IN FUEL SUPPLY PUMP PCV2 SYSTEM]….7253
G-25 ERROR CODE [C077][ABNORMALITY IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM]….7254
G-26 ERROR CODE [C079][COMMON RAIL HIGH FUEL PRESSURE ABNORMALITY 1],ERROR CODE [C07A][COMMON RAIL HIGH FUEL PRESSURE ABNORMALITY 2]….7255
G-27 ERROR CODE [C07b][FUEL SUPPLY PUMP NON-FORCE FEED 1],ERROR CODE [C07C][FUEL SUPPLY PUMP NON-FORCE FEED 2]….7256
G-28 ERROR CODE [C07d][ABNORMALITY IN COMMON RAIL FUEL PRESSURE]….7258
G-29 ERROR CODE [C080][DEFECTIVE CONTROLLER]….7258
G-30 ERROR CODE [C081][DISCONNECTION IN NO.1 FUEL INJECTOR <A> SYSTEM] ….7259
G-31 ERROR CODE [C082][DISCONNECTION IN NO.2 FUEL INJECTOR <E> SYSTEM]….7260
G-32 ERROR CODE [C083][DISCONNECTION IN NO.3 FUEL INJECTOR <C> SYSTEM]….7261
G-33 ERROR CODE [C084][DISCONNECTION IN NO.4 FUEL INJECTOR <F> SYSTEM]….7262
G-34 ERROR CODE [C085][DISCONNECTION IN NO.5 FUEL INJECTOR <B> SYSTEM]….7263
G-35 ERROR CODE [C086][DISCONNECTION IN NO.6 FUEL INJECTOR <D> SYSTEM]….7264
G-36 ERROR CODE [C08A][SHORT CIRCUIT IN NO.1<A>,NO.2<E>,NO.3<C> FUEL INJECTOR SYSTEM]….7265
G-37 ERROR CODE [C08b][SHORT CIRCUIT IN NO.4<F>,NO.5<B>,NO.6<D> FUEL INJECTOR SYSTEM]….7268
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM(A MODE) HD325-6:SERIAL NO.5680-6000,HD405-6:SERIAL NO.1055-2000,HD465-5:SEIRAL NO.4625 AND UP,HD605-5:SEIRAL NO.1013 AND UP,HD785-5:SEIRAL NO.4001 AND UP….7271
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM….7274
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE….7276
JUDGMENT TABLE FOR TRANSMISSION CONTROLLER,TRANSMISSION RELATED PARTS….7296
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM….7298
A-1 ABNORMALITY IN POWER SOURCE….7299
a) [v.v][OFF]CONTROLLER SELF-DIAGNOSTIC DISPLAY LED DOES NOT LIGHT UP….7299
b) bOO1 [E. <–>0.1,E.C<–>0.1] DROP IN VOLTAGE OF CONTROLLER POWER SOURCE IS DISPLAYED….7300
c) bOdA [E. <–>d.A,E.C<–>d.A] DROP IN VOLTAGE OF BATTERY DIRECT POWER SOURCE IS DISPLAYED….7301
d) bOdb [E. <–>d.b,E.C<–>d.b] DROP IN VOLTAGE OF MAIN POWER SOURCE IS DISPLAYED….7302
e) bOO2 [E. <–>0.2,E.C<–>0.2] ABNORMALITAY IN TRANSMISSION CUT RELAY POWER SOURCE IS DISPLAYED….7303
A-2 bOO3 [E. <–>0.3,E.C<–>0.3] ABNORMALITY IN NEUTRAL SAFETY SYSTEM IS DISPLAYED….7304
A-3 bOO5 [E. <–>0.5,E.C<–>0.5] DOUBLE ENGAGEMENT FOR CLUTCH IS DISPLAYED….7305
A-5 bOO8 [E. <–>0.8,E.C<–>0.8] ABNORMALITY IN REAR BRAKE SOLENOID SYSTEM IS DISPLAYED….7306
A-6 bOO9 [E. <–>0.9,E.C<–>0.9] ABNORMALITY IN EXHAUST BRAKE SOLENOID SYSTEM IS DISPLAYED….7307
A-7….7308
a) bOC4 [E. <–>C.4,E.C<–>C.4] SHORT CIRCUIT WITH GROUND IN BCV REAR SOLENOID IS DISPLAYED….7308
b) bOC6 [E. <–>C.6,E.C<–>C.6] SHORT CIRCUIT IN BCV REAR SOLENOID IS DISPLAYED….7309
c) bOC8 [E. <–>C.8,E.C<–>C.8] DISCONNECTION IN BCV REAR SOLENOID IS DISPLAYED….7310
A-8 ABNORMALITY IN SPEED SENSOR SYSTEM….7311
a) b010 [E. <–>1.0,E.C<–>1.0] OR b060 [E. <–>6.0,E.C<–>6.0] DISCONNECTION IN ENGINE SPEED SENSOR [B] SYSTEM IS DISPLAYED OR FAILURE IN ENGINE SPEED SENSOR IS DISPLAYED….7311
b) b011 [E. <–>1.1,E.C<–>1.1] OR b061 [E. <–>6.1,E.C<–>6.1] DISCONNECTION IN INPUT SHAFT SPEED SENSOR SYSTEM IS DISPLAYED OR FAILURE OF INPUT SHAFT SPEED SENSOR IS DISPLAYED….7312
c) b012 [E. <–>1.2,E.C<–>1.2] OR b062 [E. <–>6.2,E.C<–>6.2] DISCONNECTION IN INTERMEDIATE SHAFT SPEED SENSOR SYSTEM IS DISPLAYED OR FAILURE OF INTERMEDIATE SHAFT SPEED SENSOR IS DISPLAYED….7313
d) b013 [E. <–>1.3,E.C<–>1.3] OR b063 [E. <–>6.3,E.C<–>6.3] DISCONNECTION IN TRAVEL SPEED SENSOR(TRANSMISSION OUTPUT SHAFT SPEED SENSOR)SYSTEM IS DISPLAYED OR FAILURE OF OUTPUT SHAFT SPEED SENSOR IS DISPLAYED….7314
A-9 SPEED SENSOR SYSTEM,CLUTCH SLIPPING….7315
a) b022 [E. <–>2.2,E.C<–>2.2] OR b023 [E. <–>2.3,E.C<–>2.3] INPUT SHAFT SPEED SENSOR OR H,L CLUTCH SYSTEM IS DISPLAYED….7315
b) b024 [E. <–>2.4,E.C<–>2.4] – b028 [E. <–>2.8,E.C<–>2.8] TRAVEL SPEED SENSOR SYSTEM OR SPEED CLUTCH(1,2,3,4,R)SYSTEM IS DISPLAYED….7316
A-10 ABNORMALITY IN MODEL SELECTION SYSTEM….7317
a) b014 [E. <–>1.4,E.C<–>1.4] ABNORMALITY IN MODEL SELECTION(WIRING HARNESS)IS DISPLAYED….7317
b) b0A1 [E. <–>A.1,E.C<–>A.1] ABNORMALITY IN MODEL SELECTION(ROTARY SWITCH)IS DISPLAYED….7318
A-11 ABNORMALITY IN SHIFT LEVER SYSTEM….7319
a) b007 [E. <–>0.7,E.C<–>0.7] SHORT CIRCUIT IN SHIFT LEVER ASSEMBLY POWER SOURCE IS DISPLAYED….7319
b) b015 [E. <–>1.5,E.C<–>1.5] SHIFT LEVER POSITION SIGNAL INPUT FOR 2 OR MORE SYSTEM IS DISPLAYED….7320
c) b016 [E. <–>1.6,E.C<–>1.6] SHIFT LEVER POSITION SIGNAL IS NOT INPUT….7322
A-12 b017 [E. <–>1.7,E.C<–>1.7] ABNORMALITY IN ACCELERATOR SIGNAL IS DISPLAYED….7324
A-13 b019 [E. <–>1.9,E.C<–>1.9] ABNORMALITY IN TRANSMISSION OIL TEMPERATURE SENSOR IS DISPLAYED….7325
A-14 ABNORMALITY IN PRESSURE CONTROL VALVE SYSTEM….7326
a) b032 [E. <–>3.2,E.C<–>3.2] – b038 [E. <–>3.8,E.C<–>3.8] FILL SIGNAL(CLUTCH ON)IS DISPLAYED REGARDLESS OF COMMAND….7326
b) b042 [E. <–>4.2,E.C<–>4.2] – b048 [E. <–>4.8,E.C<–>4.8] FILL SIGNAL IS NOT INPUT AND CLUTCH SLIPPING IS DISPLAYED….7328
b-1) INSPECTING FILL SIGNAL SYSTEM….7328
b-2) b042 [E. <–>4.2,E.C<–>4.2] ・ b043 [E. <–>4.3,E.C<–>4.3] INSPECTING TRANSMISSION INPUT SHAFT SPEED SIGNAL SYSTEM,H,L CLUTCH SYSTEM(CHECK CLUTCH SLIP)….7329
b-3) b044 [E. <–>4.4,E.C<–>4.4] ・ b048 [E. <–>4.8,E.C<–>4.8] INSPECTING TRANSMISSION OUTPUT SHAFT SPEED SIGNAL SYSTEM,1-4,R CLUTCH SYSTEM(CHECK CLUTCH SLIP)….7329
A-15 b052 [E. <–>5.2,E.C<–>5.2] – b058 [E. <–>5.8,E.C<–>5.8] WHEN FILL SIGNAL IS NOT INPUT(FLOW DETECTOR VALVE SYSTEM)….7330
A-16 b071 [E. <–>7.1,E.C<–>7.1] – b078 [E. <–>7.8,E.C<–>7.8] SHORT CIRCUIT IN PRESSURE CONTROL VALVE SOLENOID SYSTEM IS DISPLAYED….7331
A-16 b091 [E. <–>9.1,E.C<–>9.1] – b098 [E. <–>9.8,E.C<–>9.8] DISCONNECTION IN PRESSURE CONTROL VALVE SOLENOID SYSTEM IS DISPLAYED….7331
A-17 ABNORMALITY IN SENSOR SYSTEM….7333
a) b0A2 [E. <–>A.2,E.C<–>A.2] ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM IS DISPLAYED….7333
b) b0A3 [E. <–>A.3,E.C<–>A.3] ABNORMALITY IN FUEL LEVEL SENSOR SYSTEM IS DISPLAYED….7334
c) b0b3 [E. <–>b.3,E.C<–>b.3] ABNORMALITY IN AIR PRESSURE SENSOR SYSTEM IS DISPLAYED….7335
d) b0b4 [E. <–>b.4,E.C<–>b.4] ABNORMALITY IN RETARDER BRAKE OIL TEMPERATURE SENSOR IS DISPLAYED….7336
A-18 WARNING DISPLAY….7337
a) b0d1 [E. <–>d.1,E.C<–>d.1] TRANSMISSION FILTER CLOGGED WARNING IS DISPLAYED….7337
b) b0d5 [E. <–>d.5,E.C<–>d.5] TILT WARNING IS DISPLAYED….7338
c) b0d6 [E. <–>d.6,E.C<–>d.6] DROP IN RADIATOR WATER LEVEL WARNING IS DISPLAYED….7339
d) b0d7 [E. <–>d.7,E.C<–>d.7] BATTERY CHARGE LEVEL WARNING IS DISPLAYED….7340
e) b0E5 [E. <–>E.5,E.C<–>E.5] STEERING OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED….7341
f) b0F6 [E. <–>F.6,E.C<–>F.6] REAR BRAKE OIL PRESSURE WARNING IS DISPLAYED….7342
A-19 b0C1 [E. <–>C.1,E.C<–>C.1] ABNORMALITY IN CONNECTOR CONNECTION IS DISPLAYED….7343
A-20….7344
a) b0d2 [E. <–>d.2,E.C<–>d.2] TORQUE CONVERTER OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED….7344
b) b0E9 [E. <–>E.9,E.C<–>E.9] AIR PRESSURE DROP WARNING IS DISPLAYED….7344
c) b0F3 [E. <–>F.3,E.C<–>F.3] RETARDER BRAKE OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED….7344
d) b0d8 [E. <–>d.8,E.C<–>d.8] ENGINE OVERRUN ACTUATED IS DISPLAYED….7345
e) b0d9 [E. <–>d.9,E.C<–>d.9] ENGINE OVERSHOOT ACTUATED IS DISPLAYED….7345
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM(A MODE) HD325-6:SERIAL NO.6001 AND UP,HD405-6:SERIAL NO.2001 AND UP….7346
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM….7349
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE….7351
JUDGMENT TABLE FOR TRANSMISSION CONTROLLER,TRANSMISSION RELATED PARTS….7371
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM….7373
A-1 ABNORMALITY IN POWER SOURCE….7374
a) [v.v][OFF]CONTROLLER SELF-DIAGNOSTIC DISPLAY LED DOES NOT LIGHT UP….7374
b) bOO1 [E. <–>0.1,E.C<–>0.1] DROP IN VOLTAGE OF CONTROLLER POWER SOURCE IS DISPLAYED….7375
c) bOdA [E. <–>d.A,E.C<–>d.A] DROP IN VOLTAGE OF BATTERY DIRECT POWER SOURCE IS DISPLAYED….7376
d) bOdb [E. <–>d.b,E.C<–>d.b] DROP IN VOLTAGE OF MAIN POWER SOURCE IS DISPLAYED….7377
e) bOO2 [E. <–>0.2,E.C<–>0.2] ABNORMALITAY IN TRANSMISSION CUT RELAY POWER SOURCE IS DISPLAYED….7378
A-2 bOO3 [E. <–>0.3,E.C<–>0.3] ABNORMALITY IN NEUTRAL SAFETY SYSTEM IS DISPLAYED….7379
A-3 bOO5 [E. <–>0.5,E.C<–>0.5] DOUBLE ENGAGEMENT FOR CLUTCH IS DISPLAYED….7380
A-5 bOO8 [E. <–>0.8,E.C<–>0.8] ABNORMALITY IN REAR BRAKE SOLENOID SYSTEM IS DISPLAYED….7381
A-6 bOO9 [E. <–>0.9,E.C<–>0.9] ABNORMALITY IN EXHAUST BRAKE SOLENOID SYSTEM IS DISPLAYED….7382
A-8 ABNORMALITY IN SPEED SENSOR SYSTEM….7383
a) b010 [E. <–>1.0,E.C<–>1.0] OR b060 [E. <–>6.0,E.C<–>6.0] DISCONNECTION IN ENGINE SPEED SENSOR [B] SYSTEM IS DISPLAYED OR FAILURE IN ENGINE SPEED SENSOR IS DISPLAYED….7383
b) b011 [E. <–>1.1,E.C<–>1.1] OR b061 [E. <–>6.1,E.C<–>6.1] DISCONNECTION IN INPUT SHAFT SPEED SENSOR SYSTEM IS DISPLAYED OR FAILURE OF INPUT SHAFT SPEED SENSOR IS DISPLAYED….7384
c) b012 [E. <–>1.2,E.C<–>1.2] OR b062 [E. <–>6.2,E.C<–>6.2] DISCONNECTION IN INTERMEDIATE SHAFT SPEED SENSOR SYSTEM IS DISPLAYED OR FAILURE OF INTERMEDIATE SHAFT SPEED SENSOR IS DISPLAYED….7385
d) b013 [E. <–>1.3,E.C<–>1.3] OR b063 [E. <–>6.3,E.C<–>6.3] DISCONNECTION IN TRAVEL SPEED SENSOR(TRANSMISSION OUTPUT SHAFT SPEED SENSOR)SYSTEM IS DISPLAYED OR FAILURE OF OUTPUT SHAFT SPEED SENSOR IS DISPLAYED….7386
A-9 SPEED SENSOR SYSTEM,CLUTCH SLIPPING….7387
a) b022 [E. <–>2.2,E.C<–>2.2] OR b023 [E. <–>2.3,E.C<–>2.3] INPUT SHAFT SPEED SENSOR OR H,L CLUTCH SYSTEM IS DISPLAYED….7387
b) b024 [E. <–>2.4,E.C<–>2.4] – b028 [E. <–>2.8,E.C<–>2.8] TRAVEL SPEED SENSOR SYSTEM OR SPEED CLUTCH(1,2,3,4,R)SYSTEM IS DISPLAYED….7388
A-10 ABNORMALITY IN MODEL SELECTION SYSTEM….7389
a) b014 [E. <–>1.4,E.C<–>1.4] ABNORMALITY IN MODEL SELECTION(WIRING HARNESS)IS DISPLAYED….7389
b) b0A1 [E. <–>A.1,E.C<–>A.1] ABNORMALITY IN MODEL SELECTION(ROTARY SWITCH)IS DISPLAYED….7390
A-11 ABNORMALITY IN SHIFT LEVER SYSTEM….7391
a) b007 [E. <–>0.7,E.C<–>0.7] SHORT CIRCUIT IN SHIFT LEVER ASSEMBLY POWER SOURCE IS DISPLAYED….7391
b) b015 [E. <–>1.5,E.C<–>1.5] SHIFT LEVER POSITION SIGNAL INPUT FOR 2 OR MORE SYSTEM IS DISPLAYED….7392
c) b016 [E. <–>1.6,E.C<–>1.6] SHIFT LEVER POSITION SIGNAL IS NOT INPUT….7394
A-12 b017 [E. <–>1.7,E.C<–>1.7] ABNORMALITY IN ACCELERATOR SIGNAL IS DISPLAYED….7396
A-13 b019 [E. <–>1.9,E.C<–>1.9] ABNORMALITY IN TRANSMISSION OIL TEMPERATURE SENSOR IS DISPLAYED….7397
A-14 ABNORMALITY IN PRESSURE CONTROL VALVE SYSTEM….7398
a) b032 [E. <–>3.2,E.C<–>3.2] – b038 [E. <–>3.8,E.C<–>3.8] FILL SIGNAL(CLUTCH ON)IS DISPLAYED REGARDLESS OF COMMAND….7398
b) b042 [E. <–>4.2,E.C<–>4.2] – b048 [E. <–>4.8,E.C<–>4.8] FILL SIGNAL IS NOT INPUT AND CLUTCH SLIPPING IS DISPLAYED….7400
b-1) INSPECTING FILL SIGNAL SYSTEM….7400
b-2) b042 [E. <–>4.2,E.C<–>4.2] ・ b043 [E. <–>4.3,E.C<–>4.3] INSPECTING TRANSMISSION INPUT SHAFT SPEED SIGNAL SYSTEM,H,L CLUTCH SYSTEM(CHECK CLUTCH SLIP)….7401
b-3) b044 [E. <–>4.4,E.C<–>4.4] ・ b048 [E. <–>4.8,E.C<–>4.8] INSPECTING TRANSMISSION OUTPUT SHAFT SPEED SIGNAL SYSTEM,1-4,R CLUTCH SYSTEM(CHECK CLUTCH SLIP)….7401
A-15 b052 [E. <–>5.2,E.C<–>5.2] – b058 [E. <–>5.8,E.C<–>5.8] WHEN FILL SIGNAL IS NOT INPUT(FLOW DETECTOR VALVE SYSTEM)….7402
A-16 b071 [E. <–>7.1,E.C<–>7.1] – b078 [E. <–>7.8,E.C<–>7.8] SHORT CIRCUIT IN PRESSURE CONTROL VALVE SOLENOID SYSTEM IS DISPLAYED….7403
A-16 b091 [E. <–>9.1,E.C<–>9.1] – b098 [E. <–>9.8,E.C<–>9.8] DISCONNECTION IN PRESSURE CONTROL VALVE SOLENOID SYSTEM IS DISPLAYED….7403
A-17 ABNORMALITY IN SENSOR SYSTEM….7405
a) b0A2 [E. <–>A.2,E.C<–>A.2] ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM IS DISPLAYED….7405
b) b0A3 [E. <–>A.3,E.C<–>A.3] ABNORMALITY IN FUEL LEVEL SENSOR SYSTEM IS DISPLAYED….7406
c) b0b3 [E. <–>b.3,E.C<–>b.3] ABNORMALITY IN AIR PRESSURE SENSOR SYSTEM IS DISPLAYED….7407
d) b0b4 [E. <–>b.4,E.C<–>b.4] ABNORMALITY IN RETARDER BRAKE OIL TEMPERATURE SENSOR IS DISPLAYED….7408
A-18 WARNING DISPLAY….7409
a) b0d1 [E. <–>d.1,E.C<–>d.1] TRANSMISSION FILTER CLOGGED WARNING IS DISPLAYED….7409
b) b0d5 [E. <–>d.5,E.C<–>d.5] TILT WARNING IS DISPLAYED….7410
c) b0d6 [E. <–>d.6,E.C<–>d.6] DROP IN RADIATOR WATER LEVEL WARNING IS DISPLAYED….7411
d) b0d7 [E. <–>d.7,E.C<–>d.7] BATTERY CHARGE LEVEL WARNING IS DISPLAYED….7412
f) b0F6 [E. <–>F.6,E.C<–>F.6] REAR BRAKE OIL PRESSURE WARNING IS DISPLAYED….7413
A-19 b0C1 [E. <–>C.1,E.C<–>C.1] ABNORMALITY IN CONNECTOR CONNECTION IS DISPLAYED….7414
A-20….7415
a) b0d2 [E. <–>d.2,E.C<–>d.2] TORQUE CONVERTER OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED….7415
b) b0E9 [E. <–>E.9,E.C<–>E.9] AIR PRESSURE DROP WARNING IS DISPLAYED….7415
c) b0F3 [E. <–>F.3,E.C<–>F.3] RETARDER BRAKE OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED….7415
d) b0d8 [E. <–>d.8,E.C<–>d.8] ENGINE OVERRUN ACTUATED IS DISPLAYED….7416
e) b0d9 [E. <–>d.9,E.C<–>d.9] ENGINE OVERSHOOT ACTUATED IS DISPLAYED….7416
90 OTHERS….7417
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM(HD325-6:5680～6000,HD405-6:1055～2000)….7418
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM(HD465-5:4626 AND UP,HD605-6:1013 AND UP)….7419
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM(HD785-5:4001 AND UP)….7420
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM(HD325-6:6001 AND UP,HD405-6:2001 AND UP)….7421
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM WITH ARSC [AUTOMATIC RETARDER SPEED CONTROLLER SYSTEM](HD325-6:6001 AND UP,HD405-6:2001 AND UP)….7422
SEN00486-13 – Dump Truck HD325-7, HD405-7 Shop Manual….7423
COVER….7423
00 Index and foreword….0
Index….7424
Composition of shop manual….7425
Table of contents….7427
Foreword and general information….7440
Safety notice….7441
How to read the shop manual….7446
Explanation of terms for maintenance standard….7448
Handling of electric equipment and hydraulic component….7450
How to read electric wire code….7462
Precautions when carrying out operation….7465
Method of disassembling and connecting push-pull type coupler….7468
Standard tightening torque table….7471
Conversion table….7475
01 Specification….0
Specification and technical data….7482
Specification drawing….7483
Specifications….7486
Weight table….7498
Fuel, coolant and lubricants….7499
10 Structure, function and maintenance standard….0
Engine and cooling system….7502
Radiator, oil cooler, aftercooler….7503
Output shaft….7505
Power train, Part 1….7508
Power train skeleton….7509
Drive shaft….7511
Torque converter and transmission hydraulic piping….7512
Power train charge pump….7513
Retarder cooling pump….7514
Torque converter….7515
Torque converter valve….7521
Transmission….7522
Transmission control valve….7538
ECMV….7539
Power train, Part 2….7548
Axle….7549
Differential….7551
Final drive….7553
Wheel….7555
Steering system….7558
Steering column….7559
Steering linkage….7560
Brake system….7564
Brake piping….7565
Brake valve….7567
Secondary brake valve….7570
Relay valve….7571
Front brake cut valve….7572
Accumulator charge valve….7573
Accumulator….7579
Slack adjuster….7581
Brake….7583
Proportional reducing valve….7588
Parking brake….7589
Parking brake solenoid….7591
Hand brake (retarder)….7592
Undercarriage and frame….7594
Suspension….7595
Suspension cylinder….7597
Rear axle support….7605
Hydraulic system….7608
Steering, hoist oil pressure piping diagram….7609
Dump body control….7611
Hydraulic tank….7613
Steering valve….7615
Cross-over relief valve….7619
Steering control valve….7620
Hoist valve….7629
Dump control valve (EPC valve)….7635
Steering cylinder….7639
Hoist cylinder….7640
Work equipment and steering pump….7641
Cab and its attachments….7644
ROPS cab….7645
Air conditioner….7646
Rear view monitor….7652
Electrical system, Part 1….7656
Machine monitor system….7657
Electrical system, Part 2….7686
Automatic shift control system….7687
Transmission controller….7691
External power supply heater….7705
Auto emergency steering system….7707
Retarder control system….7711
Battery disconnector switch….7723
Dump control lever….7725
Auto suspension system….7727
Electrical system, Part 3….7734
Payload meter II (card type)….7735
Electrical system, Part 4….7766
Sensors, switches….7767
KOMTRAX terminal system (If equipped)….7781
20 Standard value table….0
Standard service value table….7786
Standard value table for engine….7787
Standard value table for machine….7789
30 Testing and adjusting….0
Testing and adjusting, Part 1….7796
Tools for testing, adjusting, and troubleshooting….7798
Testing engine speed….7804
Testing intake air pressure (boost pressure)….7805
Testing exhaust temperature….7806
Testing exhaust gas color….7808
Adjusting valve clearance….7809
Testing compression pressure….7811
Testing blow-by pressure….7813
Testing engine oil pressure….7814
Testing EGR valve and bypass valve drive oil pressure….7815
Handling of fuel system devices….7816
Releasing residual pressure from fuel system….7816
Testing fuel pressure….7817
Testing fuel return rate and leakage….7818
Bleeding air from fuel circuit….7821
Testing the fuel circuit for leakage….7823
Testing and adjusting alternator belt tension….7824
Testing and adjusting fan belt tension….7825
Testing and adjusting air conditioner compressor belt tension….7826
Testing and adjusting, Part 2….7828
Testing torque converter stall speed….7830
Testing power train oil pressure….7831
Adjusting transmission speed sensor….7838
Testing brake oil pressure….7839
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas….7841
Testing brake performance….7846
Adjusting parking brake….7848
Bleeding air from brake circuit….7849
Testing wear of rear brake disc….7850
Testing wear of front brake pad….7851
Method for emergency release of parking brake….7852
Testing and adjusting front suspension cylinder….7853
Testing and adjusting inverted type rear suspension cylinder….7858
Testing and adjusting front suspension cylinder (mode selector hydraulic cylnder)….7862
Testing and adjusting hydraulic pressure in steering, hoist circuit….7863
Testing and adjusting dump EPC circuit oil pressure….7866
Air bleeding from steering cylinder….7867
Procedure for raising body in emergency….7868
Adjusting body positioner sensor….7869
Handling of high voltage circuit of engine controller….7870
Adjusting transmission controller….7870
Method for emergency escape at electrical system failure….7871
Testing and adjusting, Part 3….7876
Setting and adjusting of devices….7877
Special functions of machine monitor (EMMS)….7889
Testing and adjusting, Part 4….7948
How to start operation of KOMTRAX terminal….7949
Lamp display of KOMTRAX terminal….7954
Pm Clinic check sheet….7957
Setting of card-type payload meter (PLM-II ) after installation or replacement….7959
40 Troubleshooting….0
General information on troubleshooting….7966
Points to remember when troubleshooting….7967
Sequence of events in troubleshooting….7968
Checks before troubleshooting….7969
Classification and procedures of troubleshooting….7970
Connection table for connector pin numbers….7971
T- branch box and T- branch adapter table….8007
Troubleshooting by failure code, General….8012
Failure codes table….8013
Before troubleshooting by failure codes….8022
Contents of troubleshooting table….8027
Troubleshooting by failure code, Part 1….8030
Failure code [1500L0] (Dual engagement)….8032
Failure code [15B0NX] (Transmission oil filter: Clogging)….8033
Failure code [15F0KM] (R → F shifting abuse 1: Mistake in operation)….8035
Failure code [15F0MB] (R → F shifting abuse 2: Mistake in operation)….8035
Failure code [15F7KM] (Forward clutch disk abuse: Mistake in operation or setting)….8036
Failure code [15G0MW] (R clutch: Slipping)….8037
Failure code [15G7KM] (Reverse clutch disk abuse: Mistake in operation or setting)….8039
Failure code [15H0MW] (Hi clutch: Slipping)….8041
Failure code [15J0MW] ( Lo clutch: Slipping)….8043
Failure code [15K0MW] (1st clutch: Slipping)….8045
Failure code [15L0MW] (2nd clutch: Slipping)….8047
Failure code [15M0MW] (3rd clutch: Slipping)….8049
Failure code [15N0MW] (4th clutch: Slipping)….8051
Failure code [15SBL1] (R clutch solenoid: Fill signal is ON when command current is OFF)….8053
Failure code [15SBMA] (R clutch solenoid: Malfunction)….8057
Failure code [15SCL1] (Hi clutch solenoid: Fill signal is ON when command current is OFF)….8059
Failure code [15SCMA] (Hi clutch solenoid: Malfunction)….8063
Failure code [15SDL1] (Lo clutch solenoid: Fill signal is ON when command current is OFF)….8065
Failure code [15SDMA] (Lo clutch solenoid: Malfunction)….8069
Failure code [15SEL1] (1st clutch solenoid: Fill signal is ON when command current is OFF)….8071
Failure code [15SEMA] (1st clutch solenoid: Malfunction)….8075
Failure code [15SFL1] (2nd clutch solenoid: Fill signal is ON when command current is OFF)….8077
Failure code [15SFMA] (2nd clutch solenoid: Malfunction)….8081
Failure code [15SGL1] (3rd clutch solenoid: Fill signal is ON when command current is OFF)….8083
Failure code [15SGMA] (3rd clutch solenoid: Malfunction)….8087
Failure code [15SHL1] (4th clutch solenoid: Command current is OFF and fill signal is ON)….8089
Failure code [15SHMA] (4th clutch solenoid: Malfunction)….8093
Failure code [15SJMA] (Lockup clutch solenoid: Malfunction)….8095
Failure code [989A00] (Engine over run prevention command signal: Operating)….8097
Failure code [989D00] (Rear section tipping over alarm: Alarm is activated)….8097
Failure code [2F00KM] (Parking brake: Mistake in operation or setting)….8099
Failure code [2G42ZG] (Front accumulator: Lowering of oil pressure)….8101
Failure code [2G43ZG] (Rear accumulator: Lowering of oil pressure)….8101
Failure code [A570NX] (Engine oil filter: Clogging)….8102
Failure code [AA10NX] (Air cleaner element: Clogging)….8103
Failure code [AB00MA] (Alternator: Malfunction)….8105
Failure code [B@BAZG] (Abnormal lowering of engine oil pressure: Lowering of oil pressure)….8107
Failure code [B@BAZK] (Engine oil: Level too low)….8109
Failure code [B@BCZK] (Lowering of radiator coolant: Lowering of level)….8111
Failure code [B@BCNS] (Engine: Overheat)….8113
Failure code [B@C7NS] (Rear brake oil: Overheat)….8114
Failure code [B@CENS] (Torque converter oil: Overheat)….8114
Failure code [B@GAZK] (Battery electrolyte level: Lowering of level)….8115
Failure code [B@JANS] (Steering oil: Overheat)….8116
Troubleshooting by failure code, Part 2….8118
Failure code [CA111] (Abnormality in engine controller)….8120
Failure code [CA115] (Abnormal engine Ne and Bkup sensors)….8121
Failure code [CA122] (Charge pressure sensor too high)….8123
Failure code [CA123] (Charge pressure sensor too low)….8125
Failure code [CA131] (Throttle sensor too high)….8127
Failure code [CA132] (Throttle sensor too low)….8129
Failure code [CA135] (Oil pressure sensor too high)….8131
Failure code [CA141] (Oil pressure sensor too low)….8133
Failure code [CA144] (Coolant temperature sensor too high)….8135
Failure code [CA145] (Coolant temperature sensor too low)….8137
Failure code [CA153] (Charge temperature sensor too high)….8139
Failure code [CA154] (Charge temperature sensor too low)….8141
Failure code [CA187] (Sensor power source 2 too low)….8141
Failure code [CA221] (Atmospheric pressure sensor too high)….8143
Failure code [CA222] (Atmospheric pressure sensor too low)….8145
Failure code [CA227] (Sensor power source 2 too high)….8147
Failure code [CA234] (Engine over speed)….8149
Failure code [CA238] (Abnormal power source for engine Ne speed sensor)….8151
Failure code [CA263] (Fuel temperature sensor too high)….8153
Failure code [CA265] (Fuel temperature sensor too low)….8155
Failure code [CA271] (PCV1 short circuit)….8156
Failure code [CA272] (PCV1 disconnection)….8157
Failure code [CA273] (PCV2 short circuit)….8158
Failure code [CA274] (PCV2 disconnection)….8159
Failure code [CA322] (Injector No. 1 system disconnection or short circuit)….8161
Failure code [CA323] (Injector No. 5 system disconnection or short circuit)….8163
Failure code [CA324] (Injector No. 3 system disconnection or short circuit)….8165
Failure code [CA325] (Injector No. 6 system disconnection or short circuit)….8167
Failure code [CA331] (Injector No. 2 system disconnection or short circuit)….8169
Failure code [CA332] (Injector No. 4 system disconnection or short circuit)….8171
Failure code [CA342] (Abnormal engine controller data consistency)….8173
Failure code [CA351] (Abnormal injector drive circuit)….8174
Failure code [CA352] (Sensor power source 1 too low)….8175
Failure code [CA386] (Sensor power source 1 too high)….8177
Failure code [CA431] (Abnormal idle validation switch)….8179
Failure code [CA432] (Abnormal process with idle validation switch)….8182
Failure code [CA441] (Power source voltage too low)….8183
Failure code [CA442] (Power source voltage too high)….8183
Failure code [CA449] (Common rail pressure too high 2)….8184
Failure code [CA451] (Common rail pressure sensor too high)….8185
Failure code [CA452] (Common rail pressure sensor too low)….8187
Failure code [CA553] (Common rail pressure too high 1)….8187
Failure code [CA554] (In-range error of common rail pressure sensor)….8188
Failure code [CA559] (Loss of pressure feed from supply pump abnormal 1)….8189
Failure code [CA689] (Abnormal engine Ne speed sensor)….8193
Failure code [CA731] (Abnormal engine Bkup speed sensor phase)….8195
Failure code [CA757] (Loss of all engine controller data)….8195
Failure code [CA778] (Abnormal engine Bkup speed sensor)….8197
Failure code [CA1228] (Abnormal EGR valve servo 1)….8199
Failure code [CA1625] (Abnormal EGR valve servo 2)….8200
Failure code [CA1626] (Short circuit of bypass valve solenoid drive)….8201
Failure code [CA1627] (Disconnection in bypass valve solenoid drive)….8203
Failure code [CA1628] (Abnormal bypass valve servo 1)….8204
Failure code [CA1629] (Abnormal bypass valve servo 2)….8205
Troubleshooting by failure code, Part 3….8208
Failure code [CA1631] (Bypass valve lift sensor too high)….8211
Failure code [CA1632] (Bypass valve lift sensor too low)….8213
Failure code [CA1633] (Abnormal KOMNET)….8215
Failure code [CA1642] (EGR inlet pressure sensor too low)….8217
Failure code [CA1653] (EGR inlet pressure sensor too high)….8219
Failure code [CA2185] (Throttle sensor power source too high)….8221
Failure code [CA2186] (Throttle sensor power source too low)….8223
Failure code [CA2249] (Loss of pressure feed from supply pump abnormal 2)….8223
Failure code [CA2271] (EGR valve lift sensor too high)….8225
Failure code [CA2272] (EGR valve lift sensor too low)….8227
Failure code [CA2351] (EGR valve solenoid drive short circuit)….8229
Failure code [CA2352] (EGR valve solenoid drive disconnection)….8231
Failure code [CA2555] (Intake air heater relay disconnection)….8231
Failure code [CA2556] (Intake air heater relay short circuit)….8233
Failure code [D19HKB] (Stop lamp relay output system: Short circuit)….8235
Failure code [D5ZKKZ] (Front brake cut-off solenoid valve: Disconnection or short circuit)….8237
Failure code [DAF9KM] Wrong connection of connector….8239
Failure code [DAFRKR] (Abnormal CAN communication (machine monitor): Abnormal communication)….8241
Failure code [DAQ0KK] (Transmission controller direct power supply: Lowering of source voltage)….8243
Failure code [DAQ0KT] (Transmission controller nonvolatile memory: Abnormality in controller)….8245
Failure code [DAQ2KK] (Transmission controller solenoid power source: Power source voltage too low)….8246
Failure code [DAQ9KQ] (Transmission controller: Disagreement of model selection)….8247
Failure code [DAQRKR] (Communication lost: Defect communication)….8249
Failure code [DAQRMA] (Transmission controller option setting: Malfunction)….8251
Failure code [DB10KT] (Retarder controller nonvolatile memory: Abnormality in controller)….8251
Failure code [DB12KK] (Retarder controller solenoid power source: Power source voltage too low)….8253
Failure code [DB13KK] (Retarder controller direct power source: Power source voltage too low)….8255
Failure code [DB19KQ] Disagreement of model selection (Retarder controller)….8257
Failure code [DB1RKR] (CAN communication (retarder controller): Communication disabled)….8259
Failure code [DB1RMA] Disagreement of option setting (Retarder controller)….8261
Failure code [DB1SKQ] (Model selection: Wrong information)….8262
Failure code [DB2RKR] (CAN communication (engine controller): Communication disabled)….8263
Failure code [DBC9KQ] Disagreement of model selection (ABS controller)….8265
Failure code [DBCRMA] Disagreement of option setting (ABS controller)….8266
Failure code [DDD7KX] (Trouble in travel speed setting switch system: Out of input signal range) (If equipped)….8267
Failure code [DDD8KA] (ARSC system switch system: Disconnection)….8269
Failure code [DDD8KB] (ARSC system switch system: Short circuit)….8271
Failure code [DDDAKA] (ASR system switch: Disconnection) (If equipped)….8273
Failure code [DDDAKB] (ASR system switch: Short circuit)….8275
Failure code [DDTHKA] (Hi clutch fill switch: Disconnection)….8277
Failure code [DDTJKA] (Lo clutch fill switch: Disconnection)….8279
Failure code [DDTKKA] (1st clutch fill switch: Disconnection)….8281
Failure code [DDTLKA] (2nd clutch fill switch: Disconnection)….8283
Failure code [DDTMKA] (3rd clutch fill switch: Disconnection)….8285
Failure code [DDTNKA] (R clutch fill switch: Disconnection)….8287
Failure code [DDTPKA] (4th clutch fill switch : Disconnection)….8289
Failure code [DF10KA] (Gear shift lever: Disconnection)….8291
Failure code [DF10KB] (Gear shift lever: Short circuit)….8294
Failure code [DGF1KX] (Transmission oil temperature sensor: Out of input signal range)….8297
Failure code [DGR2KZ] (Retarder oil temperature sensor : Disconnection or short circuit)….8299
Failure code [DGR6KX] (Steering oil temperature sensor: Input signal out of range)….8301
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)….8303
Troubleshooting by failure code, Part 4….8306
Failure code [DHP6KA] (Suspension pressure sensor system (Rear right): Disconnection)….8309
Failure code [DHP6KX] (Failure in suspension pressure sensor system trouble (Rear right): Out of input signal range)….8311
Failure code [DHP7KA] (Suspension pressure sensor system (Rear left): Disconnection)….8313
Failure code [DHP7KX] (Failure in suspension pressure sensor system trouble (Rear left): Out of input signal range)….8315
Failure code [DHT5KX] (Torque converter oil pressure sensor: Out of input signal range)….8317
Failure code [DHT5L6] (Torque converter oil pressure sensor: Disagreement of run and stop condition with signal)….8319
Failure code [DHU2KX] (Front accumulator oil pressure sensor: Out of input signal range)….8321
Failure code [DHU3KX] (Rear accumulator oil pressure sensor: Out of input signal range)….8323
Failure code [DJF1KA] (Fuel level sensor: Disconnection)….8325
Failure code [DK30KX] Trouble in steering angle potentiometer….8326
Failure code [DK51L5] (Retarder lever potentiometer: Potentiometer signal is inconsistent with switch signal)….8328
Failure code [DK52KX] (Failure in hoist lever potentiometer 1: Out of input signal range)….8331
Failure code [DK53L8] (Failure in hoist lever potentiometer 2: Disagreement of analog signal)….8333
Failure code [DK54KX] (Body positioner sensor: Out of input signal range)….8335
Failure code [DKD0L6] (Failure in steering speed sensor: Disagreement of run and stop condition with signal) (If equipped)….8337
Failure code [DKH0KX] (Pitch angle sensor: Out of input signal range) (If equipped)….8339
Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection)….8341
Failure code [DLF1LC] (Transmission input shaft speed sensor: Disagreement of revolution speed signal)….8343
Failure code [DLF2KA] (Transmission intermediate shaft speed sensor: Disconnection)….8345
Failure code [DLF2LC] (Transmission intermediate shaft speed sensor: Disagreement of revolution speed signal)….8347
Failure code [DLF8KA] Disconnection in wheel speed sensor (Right rear)….8349
Failure code [DLF8LC] Trouble in wheel speed sensor system (Right rear)….8350
Failure code [DLF9KA] Disconnection in wheel speed sensor (Left rear)….8351
Failure code [DLF9LC] Trouble in wheel speed sensor system (Left rear)….8352
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)….8353
Failure code [DLT3LC] (Transmission output shaft speed sensor: Disagreement of revolution speed signal) (If equipped)….8355
Failure code [DLT4KA] (Transmission output shaft speed sensor: Disconnection) (If equipped)….8357
Failure code [DLT4LC] (Transmission output shaft speed sensor: Disagreement of revolution speed signal) (If equipped)….8359
Failure code [DLT4MA] Disconnection in transmission output shaft speed sensor: Defective function (If equipped)….8361
Failure code [DV00KB] Short circuit in buzzer output….8363
Failure code [DW35KZ] (Failure in output system of auto suspension solenoid 1: Disconnection or short circuit) (If equipped)….8365
Failure code [DW36KZ] (Failure in output system of auto suspension solenoid 2: Disconnection or short circuit) (If equipped)….8367
Failure code [DW72KZ] (Failure in kick-out solenoid output system: Disconnection or short circuit)….8369
Failure code [DW73KZ] (Failure in hoist select valve output system: Disconnection or short circuit)….8371
Failure code [DW78KZ] (Failure in rear brake BCV command output system: Disconnection or short circuit)….8373
Failure code [DWNBK4] Trouble in ASR shut-off valve (Valve keeps operating)….8375
Failure code [DWNBKA] Disconnection in ASR shut-off valve output circuit….8377
Failure code [DWNBKB] Ground fault in ASR shut-off valve output circuit….8379
Failure code [DWNBKY] Short circuit in ASR shut-off valve output circuit….8381
Failure code [DWNBMA] Trouble in ASR shut-off valve (Valve does not operate)….8382
Failure code [DX11K4] (Rear brake proportional pressure reducing solenoid valve: Out of control)….8383
Failure code [DX11KA] (Rear brake proportional pressure reducing solenoid valve output circuit: Disconnection)….8385
Failure code [DX11KB] (Rear brake proportional pressure reducing solenoid valve: Short circuit)….8386
Failure code [DX11KY] (Rear brake proportional pressure reducing solenoid valve: Short circuit to power source line)….8387
Failure code [DX11MA] (Rear brake proportional pressure reducing solenoid valve: Malfunction)….8389
Failure code [DX13KA] (Output circuit of hoist EPC valve: Disconnection)….8391
Failure code [DX13KB] (Output circuit of hoist EPC valve: Short circuit)….8393
Failure code [DX13KY] (Output circuit of hoist EPC valve: Short circuit with power source line)….8395
Troubleshooting by failure code, Part 5….8398
Failure code [DX17K4] Trouble in ASR proportional pressure reducing solenoid valve (right) (Valve keeps operating)….8401
Failure code [DX17KA] Disconnection in ASR proportional pressure reducing solenoid valve (right) output circuit….8403
Failure code [DX17KB] Ground fault in ASR proportional pressure reducing solenoid valve (right) output circuit….8405
Failure code [DX17KY] Short circuit in ASR proportional pressure reducing solenoid valve (right) output circuit….8407
Failure code [DX17MA] Trouble in ASR proportional pressure reducing solenoid valve (right) (Valve does not operate)….8407
Failure code [DX18K4] Trouble in ASR proportional pressure reducing solenoid valve (left) (Valve keeps operating)….8409
Failure code [DX18KA] Disconnection in ASR proportional pressure reducing solenoid valve (left) output circuit….8411
Failure code [DX18KB] Ground fault in ASR proportional pressure reducing solenoid valve (left) output circuit….8413
Failure code [DX18KY] Short circuit in ASR proportional pressure reducing solenoid valve (left) output circuit….8415
Failure code [DX18MA] Trouble in ASR proportional pressure reducing solenoid valve (left) (Valve does not operate)….8415
Failure code [DXH1KA] (Lockup clutch solenoid output circuit: Disconnection)….8417
Failure code [DXH1KB] (Lock-up clutch solenoid output circuit: Short circuit)….8419
Failure code [DXH1KY] (Lockup clutch solenoid output circuit: Short circuit to power source line)….8421
Failure code [DXH2KA] (Hi clutch solenoid output circuit: Disconnection)….8423
Failure code [DXH2KB] (Hi clutch solenoid output circuit: Short circuit)….8425
Failure code [DXH2KY] (Hi clutch solenoid output circuit: Short circuit to power source line)….8427
Failure code [DXH3KA] (Lo clutch solenoid output circuit: Disconnection)….8431
Failure code [DXH3KB] (Lo clutch solenoid output circuit: Short circuit)….8433
Failure code [DXH3KY] (Lo clutch solenoid output circuit: Short circuit in power source line)….8435
Failure code [DXH4KA] (1st clutch solenoid output circuit: Disconnection)….8439
Failure code [DXH4KB] (1st clutch solenoid output circuit: Short circuit)….8441
Failure code [DXH4KY] (1st clutch solenoid output circuit: Short circuit to power source line)….8443
Failure code [DXH5KA] (2nd clutch solenoid output circuit: Disconnection)….8447
Failure code [DXH5KB] (2nd clutch solenoid output circuit: Short circuit)….8449
Failure code [DXH5KY] (2nd clutch solenoid output circuit: Short circuit in power source line)….8451
Failure code [DXH6KA] (3rd clutch solenoid output circuit: Disconnection)….8455
Failure code [DXH6KB] (3rd clutch solenoid output circuit: Short circuit)….8457
Failure code [DXH6KY] (3rd clutch solenoid output circuit: Short circuit to power source line)….8459
Failure code [DXH7KA] (R clutch solenoid output circuit: Disconnection)….8463
Failure code [DXH7KB] (R clutch solenoid output circuit: Short circuit)….8465
Failure code [DXH7KY] (R clutch solenoid output circuit: Short circuit to power source line)….8467
Failure code [DXHHKA] (4th clutch solenoid output circuit: Disconnection)….8471
Failure code [DXHHKB] (4th clutch solenoid output circuit: Short circuit)….8473
Failure code [DXHHKY] (4th clutch solenoid output circuit: Short circuit to power source line)….8475
Troubleshooting of electrical system (E-mode)….8480
Before troubleshooting of electric system….8482
Contents of troubleshooting table….8488
E-1 Engine does not start….8490
E-2 Automatic preheating does not operate….8493
E-3 Machine monitor does not display all, when starting switch is turned ON….8497
E-4 Machine monitor does not operate when starting switch is OFF….8499
E-5 Alarm buzzer does not stop sounding….8501
E-6 Gauges of machine monitor, caution lamps or character display section do not display properly….8502
E-7 A selection of the display in character display section cannot be changed….8503
E-8 Power mode selecting function does not operate properly….8506
E-9 AISS function does not operate properly….8507
E-10 Seat belt caution lamp does not display properly….8508
E-11 Turn signal lamp or turning lamp (hazard lamp) do not work properly….8509
E-12 Night illumination (lighting) does not work properly….8512
E-13 Emergency steering does not operate….8521
Troubleshooting of hydraulic and mechanical system (H-mode)….8526
Contents of troubleshooting table….8528
H-1 Machine does not start….8529
H-2 Machine does not travel smoothly (hunting)….8531
H-3 Lockup cannot be cancelled….8531
H-4 Excessive shock when starting or shifting….8532
H-5 Transmission does not shift up….8533
H-6 Machine lacks power or speed when traveling….8534
H-7 Time lag is excessive when starting or shifting gear….8536
H-8 Torque converter oil temperature is high….8537
H-9 Torque converter oil pressure is low….8538
H-10 Front brake is ineffective….8539
H-11 Rear brake is ineffective….8540
H-12 Steering wheel is heavy….8541
H-13 Steering wheel does not work….8542
H-14 Steering wheel vibrates….8543
H-15 Dump body lifting speed is slow….8544
H-16 Dump body does not work….8545
H-17 Excessive hydraulic drift of dump body….8546
Troubleshooting of mechanical system (S-mode)….8548
Method of using troubleshooting charts….8551
S-1 Starting performance is poor….8555
S-2 Engine does not start….8557
S-3 Engine does not pick up smoothly….8561
S-4 Engine stops during operations….8562
S-5 Engine does not rotate smoothly….8563
S-6 Engine lacks output (or lacks power)….8564
S-7 Exhaust gas color is black (incomplete combustion)….8565
S-8 Oil consumption is excessive (or exhaust smoke is blue)….8567
S-9 Oil becomes contaminated quickly….8568
S-10 Fuel consumption is excessive….8569
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)….8570
S-12 Oil pressure drops….8571
S-13 Oil level rises (Entry of coolant/fuel)….8573
S-14 Coolant temperature becomes too high (overheating)….8575
S-15 Abnormal noise is made….8576
S-16 Vibration is excessive….8577
50 Disassembly and assembly….0
General information on disassembly and assembly….8580
How to read this manual….8581
Coating materials list….8583
Special tool list….8586
Sketches of special tools….8589
Engine and cooling system….8594
Removal and installation of engine assembly….8595
Removal and installation of radiator assembly….8601
Removal and installation of output shaft assembly….8609
Disassembly and assembly of output shaft assembly….8611
Removal and installation of fuel supply pump assembly….8614
Removal and installation of cylinder head assembly….8618
Removal and installation of fuel injector assembly….8629
Removal and installation of engine front seal….8634
Removal and installation of engine rear seal….8638
Power train, Part 1….8644
Removal and installation of torque converter and transmission assembly….8645
Disassembly and assembly of torque converter and control valve assembly….8652
Disassembly and assembly of torque converter assembly….8653
Disassembly and assembly of PTO assembly….8661
Disassembly and assembly of transmission assembly….8664
Removal and installation of transmission control valve assembly (ECMV assembly)….8689
Disassembly and assembly of transmission control valve assembly (ECMV assembly)….8690
Power train, Part 2….8696
Removal and installation of differential assembly….8697
Disassembly and assembly of differential assembly….8698
Removal and installation of rear final drive carrier assembly….8711
Disassembly and assembly of rear final drive carrier assembly….8713
Disassembly and assembly of rear final drive assembly….8715
Disassembly and assembly of front wheel hub assembly….8719
Steering system….8724
Disassembly and assembly of steering cylinder assembly….8725
Removal and installation of emergency steering motor pump assembly….8728
Brake system….8730
Removal and installation of front brake caliper pad….8731
Removal and installation of front brake caliper assembly….8732
Disassembly and assembly of front brake caliper assembly….8733
Removal and installation of rear brake assembly….8735
Disassembly and assembly of rear brake assembly….8736
Removal and installation of parking brake pad….8739
Removal and installation of parking brake caliper assembly….8741
Disassembly and assembly of front brake caliper pad assembly….8742
Removal and installation of parking brake spring cylinder assembly….8743
Removal and installation of slack adjuster assembly….8744
Disassembly and assembly of slack adjuster assembly….8745
Undercarriage and frame….8748
Removal and installation of front wheel assembly….8749
Removal and installation of rear wheel assembly….8750
Removal and installation of front suspension cylinder assembly….8752
Disassembly and assembly of front suspension cylinder assembly….8753
Disassembly and assembly of variable damping selector valve assembly….8755
Removal and installation of rear suspension cylinder assembly….8757
Disassembly and assembly of rear suspension cylinder assembly….8758
Hydraulic system….8762
Disassembly and assembly of hoist cylinder assembly….8763
Body….8770
Removal and installation of body assembly….8771
Cab and its attachments….8776
Disassembly and assembly of operator’s seat assembly….8777
Removal and installation of air conditioner unit assembly….8786
Electrical system….8790
Removal and installation of engine controller assembly….8791
Removal and installation of transmission controller assembly….8792
Removal and installation of retarder controller assembly….8793
90 Diagrams and drawings….0
Hydraulic diagrams and drawings….8796
Power train hydraulic circuit diagram….8797
Steering and hoist hydraulic circuit diagram HD325-7 Serial No. 7001 – 7025, 7101 – 7523 HD405-7 Serial No. 3001 – 3035, 7101 – 7523….8798
Steering and hoist hydraulic circuit diagram HD325-7 Serial No. 7524 and up HD405-7 Serial No. 7525 and up….8799
Brake hydraulic circuit diagram….8800
Electrical diagrams and drawings….8803
Electrical circuit diagram for inside cab (1/5)….8805
Electrical circuit diagram for inside cab (2/5) HD325-7 Serial No. 7001 – 7025, 7101 – 7161 HD405-7 Serial No. 3001 – 3035, 7101 – 7157….8806
Electrical circuit diagram for inside cab (2/5) HD325-7 Serial No. 7162 and up HD405-7 Serial No. 7158 and up….8807
Electrical circuit diagram for inside cab (3/5) HD325-7 Serial No. 7001 – 7025, 7101 – 7161 HD405-7 Serial No. 3001 – 3035, 7101 – 7157….8808
Electrical circuit diagram for inside cab (3/5) HD325-7 Serial No. 7162 and up HD405-7 Serial No. 7158 and up….8809
Electrical circuit diagram for inside cab (4/5)….8810
Electrical circuit diagram for inside cab (5/5)….8811
Electrical circuit diagram for outside cab (1/3)….8812
Electrical circuit diagram for outside cab (2/3)….8813
Electrical circuit diagram for outside cab (3/3)….8814
Air conditioner electrical circuit diagram….8815
Electrical circuit diagram of external power supply heater….8816
Connectors table and arrangement drawing….8818
SEN00486-14 – Dump Truck HD325-7, HD405-7 Shop Manual….8821
SEN06618-04 – Dump Truck HD325-8, HD405-8 Shop Manual….10220
COVER….10220
00 INDEX AND FOREWORD….10222
INDEX….10223
ABBREVIATIONS….10245
FOREWORD, SAFETY, BASIC INFORMATION….10250
HOW TO READ THE SHOP MANUAL….10250
Composition of the shop manual….10250
Symbols….10251
Signal word….10251
Unit….10251
SAFETY NOTICE FOR OPERATION….10252
Safety matters….10252
General precautions….10252
Precautions for preparatory work….10253
Precautions during work….10253
Precautions for slinging work and making signals….10255
Precautions for using mobile crane….10256
Precautions for using overhead traveling crane….10257
Selecting wire ropes….10257
Precautions for disconnecting air conditioner piping….10257
Precautions for air conditioner piping….10258
PRECAUTIONS TO PREVENT FIRE….10259
Fire caused by fuel, oil, coolant or window washer fluid….10259
Fire caused by accumulation or attachment of flammable material….10259
Fire coming from electric wiring….10259
Fire caused by piping….10259
Fire around the machine due to highly heated exhaust gas….10259
Explosion caused by lighting equipment….10260
ACTIONS IF FIRE OCCURS….10260
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS….10260
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS….10261
PRECAUTIONS FOR DEF….10262
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING….10262
PRECAUTIONS FOR ADDING….10262
PRECAUTIONS FOR STORING….10262
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE….10262
THE OTHER PRECAUTIONS….10262
STORE AdBlue/DEF….10263
Handling AdBlue/DEF in cold weather….10263
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT….10264
Select an appropriate workplace….10264
Disassembly and maintenance work in the field….10264
Sealing of openings (prevention of flowing out of oil)….10264
Preventing intrusion of foreign materials during refilling….10264
Replacing hydraulic oil while its temperature is high….10265
Flushing operation….10265
Cleaning operation….10265
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS….10266
Precautions for removal and disassembling work….10266
Introduction of parts for the disassembly of the face seal type hoses and tubes….10266
Introduction of parts for the disconnection of the taper seal type hoses and tubes….10267
Introduction of parts for the disconnection of the split flange type hoses and tubes….10267
Introduction of parts for the removal of O-ring boss type joint….10268
Introduction of parts for the removal of taper pipe thread type joint….10269
Precautions for installation and assembling work….10269
Precautions at the time of completion of work….10270
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT….10272
Handling wiring harnesses and connectors….10272
Main causes of failure in wiring harness….10272
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT….10274
Select an appropriate workplace….10274
Sealing the opening….10274
How to clean parts when dirt is stuck….10274
Precautions for replacing fuel filter cartridge….10274
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT….10275
Select an appropriate workplace….10275
Sealing the opening….10275
PRACTICAL USE OF KOMTRAX….10276
Merit of using KOMTRAX….10276
How to make a full use of KOMTRAX….10276
How to operate KOMTRAX….10276
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER….10277
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER….10277
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER….10278
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER….10279
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS….10281
Disconnecting connectors….10281
Connecting connectors….10282
Drying wiring harness….10283
Handling controller….10284
Precautions for troubleshooting electrical circuits….10284
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR….10285
Method for disconnecting Deutsch connector….10285
Method for connecting Deutsch connector….10285
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR….10286
Method for disconnecting slide lock type connector (FRAMATOME-3, FRAMATOME- 2)….10286
Method for connecting slide lock type connector (FRAMATOME-3, FRAMATOME- 2)….10286
Method for disconnecting slide lock type connector (FRAMATOME-24)….10286
Method for connecting slide lock type connector (FRAMATOME-24)….10287
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL….10287
Method for disconnecting connector with lock to pull….10287
Method for connecting connector with lock to pull….10287
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH….10288
Method for disconnecting connector with lock to push (BOSCH-3)….10288
Method for connecting connector with lock to push (BOSCH-3)….10288
Method for disconnecting connector with lock to push (AMP-3)….10289
Method for connecting connector with lock to push (AMP-3)….10289
Method for disconnecting connector with lock to push (SUMITOMO-3)….10289
Method for connecting connector with lock to push (SUMITOMO-3)….10289
Method for disconnecting connector with lock to push (SUMITOMO-4)….10289
Method for connecting connector with lock to push (SUMITOMO-4)….10289
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE….10290
Method for disconnecting connector with housing to rotate….10290
Method for connecting connector with housing to rotate….10290
HOW TO READ ELECTRICAL WIRE CODE….10291
Type, symbol, and material….10291
Dimensions….10291
Color codes table….10293
Types of circuits and color codes….10294
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD….10295
Standard dimension and tolerance….10295
Standard clearance and standard value….10296
Standard interference….10296
Repair limit and allowable value or allowable dimension….10296
Allowable clearance….10296
Allowable interference….10296
STANDARD TIGHTENING TORQUE TABLE….10297
Table of tightening torque for bolts and nuts….10297
Table of tightening torque for O-ring boss piping joints….10300
Table of tightening torque for O-ring boss plugs….10300
Table of tightening torque for hose (taper seal type and face seal type)….10301
Table of tightening torque for face seal joints….10302
Tightening torque table for bolts and nuts on 102,107 and 114 series engines….10302
Tightening torque table for 102, 107, and 114 series engines (joint bolts)….10303
Tightening torque table for tapered screws on 102,107, and 114 series engines (National taper pipe thread (NPT))….10303
CONVERSION TABLE….10304
Method of using the conversion table….10304
Examples of using the conversion table to convert a unit from mm to in….10304
mm to in….10304
mm to in….10304
kg to lb….10305
l to U.S.Gal….10305
l to U.K.Gal….10305
kgm to lbft….10306
kg/cm2 to lb/in2….10306
Temperature….10307
01 SPECIFICATIONS….10310
CONTENTS….10311
ABBREVIATIONS….10312
SPECIFICATIONS….10317
SPECIFICATION DRAWING….10317
SPECIFICATION DRAWING: HD325-8….10317
SPECIFICATION DRAWING: HD405-8….10319
SPECIFICATIONS….10321
SPECIFICATIONS: HD325-8….10321
SPECIFICATIONS: HD405-8….10326
WEIGHT TABLE….10331
WEIGHT TABLE: HD325-8….10331
WEIGHT TABLE: HD405-8….10332
FUEL, COOLANT, AND LUBRICATING OIL (NORTH AMERICAN SPECIFICATION)….10333
USAGE OF FUEL, COOLANT, AND LUBRICATING OIL ACCORDING TO AMBIENT TEMPERATURE….10333
FUEL, COOLANT, AND LUBRICATING OIL (EU SPECIFICATION)….10335
USAGE OF FUEL, COOLANT, AND LUBRICATING OIL ACCORDING TO AMBIENT TEMPERATURE….10335
10 STRUCTURE AND FUNCTION….10338
CONTENTS….10339
ABBREVIATIONS….10343
UREA SCR SYSTEM….10348
LAYOUT DRAWING OF UREA SCR STSTEM….10348
UREA SCR SYSTEM DIAGRAM….10351
FUNCTION OF UREA SCR SYSTEM….10352
FUNCTION OF AdBlue/DEF SYSTEM….10352
INDUCEMENT STRATEGY….10354
COMPONENT PARTS OF UREA SCR SYSTEM….10369
AdBlue/DEF MIXING TUBE….10369
SCR ASSEMBLY….10370
AdBlue/DEF TANK….10372
AdBlue/DEF PUMP….10374
AdBlue/DEF INJECTOR….10375
AdBlue/DEF HOSE….10376
AdBlue/DEF TANK HEATING VALVE….10377
BOOT-UP SYSTEM….10378
LAYOUT DRAWING OF BOOT-UP SYSTEM….10378
LAYOUT DRAWING OF BOOT-UP SYSTEM (For machines equipped with emergency engine stop switch)….10380
SYSTEM OPERATING LAMP SYSTEM….10382
SYSTEM OPERATING LAMP SYSTEM DIAGRAM….10382
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM….10382
BATTERY DISCONNECT SWITCH….10383
FUNCTION OF BATTERY DISCONNECT SWITCH….10383
ENGINE SHUTDOWN SECONDARY SWITCH….10384
LAYOUT DRAWING OF ENGINE SHUTDOWN SECONDARY SWITCH….10384
FUNCTION OF ENGINE SHUTDOWN SECONDARY SWITCH….10384
OPERATION OF ENGINE SHUTDOWN SECONDARY SWITCH….10385
ENGINE SYSTEM….10386
LAYOUT DRAWING OF ENGINE SYSTEM….10386
FUNCTION OF ENGINE SYSTEM….10388
ENGINE CONTROL SYSTEM….10389
ENGINE CONTROL SYSTEM DIAGRAM….10389
FUNCTION OF ENGINE CONTROL SYSTEM….10390
OPERATION OF ENGINE CONTROL SYSTEM….10391
AUTOMATIC IDLE STOP SYSTEM….10393
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM….10393
COMPONENT PARTS OF ENGINE SYSTEM….10395
OUTPUT SHAFT….10395
VGT….10396
EGR SYSTEM….10400
EGR VALVE….10402
EGR COOLER….10404
KCCV SYSTEM….10405
KCCV VENTILATOR….10407
KDPF….10409
COOLING SYSTEM….10413
LAYOUT DRAWING OF COOLING SYSTEM….10413
SPECIFICATIONS OF COOLING SYSTEM….10414
RADIATOR FAN CONTROL SYSTEM….10415
RADIATOR FAN CONTROL SYSTEM DIAGRAM….10415
FUNCTION OF RADIATOR FAN CONTROL SYSTEM….10415
COMPONENT PARTS OF COOLING SYSTEM….10417
COOLING FAN AND HOIST PUMP….10417
COOLING FAN MOTOR….10425
CONTROL SYSTEM….10432
LAYOUT DRAWING OF CONTROL SYSTEM….10432
RETARDER AND HOIST CONTROL SYSTEM….10434
RETARDER AND HOIST CONTROL SYSTEM DIAGRAM….10434
MACHINE MONITOR SYSTEM….10436
MACHINE MONITOR SYSTEM DIAGRAM….10436
FUNCTION OF MACHINE MONITOR SYSTEM….10437
REARVIEW MONITOR SYSTEM….10438
REARVIEW MONITOR SYSTEM DIAGRAM….10438
FUNCTION OF REARVIEW MONITOR SYSTEM….10438
KOMTRAX SYSTEM….10439
KOMTRAX SYSTEM DIAGRAM….10439
FUNCTION OF KOMTRAX SYSTEM….10439
PAYLOAD METER SYSTEM….10440
LAYOUT DRAWING OF PAYLOAD METER SYSTEM….10440
PAYLOAD METER SYSTEM DIAGRAM….10441
FUNCTION OF PAYLOAD METER SYSTEM….10441
COMPONENT PARTS OF CONTROL SYSTEM….10451
MACHINE MONITOR….10451
SWITCH PANEL….10468
REARVIEW MONITOR….10469
REARVIEW CAMERA….10470
KOMTRAX TERMINAL….10471
TRANSMISSION CONTROLLER….10473
RETARDER AND HOIST CONTROLLER….10477
MONITOR CONTROLLER….10482
ENGINE CONTROLLER….10487
PAYLOAD METER CONTROLLER….10493
ACCELERATOR PEDAL….10497
GEAR SHIFT LEVER….10498
RETARDER CONTROL LEVER….10499
HYDRAULIC SYSTEM….10500
LAYOUT DRAWING OF HYDRAULIC SYSTEM….10500
COMPONENT PARTS OF HYDRAULIC SYSTEM….10501
HYDRAULIC TANK….10501
STEERING AND HOIST PUMP….10502
POWER TRAIN AND BRAKE CONTROL DUPLEX PUMP….10512
BRAKE COOLING DUPLEX PUMP….10513
HOIST VALVE….10514
POWER TRAIN SYSTEM….10520
LAYOUT DRAWING OF POWER TRAIN SYSTEM….10520
TRANSMISSION CONTROL SYSTEM….10523
TRANSMISSION CONTROL SYSTEM DIAGRAM….10523
GEAR SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFT RANGE….10525
GEAR SHIFT CONTROL SYSTEM….10529
AUTOMATIC GEAR SHIFT CONTROL OF GEAR SHIFT CONTROL SYSTEM….10529
SHIFTING METHOD IN EACH GEAR SHIFT LEVER POSITIONS OF GEAR SHIFT CONTROL SYSTEM….10530
GEAR SHIFT DISABLED TIME CONTROL OF GEAR SHIFT CONTROL SYSTEM….10531
DIRECTION CONTROL SYSTEM….10532
RIM PULL LIMIT FUNCTION FOR OVERLOAD PREVENTION OF DIRECTION CONTROL SYSTEM….10532
FUNCTION OF THROTTLE LIMIT FUNCTION AT F1 START AT D POSITION SETTING OF DIRECTION CONTROL SYSTEM….10532
KOMATSU TRACTION CONTROL SYSTEM (KTCS)….10533
KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM DIAGRAM….10533
FUNCTION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS)….10533
OPERATION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM LOGIC….10534
TRAVEL SPEED LIMITATION SYSTEM….10535
SYSTEM DIAGRAM OF TRAVEL SPEED LIMITATION SYSTEM….10535
FUNCTION OF TRAVEL SPEED LIMITATION SYSTEM….10536
OPERATION OF TRAVEL SPEED LIMITATION SYSTEM….10537
COMPONENT PARTS OF POWER TRAIN SYSTEM….10539
DRIVE SHAFT….10539
TORQUE CONVERTER AND PTO….10541
LOCKUP CLUTCH ECMV….10545
TRANSMISSION….10548
TRANSMISSION CONTROL VALVE….10569
FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV….10571
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE….10576
MAIN RELIEF VALVE….10578
TORQUE CONVERTER RELIEF VALVE….10580
AXLE….10581
DIFFERENTIAL….10583
FINAL DRIVE….10585
WORK EQUIPMENT SYSTEM….10586
WORK EQUIPMENT CONTROL….10586
LAYOUT DRAWING OF WORK EQUIPMENT CONTROL….10586
FUNCTION OF WORK EQUIPMENT CONTROL….10586
HOIST CONTROL….10587
HOIST CONTROL SYSTEM DIAGRAM….10587
FUNCTION OF HOIST CONTROL….10587
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM….10589
HOIST AND COOLING FAN DIRECTION SELECTOR SOLENOID VALVE….10589
DUMP LEVER….10590
HOIST EPC VALVE….10595
STEERING SYSTEM….10596
LAYOUT DRAWING OF STEERING SYSTEM….10596
FUNCTION OF STEERING SYSTEM….10597
STEERING COLUMN….10598
STRUCTURE OF STEERING COLUMN….10598
STEERING CONTROL LINKAGE….10599
STRUCTURE OF STEERING CONTROL LINKAGE….10599
COMPONENT PARTS OF STEERING SYSTEM….10600
DEMAND VALVE….10600
ORBITROL VALVE….10608
STEERING PUMP SELECTOR SOLENOID VALVE….10614
CROSS-OVER RELIEF VALVE….10615
SECONDARY STEERING PUMP….10616
SECONDARY STEERING MOTOR….10617
BRAKE SYSTEM….10618
LAYOUT DRAWING OF BRAKE SYSTEM….10618
RETARDER CONTROL….10619
RETARDER CONTROL SYSTEM DIAGRAM….10619
FUNCTION OF RETARDER CONTROL….10619
ARSC SYSTEM….10620
ARSC SYSTEM DIAGRAM….10620
FUNCTION OF ARSC SYSTEM….10620
COMPONENT PARTS OF BRAKE SYSTEM….10621
BRAKE CONTROL PUMP….10621
PARKING BRAKE SOLENOID VALVE….10622
ACCUMULATOR CHARGE VALVE….10623
BRAKE CIRCUIT ACCUMULATOR….10627
BRAKE VALVE….10628
SECONDARY BRAKE VALVE….10632
SECONDARY BRAKE RELAY VALVE….10633
FRONT BRAKE CUT SOLENOID VALVE….10634
PROPORTIONAL PRESSURE REDUCING VALVE….10635
SLACK ADJUSTER….10636
BRAKE COOLING OIL CONTROL VALVE….10638
BRAKE….10639
STRUCTURE OF REAR BRAKE….10640
PARKING BRAKE….10642
BRAKE SUB-TANK….10643
UNDERCARRIAGE AND FRAME….10644
REAR AXLE SUPPORT….10644
STRUCTURE OF REAR AXLE SUPPORT….10644
SUSPENSION….10645
STRUCTURE OF SUSPENSION….10645
FUNCTION OF SUSPENSION….10646
FRONT SUSPENSION….10647
STRUCTURE OF FRONT SUSPENSION….10647
FUNCTION OF FRONT SUSPENSION….10648
REAR SUSPENSION….10649
STRUCTURE OF REAR SUSPENSION….10649
FUNCTION OF REAR SUSPENSION….10650
SUSPENSION CYLINDER….10651
STRUCTURE OF SUSPENSION CYLINDER….10651
FUNCTION OF SUSPENSION CYLINDER….10651
OPERATION OF SUSPENSION CYLINDER….10651
WORK EQUIPMENT….10652
STRUCTURE OF WORK EQUIPMENT….10652
FUNCTION OF WORK EQUIPMENT….10652
CAB AND ITS ATTACHMENTS….10653
ROPS CAB….10653
STRUCTURE OF ROPS CAB….10653
FUNCTION OF ROPS CAB….10653
CAB MOUNT….10654
STRUCTURE OF CAB MOUNT….10654
FUNCTION OF CAB MOUNT….10654
20 STANDARD VALUE TABLE….10656
CONTENTS….10657
ABBREVIATIONS….10658
STANDARD VALUE TABLE FOR ENGINE….10663
STANDARD VALUE TABLE FOR ENGINE: HD325-8….10663
STANDARD VALUE TABLE FOR ENGINE: HD405-8….10666
STANDARD VALUE TABLE FOR MACHINE….10669
STANDARD VALUE TABLE FOR MACHINE: HD325-8….10669
STANDARD VALUE TABLE FOR MACHINE: HD405-8….10683
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE….10697
30 TESTING AND ADJUSTING….10698
CONTENTS….10699
ABBREVIATIONS….10703
RELATED INFORMATION TO TEST AND ADJUST….10708
TOOLS TO TEST AND ADJUST….10708
DIAGRAM FOR TEST AND ADJUST TOOLS….10718
ENGINE AND COOLING SYSTEM….10720
TEST ENGINE SPEED….10720
PROCEDURE TO TEST ENGINE SPEED….10720
TEST BOOST PRESSURE….10722
PROCEDURE TO TEST BOOST PRESSURE WITH MACHINE MONITOR….10722
PROCEDURE TO TEST BOOST PRESSURE WITH TEST TOOLS….10724
TEST EXHAUST GAS TEMPERATURE….10726
PROCEDURE TO TEST EXHAUST GAS TEMPERATURE….10726
TEST EXHAUST GAS COLOR….10729
PROCEDURE TO TEST EXHAUST GAS COLOR WITH HANDY SMOKE CHECKER….10729
PROCEDURE TO TEST EXHAUST GAS COLOR WITH SMOKE METER….10730
TEST AND ADJUST VALVE CLEARANCE….10732
PROCEDURE TO TEST VALVE CLEARANCE….10732
PROCEDURE TO ADJUST VALVE CLEARANCE….10733
TEST COMPRESSION PRESSURE….10735
PROCEDURE TO TEST COMPRESSION PRESSURE….10735
TEST BLOWBY PRESSURE….10738
PROCEDURE TO TEST BLOWBY PRESSURE….10738
TEST ENGINE OIL PRESSURE….10741
PROCEDURE TO TEST ENGINE OIL PRESSURE WITH MACHINE MONITOR….10741
PROCEDURE TO TEST ENGINE OIL PRESSURE WITH TEST TOOLS….10741
TEST EGR VALVE AND VGT OIL PRESSURE….10743
PROCEDURE TO TEST EGR VALVE AND VGT OIL PRESSURE….10743
TEST FUEL PRESSURE….10744
PROCEDURE TO TEST FUEL PRESSURE….10744
TEST FUEL RETURN RATE AND LEAKAGE….10746
PROCEDURE TO TEST FUEL RETURN RATE AND LEAKAGE….10747
BLEED AIR FROM FUEL SYSTEM….10751
PROCEDURE TO BLEED AIR FROM FUEL SYSTEM….10751
TEST FUEL CIRCUIT LEAK….10753
PROCEDURE TO TEST FUEL CIRCUIT LEAK….10753
CYLINDER CUT-OUT MODE….10755
NO-INJECTION CRANKING….10756
CLEAN FUEL DOSER….10757
PROCEDURE TO CLEAN FUEL DOSER….10757
PROGRAM INJECTOR TRIM CODE VALUE TO ENGINE CONTROLLER….10760
PROCEDURE TO PROGRAM INJECTOR TRIM CODE VALUE….10761
PROGRAM ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLER….10767
PROCEDURE TO PROGRAM SOOT ASH ACCUMULATION CORRECTION TO ENGINE CONTROLLER….10767
TEST SCR RELATED FUNCTIONS….10768
TEST AdBlue/DEF PUMP RAISED PRESSURE….10771
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR….10774
TEST AdBlue/DEF LINE HEATER RELAY 1….10779
TEST AdBlue/DEF LINE HEATER RELAY 2….10783
TEST AdBlue/DEF PUMP HEATER RELAY….10787
TEST AdBlue/DEF TANK HEATER VALVE….10791
TEST DENITRATION EFFICIENCY OF SCR….10795
CLEAN AdBlue/DEF TANK….10798
PROCEDURE TO CLEAN AdBlue/DEF TANK….10798
TEST TORQUE CONVERTER STALL SPEED….10804
PROCEDURE TO TEST TORQUE CONVERTER STALL SPEED….10804
TEST RADIATOR FAN SPEED….10806
PROCEDURE TO TEST RADIATOR FAN SPEED….10806
POWER TRAIN….10808
TEST POWER TRAIN OIL PRESSURE….10808
PROCEDURE TO TEST POWER TRAIN OIL PRESSURE….10811
ADJUST TRANSMISSION INPUT SHAFT SPEED SENSOR….10822
PROCEDURE TO ADJUST TRANSMISSION INPUT SHAFT SPEED SENSOR….10822
ADJUST TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR….10823
PROCEDURE TO ADJUST TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR….10823
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR….10824
PROCEDURE TO ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR….10824
CHECK AFTER ADJUSTING TRANSMISSION SPEED SENSOR….10825
PROCEDURE TO CHECK AFTER ADJUSTING TRANSMISSION SPEED SENSOR….10825
MOVE MACHINE WITH ELECTRICAL SYSTEM PROBLEMS….10826
PROCEDURE TO MOVE MACHINE WITH ENGINE CONTROL SYSTEM PROBLEMS….10826
PROCEDURE TO MOVE MACHINE WITH TRANSMISSION CONTROL SYSTEM PROBLEMS….10826
STEERING SYSTEM….10831
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE….10831
PROCEDURE TO TEST STEERING CIRCUIT OIL PRESSURE WITH MACHINE MONITOR….10831
PROCEDURE TO TEST STEERING CIRCUIT OIL PRESSURE WITH TEST TOOLS….10831
PROCEDURE TO ADJUST STEERING CIRCUIT OIL PRESSURE….10833
TEST SUPPLY PRESSURE OF ORBITROL VALVE….10834
PROCEDURE TO TEST SUPPLY PRESSURE OF ORBITROL VALVE….10834
TEST STEERING CYLINDER PRESSURE….10836
PROCEDURE TO TEST STEERING CYLINDER PRESSURE….10836
BLEED AIR FROM STEERING CYLINDER CIRCUIT….10838
PROCEDURE TO BLEED AIR FROM STEERING CYLINDER CIRCUIT….10838
BRAKE SYSTEM….10839
RELEASE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT….10839
PROCEDURE TO RELEASE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT….10839
TEST WHEEL BRAKE OIL PRESSURE….10840
PROCEDURE TO TEST FRONT BRAKE ACCUATION PRESSURE….10840
PROCEDURE TO TEST REAR BRAKE ACCUATION PRESSURE….10841
PROCEDURE TO TEST RETARDER BRAKE ACCUATION PRESSURE….10842
PROCEDURE TO TEST RETARDER BRAKE ACCUATION PRESSURE (FOR MACHINE WITH KTCS)….10842
TEST AND ADJUST BRAKE ACCUMULATOR PRESSURE….10844
PROCEDURE TO TEST BRAKE ACCUMULATOR PRESSURE WITH MACHINE MONITOR….10844
PROCEDURE TO TEST BRAKE ACCUMULATOR PRESSURE WITH TEST TOOLS….10845
PROCEDURE TO ADJUST BRAKE ACCUMULATOR PRESSURE….10846
TEST AND PRESSURIZE BRAKE ACCUMULATOR WITH NITROGEN GAS….10847
PROCEDURE TO TEST BRAKE ACCUMULATOR NITROGEN GAS PRESSURE (FRONT BRAKE)….10847
PROCEDURE TO TEST BRAKE ACCUMULATOR NITROGEN GAS PRESSURE (REAR AND PARKING)….10851
PROCEDURE TO PRESSURIZE BRAKE ACCUMULATOR WITH NITROGEN GAS….10853
TEST BRAKE PERFORMANCE….10856
PROCEDURE TO TEST FOOT BRAKE PERFORMANCE….10856
PROCEDURE TO TEST RETARDER BRAKE PERFORMANCE….10857
PROCEDURE TO TEST PARKING BRAKE PERFORMANCE….10858
BLEED AIR FROM BRAKE CIRCUIT….10859
PROCEDURE TO BLEED AIR FROM FRONT BRAKE CIRCUIT….10859
PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT (FOR MACHINE WITHOUT KTCS)….10859
PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT (FOR MACHINE WITH KTCS)….10860
PROCEDURE TO BLEED AIR FROM PARKING BRAKE CIRCUIT….10862
TEST PARKING BRAKE OIL PRESSURE….10863
PROCEDURE TO TEST PARKING BRAKE OIL PRESSURE….10863
RELEASE PARKING BRAKE MANUALLY….10865
PROCEDURE TO RELEASE PARKING BRAKE MANUALLY….10865
TEST THE AMOUNT OF FRONT BRAKE PAD WEAR….10866
PROCEDURE TO VISUALLY TEST THE AMOUNT OF FRONT BRAKE PAD WEAR….10866
PROCEDURE TO TEST THE AMOUNT OF FRONT BRAKE PAD WEAR WITH GUAGE MEASURE….10866
TEST THE AMOUNT OF REAR BRAKE DISC WEAR….10867
PROCEDURE TO VISUALLY TEST THE AMOUNT OF REAR BRAKE DISC WEAR….10867
TEST AND ADJUST PARKING BRAKE PAD….10868
PROCEDURE TO TEST PARKING BRAKE PAD CLEARANCE….10868
PROCEDURE TO ADJUST PARKING BRAKE PAD CLEARANCE….10869
HYDRAULIC SYSTEM….10870
TEST AND ADJUST HOIST CIRCUIT OIL PRESSURE….10870
PROCEDURE TO TEST HOIST CIRCUIT OIL PRESSURE….10870
PROCEDURE TO ADJUST HOIST CIRCUIT OIL PRESSURE….10871
TEST HOIST CYLINDER SUPPLY PRESSURE….10872
PROCEDURE TO TEST HOIST CYLINDER SUPPLY PRESSURE….10872
TEST OIL PRESSURE OF HOIST EPC VALVE CIRCUIT….10874
PROCEDURE TO TEST HOIST EPC VALVE SUPPLY PRESSURE….10874
PROCEDURE TO TEST HOIST EPC VALVE OUTLET PRESSURE….10875
TEST RADIATOR FAN CIRCUIT OIL PRESSURE….10876
PROCEDURE TO TEST RADIATOR FAN CIRCUIT OIL PRESSURE….10876
TEST AND ADJUST FRONT SUSPENSION CYLINDER….10878
PROCEDURE TO TEST FRONT SUSPENSION CYLINDER….10878
PROCEDURE TO ADJUST FRONT SUSPENSION CYLINDER….10879
TEST AND ADJUST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION)….10884
PROCEDURE TO TEST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION)….10884
PROCEDURE TO ADJUST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION)….10885
TEST AND ADJUST REAR SUSPENSION CYLINDER….10886
PROCEDURE TO TEST REAR SUSPENSION CYLINDER….10886
PROCEDURE TO ADJUST REAR SUSPENSION CYLINDER….10887
TEST KTCS CIRCUIT OIL PRESSURE (FOR MACHINE WITH KTCS)….10892
PROCEDURE TO TEST KTCS CIRCUIT OIL PRESSURE WITH MACHINE MONITOR….10892
PROCEDURE TO TEST KTCS CIRCUIT OIL PRESSURE WITH TEST TOOLS….10892
WORK EQUIPMENT….10894
TEST AND ADJUST DUMP BODY POSITIONER SENSOR….10894
PROCEDURE TO TEST BODY POSITIONER SENSOR….10894
PROCEDURE TO ADJUST DUMP BODY POSITIONER SENSOR….10894
PROCEDURE TO CALIBRATE AFTER YOU ADJUST BODY POSITION SENSOR….10894
LOWER THE BODY MANUALLY….10896
PROCEDURE TO LOWER THE BODY MANUALLY….10896
LIFT THE BODY MANUALLY….10897
PROCEDURE TO LIFT THE BODY MANUALLY….10897
CAB AND ITS ATTACHMENTS….10898
ADJUST STEERING WHEEL TILT LOCK LEVER….10898
PROCEDURE TO ADJUST STEERING WHEEL TILT LOCK LEVER….10898
ADJUST RATTLING OPERATOR'S SEAT….10899
METHOD FOR ADJUSTING RATTLING OPERATOR'S SEAT….10899
ELECTRICAL SYSTEM….10900
SET AND ADJUST EACH EQUIPMENT….10900
SET AND OPERATE OF MACHINE MONITOR….10902
OPERATOR MODE….10906
SERVICE MODE….10919
ABNORMALITY RECORD MENU….10946
DEFAULT MENU….10961
DIAGNOSTIC TESTS MENU….10975
ADJUSTMENT MENU….10987
PROCEDURE TO PERFORM NO-INJECTION CRANKING….11011
PAYLOAD METER SETTING….11013
KOMTRAX SETTINGS MENU….11035
PROCEDURE TO DISPLAY SERVICE MESSAGE….11038
PROCEDURE TO START UP KOMTRAX TERMINAL….11040
ADJUST REARVIEW CAMERA ANGLE….11045
PROCEDURE TO ADJUST REARVIEW CAMERA ANGLE….11045
VOLTAGE CIRCUIT OF ENGINE CONTROLLER WORK….11046
BATTERY DISCONNECT SWITCH WORK….11047
TEST DIODES….11048
PROCEDURE TO TEST DIODE USING DIGITAL TESTER….11048
PROCEDURE TO TEST DIODE USING ANALOG TESTER….11048
Pm CLINIC….11049
Pm CLINIC SERVICE….11049
Pm CLINIC CHECK SHEET: HD325-8….11052
Pm CLINIC CHECK SHEET: HD405-8….11059
40 TROUBLESHOOTING….11066
CONTENTS….11067
ABBREVIATIONS….11081
RELATED INFORMATION ON TROUBLESHOOTING….11086
GENERAL TROUBLESHOOTING POINTS….11086
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM….11087
SEQUENCE OF EVENTS IN TROUBLESHOOTING….11099
CHECKS BEFORE TROUBLESHOOTING….11101
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING….11104
WALK-AROUND CHECK….11104
TESTING IN ACCORDANCE WITH TESTING PROCEDURE….11106
CHECK FUEL LEVEL AND TYPE….11106
CHECK IMPURE INGREDIENT IN FUEL….11106
CHECK AdBlue/DEF LEVEL AND TYPE….11106
CHECK FUEL PREFILTER….11107
CHECK MAIN FILTER….11109
OIL PAN – CHECK ENGINE OIL LEVEL AND TYPE….11111
CHECK COOLANT LEVEL (RESERVOIR TANK)….11112
CHECK CLOGGING OF AIR CLEANER….11113
CHECK OF AIR CLEANER….11114
OUTER ELEMENT – CLEAN….11114
REPLACE ELEMENT….11116
CHECK HYDRAULIC OIL LEVEL….11118
CHECK HYDRAULIC OIL STRAINER….11118
CHECK HYDRAULIC FILTER….11119
CHECK OIL LEVEL IN TRANSMISSION CASE….11119
CHECK OIL LEVEL IN DIFFERENTIAL CASE….11120
CHECK OIL LEVEL IN FINAL DRIVE CASE….11120
BLEED AIR FROM FUEL SYSTEM….11121
BLEED AIR FROM HYDRAULIC SYSTEM….11121
METHOD FOR CHECKING ELECTRIC EQUIPMENT METHOD….11121
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION….11127
PROCEDURE FOR TESTING AND TROUBLESHOOTING….11137
SYMPTOM AND TROUBLESHOOTING NUMBERS….11139
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE….11143
CONNECTORS LIST AND LAYOUT….11146
CONNECTOR CONTACT IDENTIFICATION….11169
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE….11209
FUSE LOCATION TABLE….11215
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)….11221
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR….11224
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT….11226
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] and [CA3135])….11232
FAILURE CODES TABLE….11234
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)….11257
FAILURE CODE [1500L0]….11257
FAILURE CODE [15B0NX]….11258
FAILURE CODE [15F0KM]….11260
FAILURE CODE [15F0MB]….11261
FAILURE CODE [15F7KM]….11262
FAILURE CODE [15G0MW]….11263
FAILURE CODE [15G7KM]….11264
FAILURE CODE [15H0MW]….11265
FAILURE CODE [15J0MW]….11266
FAILURE CODE [15K0MW]….11267
FAILURE CODE [15L0MW]….11269
FAILURE CODE [15M0MW]….11271
FAILURE CODE [15N0MW]….11273
FAILURE CODE [15SBL1]….11274
FAILURE CODE [15SBMA]….11277
FAILURE CODE [15SCL1]….11278
FAILURE CODE [15SCMA]….11281
FAILURE CODE [15SDL1]….11282
FAILURE CODE [15SDMA]….11285
FAILURE CODE [15SEL1]….11286
FAILURE CODE [15SEMA]….11289
FAILURE CODE [15SFL1]….11290
FAILURE CODE [15SFMA]….11293
FAILURE CODE [15SGL1]….11294
FAILURE CODE [15SGMA]….11297
FAILURE CODE [15SHL1]….11298
FAILURE CODE [15SHMA]….11301
FAILURE CODE [15SJMA]….11302
FAILURE CODE [2C4MNX]….11303
FAILURE CODE [2F00KM]….11304
FAILURE CODE [2G42ZG]….11308
FAILURE CODE [2G43ZG]….11309
FAILURE CODE [6014NX]….11310
FAILURE CODE [879AKA]….11311
FAILURE CODE [879AKB]….11312
FAILURE CODE [879BKA]….11313
FAILURE CODE [879BKB]….11314
FAILURE CODE [879CKA]….11315
FAILURE CODE [879CKB]….11316
FAILURE CODE [879EMC]….11317
FAILURE CODE [879FMC]….11318
FAILURE CODE [879GKX]….11319
FAILURE CODE [989D00]….11320
FAILURE CODE [989L00]….11321
FAILURE CODE [989M00]….11322
FAILURE CODE [989N00]….11323
FAILURE CODE [989X00]….11324
FAILURE CODE [A1U0N3]….11325
FAILURE CODE [A1U0N4]….11326
FAILURE CODE [AA10NX]….11327
FAILURE CODE [AB00KE]….11329
FAILURE CODE [AB00KY]….11331
FAILURE CODE [AQ10N3]….11332
FAILURE CODE [AS00N3]….11333
FAILURE CODE [AS00R2]….11334
FAILURE CODE [AS00R3]….11335
FAILURE CODE [AS00R4]….11336
FAILURE CODE [AS00R5]….11337
FAILURE CODE [AS00R6]….11338
FAILURE CODE [AS00ZK]….11339
FAILURE CODE [AS10KM]….11340
FAILURE CODE [AS10NR]….11341
FAILURE CODE [AS10NT]….11342
FAILURE CODE [B@BAZG]….11343
FAILURE CODE [B@BAZK]….11344
FAILURE CODE [B@BCNS]….11345
FAILURE CODE [B@BCZK]….11346
FAILURE CODE [B@C7NS]….11348
FAILURE CODE [B@CENS]….11350
FAILURE CODE [B@JANS]….11351
FAILURE CODE [CA115]….11352
FAILURE CODE [CA122]….11353
FAILURE CODE [CA123]….11355
FAILURE CODE [CA131]….11357
FAILURE CODE [CA132]….11359
FAILURE CODE [CA135]….11361
FAILURE CODE [CA141]….11363
FAILURE CODE [CA144]….11365
FAILURE CODE [CA145]….11367
FAILURE CODE [CA153]….11369
FAILURE CODE [CA154]….11371
FAILURE CODE [CA187]….11373
FAILURE CODE [CA221]….11375
FAILURE CODE [CA222]….11377
FAILURE CODE [CA227]….11379
FAILURE CODE [CA234]….11380
FAILURE CODE [CA238]….11381
FAILURE CODE [CA239]….11383
FAILURE CODE [CA249]….11385
FAILURE CODE [CA256]….11387
FAILURE CODE [CA271]….11389
FAILURE CODE [CA272]….11391
FAILURE CODE [CA273]….11392
FAILURE CODE [CA274]….11394
FAILURE CODE [CA322]….11395
FAILURE CODE [CA323]….11397
FAILURE CODE [CA324]….11399
FAILURE CODE [CA325]….11401
FAILURE CODE [CA331]….11403
FAILURE CODE [CA332]….11405
FAILURE CODE [CA343]….11407
FAILURE CODE [CA351]….11408
FAILURE CODE [CA352]….11409
FAILURE CODE [CA356]….11411
FAILURE CODE [CA357]….11413
FAILURE CODE [CA386]….11415
FAILURE CODE [CA431]….11416
FAILURE CODE [CA432]….11419
FAILURE CODE [CA441]….11422
FAILURE CODE [CA442]….11425
FAILURE CODE [CA449]….11426
FAILURE CODE [CA451]….11427
FAILURE CODE [CA452]….11429
FAILURE CODE [CA515]….11431
FAILURE CODE [CA516]….11433
FAILURE CODE [CA553]….11435
FAILURE CODE [CA555]….11436
FAILURE CODE [CA556]….11437
FAILURE CODE [CA559]….11438
FAILURE CODE [CA595]….11442
FAILURE CODE [CA687]….11443
FAILURE CODE [CA689]….11445
FAILURE CODE [CA691]….11447
FAILURE CODE [CA692]….11449
FAILURE CODE [CA697]….11451
FAILURE CODE [CA698]….11452
FAILURE CODE [CA731]….11453
FAILURE CODE [CA778]….11454
FAILURE CODE [CA1117]….11457
FAILURE CODE [CA1664]….11459
FAILURE CODE [CA1669]….11461
FAILURE CODE [CA1673]….11462
FAILURE CODE [CA1677]….11463
FAILURE CODE [CA1678]….11464
FAILURE CODE [CA1682]….11465
FAILURE CODE [CA1683]….11467
FAILURE CODE [CA1684]….11469
FAILURE CODE [CA1686]….11471
FAILURE CODE [CA1691]….11472
FAILURE CODE [CA1694]….11474
FAILURE CODE [CA1695]….11476
FAILURE CODE [CA1696]….11477
FAILURE CODE [CA1712]….11479
FAILURE CODE [CA1713]….11481
FAILURE CODE [CA1714]….11483
FAILURE CODE [CA1715]….11484
FAILURE CODE [CA1776]….11485
FAILURE CODE [CA1777]….11488
FAILURE CODE [CA1843]….11491
FAILURE CODE [CA1844]….11493
FAILURE CODE [CA1879]….11495
FAILURE CODE [CA1881]….11497
FAILURE CODE [CA1883]….11499
FAILURE CODE [CA1885]….11502
FAILURE CODE [CA1887]….11504
FAILURE CODE [CA1921]….11506
FAILURE CODE [CA1922]….11508
FAILURE CODE [CA1923]….11511
FAILURE CODE [CA1924]….11513
FAILURE CODE [CA1925]….11515
FAILURE CODE [CA1927]….11517
FAILURE CODE [CA1928]….11519
FAILURE CODE [CA1942]….11521
FAILURE CODE [CA1963]….11522
FAILURE CODE [CA1977]….11525
FAILURE CODE [CA1993]….11527
FAILURE CODE [CA2185]….11529
FAILURE CODE [CA2186]….11531
FAILURE CODE [CA2249]….11533
FAILURE CODE [CA2265]….11534
FAILURE CODE [CA2266]….11536
FAILURE CODE [CA2271]….11538
FAILURE CODE [CA2272]….11540
FAILURE CODE [CA2349]….11542
FAILURE CODE [CA2353]….11544
FAILURE CODE [CA2357]….11546
FAILURE CODE [CA2381]….11547
FAILURE CODE [CA2382]….11549
FAILURE CODE [CA2383]….11551
FAILURE CODE [CA2386]….11553
FAILURE CODE [CA2387]….11555
FAILURE CODE [CA2555]….11556
FAILURE CODE [CA2556]….11558
FAILURE CODE [CA2637]….11560
FAILURE CODE [CA2639]….11562
FAILURE CODE [CA2732]….11564
FAILURE CODE [CA2733]….11566
FAILURE CODE [CA2741]….11568
FAILURE CODE [CA2765]….11569
FAILURE CODE [CA2771]….11570
FAILURE CODE [CA2777]….11575
FAILURE CODE [CA2878]….11576
FAILURE CODE [CA2881]….11579
FAILURE CODE [CA2976]….11583
FAILURE CODE [CA3133]….11585
FAILURE CODE [CA3134]….11587
FAILURE CODE [CA3135]….11589
FAILURE CODE [CA3142]….11592
FAILURE CODE [CA3143]….11593
FAILURE CODE [CA3144]….11594
FAILURE CODE [CA3146]….11596
FAILURE CODE [CA3147]….11597
FAILURE CODE [CA3148]….11598
FAILURE CODE [CA3151]….11600
FAILURE CODE [CA3165]….11605
FAILURE CODE [CA3167]….11607
FAILURE CODE [CA3229]….11610
FAILURE CODE [CA3231]….11612
FAILURE CODE [CA3232]….11614
FAILURE CODE [CA3235]….11618
FAILURE CODE [CA3239]….11620
FAILURE CODE [CA3241]….11623
FAILURE CODE [CA3242]….11626
FAILURE CODE [CA3251]….11628
FAILURE CODE [CA3253]….11630
FAILURE CODE [CA3254]….11633
FAILURE CODE [CA3255]….11635
FAILURE CODE [CA3256]….11637
FAILURE CODE [CA3311]….11639
FAILURE CODE [CA3312]….11641
FAILURE CODE [CA3313]….11643
FAILURE CODE [CA3314]….11644
FAILURE CODE [CA3315]….11645
FAILURE CODE [CA3316]….11648
FAILURE CODE [CA3317]….11649
FAILURE CODE [CA3318]….11650
FAILURE CODE [CA3319]….11653
FAILURE CODE [CA3321]….11654
FAILURE CODE [CA3322]….11655
FAILURE CODE [CA3419]….11658
FAILURE CODE [CA3421]….11660
FAILURE CODE [CA3497]….11662
FAILURE CODE [CA3498]….11663
FAILURE CODE [CA3543]….11664
FAILURE CODE [CA3545]….11669
FAILURE CODE [CA3547]….11671
FAILURE CODE [CA3558]….11672
FAILURE CODE [CA3559]….11674
FAILURE CODE [CA3562]….11676
FAILURE CODE [CA3563]….11678
FAILURE CODE [CA3567]….11681
FAILURE CODE [CA3568]….11683
FAILURE CODE [CA3571]….11686
FAILURE CODE [CA3572]….11688
FAILURE CODE [CA3574]….11690
FAILURE CODE [CA3575]….11692
FAILURE CODE [CA3577]….11694
FAILURE CODE [CA3578]….11696
FAILURE CODE [CA3582]….11698
FAILURE CODE [CA3583]….11702
FAILURE CODE [CA3596]….11704
FAILURE CODE [CA3649]….11707
FAILURE CODE [CA3681]….11709
FAILURE CODE [CA3682]….11713
FAILURE CODE [CA3713]….11717
FAILURE CODE [CA3717]….11720
FAILURE CODE [CA3718]….11721
FAILURE CODE [CA3725]….11722
FAILURE CODE [CA3748]….11725
FAILURE CODE [CA3751]….11727
FAILURE CODE [CA3755]….11728
FAILURE CODE [CA3866]….11730
FAILURE CODE [CA3867]….11733
FAILURE CODE [CA3868]….11736
FAILURE CODE [CA3899]….11740
FAILURE CODE [CA3911]….11742
FAILURE CODE [CA3912]….11746
FAILURE CODE [CA3932]….11748
FAILURE CODE [CA3933]….11750
FAILURE CODE [CA3934]….11752
FAILURE CODE [CA3935]….11755
FAILURE CODE [CA3936]….11757
FAILURE CODE [CA4151]….11759
FAILURE CODE [CA4152]….11763
FAILURE CODE [CA4155]….11767
FAILURE CODE [CA4156]….11769
FAILURE CODE [CA4157]….11771
FAILURE CODE [CA4158]….11773
FAILURE CODE [CA4159]….11775
FAILURE CODE [CA4161]….11776
FAILURE CODE [CA4162]….11778
FAILURE CODE [CA4163]….11780
FAILURE CODE [CA4164]….11782
FAILURE CODE [CA4165]….11784
FAILURE CODE [CA4166]….11786
FAILURE CODE [CA4168]….11787
FAILURE CODE [CA4169]….11792
FAILURE CODE [CA4171]….11797
FAILURE CODE [CA4249]….11802
FAILURE CODE [CA4251]….11807
FAILURE CODE [CA4259]….11812
FAILURE CODE [CA4261]….11815
FAILURE CODE [CA4277]….11817
FAILURE CODE [CA4281]….11819
FAILURE CODE [CA4459]….11822
FAILURE CODE [CA4461]….11824
FAILURE CODE [CA4658]….11827
FAILURE CODE [CA4731]….11830
FAILURE CODE [CA4732]….11831
FAILURE CODE [CA4739]….11832
FAILURE CODE [CA4768]….11833
FAILURE CODE [CA4769]….11835
FAILURE CODE [CA4842]….11837
FAILURE CODE [CA4952]….11840
FAILURE CODE [CA5115]….11842
FAILURE CODE [CA5179]….11845
FAILURE CODE [CA5181]….11847
FAILURE CODE [CA5383]….11849
FAILURE CODE [D150KB]….11850
FAILURE CODE [D150KZ]….11851
FAILURE CODE [D164KY]….11852
FAILURE CODE [D19HKZ]….11853
FAILURE CODE [D19JKZ]….11855
FAILURE CODE [D19QKZ]….11856
FAILURE CODE [D1EHKA]….11858
FAILURE CODE [D1EHKB]….11859
FAILURE CODE [D1EHKY]….11860
FAILURE CODE [D1EMKA]….11861
FAILURE CODE [D1EMKB]….11862
FAILURE CODE [D1EMKY]….11863
FAILURE CODE [D1FBKB]….11864
FAILURE CODE [D5ZHL6]….11865
FAILURE CODE [D5ZKKZ]….11867
FAILURE CODE [D811MC]….11869
FAILURE CODE [D862KA]….11870
FAILURE CODE [D8ALKA]….11871
FAILURE CODE [D8ALKB]….11873
FAILURE CODE [D8AQK4]….11875
FAILURE CODE [D8AQKR]….11876
FAILURE CODE [DAF0KT]….11877
FAILURE CODE [DAF0MB]….11878
FAILURE CODE [DAF0MC]….11879
FAILURE CODE [DAF3KK]….11880
FAILURE CODE [DAF8KB]….11882
FAILURE CODE [DAFDKB]….11883
FAILURE CODE [DAFGMC]….11885
FAILURE CODE [DAFLKA]….11886
FAILURE CODE [DAFLKB]….11888
FAILURE CODE [DAFQKR]….11890
FAILURE CODE [DAQ0KK]….11891
FAILURE CODE [DAQ0KT]….11894
FAILURE CODE [DAQ0MC]….11895
FAILURE CODE [DAQ1KA]….11896
FAILURE CODE [DAQ2KK]….11899
FAILURE CODE [DAQ9KQ]….11902
FAILURE CODE [DAQLKA]….11903
FAILURE CODE [DAQLKB]….11905
FAILURE CODE [DAQQKR]….11907
FAILURE CODE [DAQRKR]….11908
FAILURE CODE [DAQRMA]….11909
FAILURE CODE [DAQV00]….11910
FAILURE CODE [DAQW00]….11911
FAILURE CODE [DAZ9KQ]….11912
FAILURE CODE [DAZQKR]….11913
FAILURE CODE [DB10KT]….11914
FAILURE CODE [DB10MC]….11915
FAILURE CODE [DB11KA]….11916
FAILURE CODE [DB11KA] (For machines equipped with emergency engine stop switch)….11919
FAILURE CODE [DB12KK]….11922
FAILURE CODE [DB13KK]….11925
FAILURE CODE [DB19KQ]….11928
FAILURE CODE [DB1LKA]….11929
FAILURE CODE [DB1LKB]….11931
FAILURE CODE [DB1QKR]….11933
FAILURE CODE [DB1QMA]….11934
FAILURE CODE [DB1RKR]….11935
FAILURE CODE [DB2QKR]….11936
FAILURE CODE [DB2RKR]….11942
FAILURE CODE [DBS0KK]….11947
FAILURE CODE [DBS6KP]….11950
FAILURE CODE [DBSQKQ]….11952
FAILURE CODE [DBSQKR]….11953
FAILURE CODE [DBSRKR]….11954
FAILURE CODE [DDAAL6]….11955
FAILURE CODE [DDAAL6] (For machines equipped with emergency engine stop switch)….11957
FAILURE CODE [DDD7KX]….11959
FAILURE CODE [DDTHKA]….11961
FAILURE CODE [DDTJKA]….11963
FAILURE CODE [DDTKKA]….11965
FAILURE CODE [DDTLKA]….11967
FAILURE CODE [DDTMKA]….11969
FAILURE CODE [DDTNKA]….11971
FAILURE CODE [DDTPKA]….11973
FAILURE CODE [DF10KA]….11975
FAILURE CODE [DF10KB]….11979
FAILURE CODE [DGF1KX]….11984
FAILURE CODE [DGR2KB]….11986
FAILURE CODE [DGR6KB]….11988
FAILURE CODE [DGR6L8]….11989
FAILURE CODE [DGT1KX]….11991
FAILURE CODE [DHA4KA]….11993
FAILURE CODE [DHAAMA]….11995
FAILURE CODE [DHACMA]….11996
FAILURE CODE [DHP4KY]….11997
FAILURE CODE [DHP4KZ]….11999
FAILURE CODE [DHP5KY]….12001
FAILURE CODE [DHP5KZ]….12003
FAILURE CODE [DHP6KA]….12005
FAILURE CODE [DHP6KX]….12007
FAILURE CODE [DHP6KY]….12009
FAILURE CODE [DHP6KZ]….12011
FAILURE CODE [DHP7KA]….12013
FAILURE CODE [DHP7KX]….12015
FAILURE CODE [DHP7KY]….12017
FAILURE CODE [DHP7KZ]….12019
FAILURE CODE [DHQ4KX]….12021
FAILURE CODE [DHT5KX]….12023
FAILURE CODE [DHT5L6]….12025
FAILURE CODE [DHT8KX]….12027
FAILURE CODE [DHT8ZG]….12029
FAILURE CODE [DHU2KX]….12030
FAILURE CODE [DHU3KX]….12032
FAILURE CODE [DHUCKX]….12034
FAILURE CODE [DHUDKX]….12037
FAILURE CODE [DHUHKX]….12039
FAILURE CODE [DHULKX]….12041
FAILURE CODE [DHUMKX]….12043
FAILURE CODE [DHUPKX]….12045
FAILURE CODE [DJF1KA]….12047
FAILURE CODE [DK30KX]….12049
FAILURE CODE [DK51L5]….12051
FAILURE CODE [DK52KX]….12054
FAILURE CODE [DK53L8]….12056
FAILURE CODE [DK54KX]….12058
FAILURE CODE [DK60KX]….12060
FAILURE CODE [DKD0L6]….12062
FAILURE CODE [DKH0KX]….12064
FAILURE CODE [DKH1KX]….12067
FAILURE CODE [DLF1KA]….12069
FAILURE CODE [DLF1LC]….12070
FAILURE CODE [DLF2KA]….12072
FAILURE CODE [DLF2LC]….12073
FAILURE CODE [DLF8KA]….12075
FAILURE CODE [DLF8LC]….12077
FAILURE CODE [DLF9KA]….12079
FAILURE CODE [DLF9LC]….12081
FAILURE CODE [DLM3KA]….12083
FAILURE CODE [DLM3LC]….12084
FAILURE CODE [DLM3MB]….12086
FAILURE CODE [DLT3KA]….12087
FAILURE CODE [DLT3LC]….12088
FAILURE CODE [DPQ1KR]….12090
FAILURE CODE [DPQ2KR]….12093
FAILURE CODE [DPQ3KR]….12096
FAILURE CODE [DSJ0KR]….12100
FAILURE CODE [DV00KB]….12101
FAILURE CODE [DW2AKA]….12103
FAILURE CODE [DW2AKB]….12104
FAILURE CODE [DW2AKY]….12106
FAILURE CODE [DW2AL1]….12107
FAILURE CODE [DW2ALH]….12108
FAILURE CODE [DW35KZ]….12109
FAILURE CODE [DW36KZ]….12111
FAILURE CODE [DW4BK4]….12113
FAILURE CODE [DW4BMA]….12115
FAILURE CODE [DW72KZ]….12117
FAILURE CODE [DW73KA]….12119
FAILURE CODE [DW73KB]….12121
FAILURE CODE [DW73KY]….12123
FAILURE CODE [DW78KZ]….12124
FAILURE CODE [DW7BKB]….12126
FAILURE CODE [DW7BKY]….12127
FAILURE CODE [DW7BKZ]….12128
FAILURE CODE [DW7MKB]….12129
FAILURE CODE [DW7MKY]….12131
FAILURE CODE [DW7MKZ]….12132
FAILURE CODE [DW7NKZ]….12134
FAILURE CODE [DWNMKZ]….12136
FAILURE CODE [DX11K4]….12138
FAILURE CODE [DX11KA]….12140
FAILURE CODE [DX11KB]….12142
FAILURE CODE [DX11KY]….12144
FAILURE CODE [DX11MA]….12145
FAILURE CODE [DX13KA]….12147
FAILURE CODE [DX13KB]….12149
FAILURE CODE [DX13KY]….12151
FAILURE CODE [DX16KA]….12152
FAILURE CODE [DX16KB]….12153
FAILURE CODE [DX16KY]….12155
FAILURE CODE [DX37K4]….12156
FAILURE CODE [DX37KA]….12158
FAILURE CODE [DX37KB]….12160
FAILURE CODE [DX37KY]….12162
FAILURE CODE [DX37MA]….12163
FAILURE CODE [DX38K4]….12165
FAILURE CODE [DX38KA]….12167
FAILURE CODE [DX38KB]….12169
FAILURE CODE [DX38KY]….12171
FAILURE CODE [DX38MA]….12172
FAILURE CODE [DXH1KA]….12174
FAILURE CODE [DXH1KB]….12176
FAILURE CODE [DXH1KY]….12178
FAILURE CODE [DXH2KA]….12180
FAILURE CODE [DXH2KB]….12182
FAILURE CODE [DXH2KY]….12184
FAILURE CODE [DXH3KA]….12187
FAILURE CODE [DXH3KB]….12189
FAILURE CODE [DXH3KY]….12191
FAILURE CODE [DXH4KA]….12194
FAILURE CODE [DXH4KB]….12196
FAILURE CODE [DXH4KY]….12198
FAILURE CODE [DXH5KA]….12201
FAILURE CODE [DXH5KB]….12203
FAILURE CODE [DXH5KY]….12205
FAILURE CODE [DXH6KA]….12208
FAILURE CODE [DXH6KB]….12210
FAILURE CODE [DXH6KY]….12212
FAILURE CODE [DXH7KA]….12215
FAILURE CODE [DXH7KB]….12217
FAILURE CODE [DXH7KY]….12219
FAILURE CODE [DXHHKA]….12221
FAILURE CODE [DXHHKB]….12223
FAILURE CODE [DXHHKY]….12225
FAILURE CODE [DY30MA]….12227
FAILURE CODE [DY30MC]….12229
FAILURE CODE [DY30ME]….12232
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)….12234
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)….12234
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK….12241
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK….12244
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP….12246
E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING….12247
E-6 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING (For machines equipped with emergency engine stop switch)….12250
E-7 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING….12253
E-8 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS)….12255
E-9 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY….12257
E-10 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL….12259
E-11 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL….12262
E-12 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL….12265
E-13 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY….12268
E-14 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION….12270
E-15 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL….12272
E-16 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY….12274
E-17 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS….12275
E-18 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY….12279
E-19 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED….12283
E-20 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL….12286
E-21 REARVIEW MONITOR DOES NOT DISPLAY IMAGES WHILE REVERSE LINKED DISPLAY FUNCTION IS ENABLED….12288
E-22 GUIDE LINE ON REARVIEW MONITOR IS NOT DISPLAYED WHILE GUIDE LINE IS SET….12291
E-23 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL….12293
E-24 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL….12295
E-25 MACHINE MONITOR CANNOT BE OPERATED WHEN STARTING SWITCH IS IN OFF POSITION….12297
E-26 ALARM BUZZER DOES NOT SOUND….12298
E-27 ALARM BUZZER DOES NOT STOP SOUNDING….12300
E-28 ENGINE MODE SELECTOR FUNCTION DOES NOT OPERATE PROPERLY….12302
E-29 AISS FUNCTION DOES NOT OPERATE PROPERLY….12304
E-30 HOIST LEVER DOES NOT OPERATE PROPERLY….12306
E-31 FUEL FEED PUMP DOES NOT OPERATE OR DOES NOT STOP AUTOMATICALLY….12308
E-32 TURN SIGNAL LAMP AND WINKER LAMP (HAZARD LAMP) DO NOT OPERATE PROPERLY….12311
E-33 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS….12315
E-34 SMALL LAMP (CLEARANCE LAMP) DOES NOT LIGHT UP….12318
E-35 TAIL LAMP DOES NOT LIGHT UP….12321
E-36 (LOW BEAM) HEAD LAMP DOES NOT LIGHT UP….12324
E-37 (HIGH BEAM) HEAD LAMP DOES NOT LIGHT UP….12326
E-38 NEITHER (LOW BEAM) NOR (HIGH BEAM) HEAD LAMPS LIGHTS UP….12328
E-39 HIGH BEAMS DO NOT LIGHT UP WHILE PASSING SWITCH IS OPERATED….12330
E-40 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY….12332
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)….12334
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)….12334
FAILURE MODE AND CAUSE TABLE….12335
H-1 MACHINE DOES NOT START….12343
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE HUNTS)….12347
H-3 LOCKUP IS NOT RELEASED….12348
H-4 ABNORMALLY LARGE SHOCKS RESULT FROM STARTING OF MACHINE AND GEAR SHIFTING….12349
H-5 GEAR IS NOT SHIFTED UP….12351
H-6 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN LOCKUP DRIVE MODE AT ALL GEAR SPEEDS….12354
H-7 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN TORQUE CONVERTER DRIVE MODE….12355
H-8 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING AT SOME GEAR SPEED….12356
H-9 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED….12358
H-10 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH….12361
H-11 OIL PRESSURE OF TORQUE CONVERTER IS LOW….12362
H-12 STEERING WHEEL IS HEAVY TO OPERATE….12363
H-13 STEERING WHEEL CANNOT BE OPERATED….12364
H-14 STEERING WHEEL WAGGLES….12365
H-15 FRONT BRAKE DOES NOT WORK ENOUGH….12366
H-16 REAR BRAKE DOES NOT WORK ENOUGH….12367
H-17 DUMP BODY RISING SPEED IS LOW….12368
H-18 HYDRAULIC DRIFT OF DUMP BODY IS LARGE….12370
H-19 DUMP BODY DOES NOT MOVE….12371
H-20 RADIATOR FAN SPEED IS UNUSUAL (EXCESSIVELY HIGH OR LOW, OR FAN STOPS)….12373
H-21 UNUSUAL NOISE IS HEARD FROM AROUND RADIATOR FAN….12374
TROUBLESHOOTING OF ENGINE (S-MODE)….12375
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)….12375
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION….12376
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT….12377
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)….12378
S-4 ENGINE STARTABILITY IS POOR….12379
S-5 ENGINE DOES NOT PICK UP SMOOTHLY….12381
S-6 ENGINE STOPS DURING OPERATION….12383
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE….12385
S-8 ENGINE LACKS POWER….12386
S-9 KDPF GETS CLOGGED IN A SHORT TIME….12388
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE….12390
S-11 OIL BECOMES CONTAMINATED QUICKLY….12391
S-12 FUEL CONSUMPTION IS EXCESSIVE….12392
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)….12393
S-14 OIL PRESSURE DROPS….12394
S-15 FUEL MIXES INTO ENGINE OIL….12395
S-16 WATER MIXES INTO ENGINE OIL (MILKY)….12396
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)….12397
S-18 UNUSUAL NOISE IS HEARD….12398
S-19 VIBRATION IS EXCESSIVE….12399
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT….12400
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY….12401
S-22 ACTIVE REGENERATION TAKES TIME….12403
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION….12404
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE….12405
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)….12407
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)….12408
50 DISASSEMBLY AND ASSEMBLY….12410
CONTENTS….12411
ABBREVIATIONS….12416
DISASSEMBLE AND ASSEMBLE-RELATED INFORMATION….12421
HOW TO READ THIS MANUAL….12421
COATING MATERIALS LIST….12423
SPECIAL TOOL LIST….12426
DIAGRAMS OF SPECIAL TOOLS….12441
ENGINE AND COOLING SYSTEM….12446
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY….12446
PROCEDURE TO REMOVE SUPPLY PUMP ASSEMBLY….12446
PROCEDURE TO INSTALL SUPPLY PUMP ASSEMBLY….12447
REMOVE AND INSTALL INJECTOR ASSEMBLY….12451
PROCEDURE TO REMOVE INJECTOR ASSEMBLY….12451
PROCEDURE TO INSTALL INJECTOR ASSEMBLY….12465
REMOVE AND INSTALL FUEL DOSER ASSEMBLY….12483
PROCEDURE TO REMOVE FUEL DOSER ASSEMBLY….12483
PROCEDURE TO INSTALL FUEL DOSER ASSEMBLY….12485
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY….12487
PROCEDURE TO REMOVE CYLINDER HEAD ASSEMBLY….12488
PROCEDURE TO INSTALL CYLINDER HEAD ASSEMBLY….12503
REMOVE AND INSTALL EGR VALVE ASSEMBLY….12526
PROCEDURE TO REMOVE EGR VALVE ASSEMBLY….12526
PROCEDURE TO INSTALL EGR VALVE ASSEMBLY….12529
REMOVE AND INSTALL EGR COOLER ASSEMBLY….12532
PROCEDURE TO REMOVE EGR COOLER ASSEMBLY….12532
PROCEDURE TO INSTALL EGR COOLER ASSEMBLY….12538
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY….12544
PROCEDURE TO REMOVE STARTING MOTOR ASSEMBLY….12544
PROCEDURE TO INSTALL STARTING MOTOR ASSEMBLY….12545
REMOVE AND INSTALL ALTERNATOR BELT….12546
PROCEDURE TO REMOVE ALTERNATOR BELT….12546
PROCEDURE TO INSTALL ALTERNATOR BELT….12547
REMOVE AND INSTALL RADIATOR….12550
PROCEDURE TO REMOVE RADIATOR….12551
PROCEDURE TO INSTALL RADIATOR….12555
REMOVE AND INSTALL COOLER ASSEMBLY….12559
PROCEDURE TO REMOVE COOLER ASSEMBLY….12559
PROCEDURE TO INSTALL COOLER ASSEMBLY….12570
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY….12582
PROCEDURE TO REMOVE COOLING FAN AND COOLING FAN MOTOR ASSEMBLY….12582
PROCEDURE TO INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY….12586
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY….12591
PROCEDURE TO REMOVE AFTERCOOLER ASSEMBLY….12591
PROCEDURE TO INSTALL AFTERCOOLER ASSEMBLY….12592
REMOVE AND INSTALL GRILLE GUARD ASSEMBLY….12594
PROCEDURE TO REMOVE GRILLE GUARD ASSEMBLY….12594
PROCEDURE TO INSTALL GRILLE GUARD ASSEMBLY….12598
REMOVE AND INSTALL ENGINE ASSEMBLY….12602
PROCEDURE TO REMOVE ENGINE ASSEMBLY….12603
PROCEDURE TO INSTALL ENGINE ASSEMBLY….12612
REMOVE AND INSTALL ENGINE FRONT OIL SEAL….12627
PROCEDURE TO REMOVE ENGINE FRONT OIL SEAL….12627
PROCEDURE TO INSTALL ENGINE FRONT OIL SEAL….12628
REMOVE AND INSTALL ENGINE REAR OIL SEAL….12630
PROCEDURE TO REMOVE ENGINE REAR OIL SEAL….12630
PROCEDURE TO INSTALL ENGINE REAR OIL SEAL….12632
REMOVE AND INSTALL OUTPUT SHAFT ASSEMBLY….12638
PROCEDURE TO REMOVE OUTPUT SHAFT ASSEMBLY….12638
PROCEDURE TO INSTALL OUTPUT SHAFT ASSEMBLY….12639
DISASSEMBLE AND ASSEMBLE OF OUTPUT SHAFT ASSEMBLY….12641
PROCEDURE TO DISASSEMBLE OUTPUT SHAFT ASSEMBLY….12641
PROCEDURE TO ASSEMBLE OUTPUT SHAFT ASSEMBLY….12642
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY….12644
PROCEDURE TO REMOVE AdBlue/DEF TANK ASSEMBLY….12645
PROCEDURE TO INSTALL AdBlue/DEF TANK ASSEMBLY….12652
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY….12657
PROCEDURE TO REMOVE AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY….12658
PROCEDURE TO INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY….12665
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR….12670
PROCEDURE TO REMOVE AdBlue/DEF TANK SENSOR….12670
PROCEDURE TO INSTALL AdBlue/DEF TANK SENSOR….12671
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER….12673
PROCEDURE TO REMOVE AdBlue/DEF TANK STRAINER….12673
PROCEDURE TO INSTALL AdBlue/DEF TANK STRAINER….12673
REMOVE AND INSTALL KDPF, SCR ASSEMBLY….12674
PROCEDURE TO REMOVE KDPF, SCR ASSEMBLY….12675
PROCEDURE TO INSTALL KDPF, SCR ASSEMBLY….12685
REMOVE AND INSTALL KDPF ASSEMBLY….12695
PROCEDURE TO REMOVE KDPF ASSEMBLY….12695
PROCEDURE TO INSTALL KDPF ASSEMBLY….12699
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY….12705
PROCEDURE TO DISASSEMBLE KDPF ASSEMBLY….12706
PROCEDURE TO ASSEMBLE KDPF ASSEMBLY….12711
REMOVE AND INSTALL SCR ASSEMBLY….12716
PROCEDURE TO REMOVE SCR ASSEMBLY….12716
PROCEDURE TO INSTALL SCR ASSEMBLY….12719
REMOVE AND INSTALL KCCV ASSEMBLY….12724
PROCEDURE TO REMOVE KCCV ASSEMBLY….12724
PROCEDURE TO INSTALL KCCV ASSEMBLY….12728
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE….12732
PROCEDURE TO REMOVE AdBlue/DEF MIXING TUBE….12733
PROCEDURE TO INSTALL AdBlue/DEF MIXING TUBE….12741
REMOVE AND INSTALL AdBlue/DEF INJECTOR….12752
PROCEDURE TO REMOVE AdBlue/DEF INJECTOR….12753
PROCEDURE TO INSTALL AdBlue/DEF INJECTOR….12759
REMOVE AND INSTALL AdBlue/DEF PUMP….12764
PROCEDURE TO REMOVE AdBlue/DEF PUMP….12764
PROCEDURE TO INSTALL AdBlue/DEF PUMP….12769
REMOVE AND INSTALL AdBlue/DEF HOSE….12773
PROCEDURE TO REMOVE AdBlue/DEF HOSE….12774
PROCEDURE TO INSTALL AdBlue/DEF HOSE….12785
REMOVE AND INSTALL AIR CLEANER ASSEMBLY….12796
PROCEDURE TO REMOVE AIR CLEANER ASSEMBLY….12796
PROCEDURE TO INSTALL AIR CLEANER ASSEMBLY….12798
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY….12801
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY….12801
PROCEDURE TO INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY….12802
POWER TRAIN….12803
REMOVE AND INSTALL TORQUE CONVERTER AND TRANSMISSION ASSEMBLY….12803
PROCEDURE TO REMOVE TORQUE CONVERTER AND TRANSMISSION ASSEMBLY….12804
PROCEDURE TO INSTALL TORQUE CONVERTER AND TRANSMISSION ASSEMBLY….12816
DISCONNECT AND CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY….12831
PROCEDURE TO DISCONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY….12831
PROCEDURE TO CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY….12843
DISASSEMBLE AND ASSEMBLE OF TORQUE CONVERTER ASSEMBLY….12857
PROCEDURE TO DISASSEMBLE TORQUE CONVERTER ASSEMBLY….12858
PROCEDURE TO ASSEMBLE TORQUE CONVERTER ASSEMBLY….12864
DISASSEMBLE AND ASSEMBLE OF TRANSMISSION ASSEMBLY….12874
PROCEDURE TO DISASSEMBLE TRANSMISSION ASSEMBLY….12875
PROCEDURE TO ASSEMBLE TRANSMISSION ASSEMBLY….12892
REMOVE AND INSTALL DIFFERENTIAL ASSEMBLY….12913
PROCEDURE TO REMOVE DIFFERENTIAL ASSEMBLY….12913
PROCEDURE TO INSTALL DIFFERENTIAL ASSEMBLY….12915
DISASSEMBLE AND ASSEMBLE OF DIFFERENTIAL ASSEMBLY….12917
PROCEDURE TO DISASSEMBLE DIFFERENTIAL ASSEMBLY….12918
PROCEDURE TO ASSEMBLE DIFFERENTIAL ASSEMBLY….12923
REMOVE AND INSTALL FRONT BRAKE CALIPER PAD….12934
PROCEDURE TO REMOVE FRONT BRAKE CALIPER PAD….12934
PROCEDURE TO INSTALL FRONT BRAKE CALIPER PAD….12934
REMOVE AND INSTALL FRONT BRAKE CALIPER ASSEMBLY….12935
PROCEDURE TO REMOVE FRONT BRAKE CALIPER ASSEMBLY….12935
PROCEDURE TO INSTALL FRONT BRAKE CALIPER ASSEMBLY….12935
DISASSEMBLE AND ASSEMBLE OF FRONT BRAKE CALIPER ASSEMBLY….12937
PROCEDURE TO DISASSEMBLE FRONT BRAKE CALIPER ASSEMBLY….12937
PROCEDURE TO ASSEMBLE FRONT BRAKE CALIPER ASSEMBLY….12938
REMOVE AND INSTALL FINAL DRIVE AND REAR BRAKE ASSEMBLY….12940
PROCEDURE TO REMOVE FINAL DRIVE AND REAR BRAKE ASSEMBLY….12940
PROCEDURE TO INSTALL FINAL DRIVE AND REAR BRAKE ASSEMBLY….12941
REMOVE AND INSTALL PARKING BRAKE PAD ASSEMBLY….12943
PROCEDURE TO REMOVE PARKING BRAKE PAD ASSEMBLY….12943
PROCEDURE TO INSTALL PARKING BRAKE PAD ASSEMBLY….12944
REMOVE AND INSTALL PARKING BRAKE CALIPER ASSEMBLY….12946
PROCEDURE TO REMOVE PARKING BRAKE CALIPER ASSEMBLY….12946
PROCEDURE TO INSTALL PARKING BRAKE CALIPER ASSEMBLY….12946
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE CARRIER ASSEMBLY….12947
PROCEDURE TO DISASSEMBLE FINAL DRIVE CARRIER ASSEMBLY….12947
PROCEDURE TO ASSEMBLE FINAL DRIVE CARRIER ASSEMBLY….12948
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE ASSEMBLY….12950
PROCEDURE TO DISASSEMBLE FINAL DRIVE ASSEMBLY….12950
PROCEDURE TO ASSEMBLE FINAL DRIVE ASSEMBLY….12954
REMOVE AND INSTALL SLACK ADJUSTER ASSEMBLY….12959
PROCEDURE TO REMOVE SLACK ADJUSTER ASSEMBLY….12959
PROCEDURE TO INSTALL SLACK ADJUSTER ASSEMBLY….12960
STEERING SYSTEM….12962
REMOVE AND INSTALL STEERING VALVE ASSEMBLY….12962
PROCEDURE TO REMOVE STEERING VALVE ASSEMBLY….12962
PROCEDURE TO INSTALL STEERING VALVE ASSEMBLY….12965
DISASSEMBLE AND ASSEMBLE OF STEERING CYLINDER ASSEMBLY….12968
PROCEDURE TO DISASSEMBLE STEERING CYLINDER ASSEMBLY….12968
PROCEDURE TO ASSEMBLE STEERING CYLINDER ASSEMBLY….12970
REMOVE AND INSTALL SECONDARY STEERING MOTOR PUMP ASSEMBLY….12973
PROCEDURE TO REMOVE SECONDARY STEERING MOTOR PUMP ASSEMBLY….12973
PROCEDURE TO INSTALL SECONDARY STEERING MOTOR PUMP ASSEMBLY….12976
UNDERCARRIAGE AND FRAME….12979
REMOVE AND INSTALL FRONT WHEEL ASSEMBLY….12979
PROCEDURE TO REMOVE FRONT WHEEL ASSEMBLY….12979
PROCEDURE TO INSTALL FRONT WHEEL ASSEMBLY….12980
REMOVE AND INSTALL REAR WHEEL ASSEMBLY….12982
PROCEDURE TO REMOVE REAR WHEEL ASSEMBLY….12982
PROCEDURE TO INSTALL REAR WHEEL ASSEMBLY….12984
REMOVE AND INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY….12986
PROCEDURE TO REMOVE FRONT SUSPENSION CYLINDER ASSEMBLY….12986
PROCEDURE TO INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY….12987
DISASSEMBLE AND ASSEMBLE OF FRONT SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER RING)….12990
PROCEDURE TO DISASSEMBLE FRONT SUSPENSION CYLINDER ASSEMBLY….12990
PROCEDURE TO ASSEMBLE FRONT SUSPENSION CYLINDER ASSEMBLY….12992
REMOVE AND INSTALL KING PIN….12994
PROCEDURE TO REMOVE KING PIN….12994
PROCEDURE TO INSTALL KING PIN….12995
DISASSEMBLE AND ASSEMBLE OF VARIABLE DAMPING SELECTOR VALVE ASSEMBLY….12996
PROCEDURE TO DISASSEMBLE VARIABLE DAMPING SELECTOR VALVE ASSEMBLY….12998
PROCEDURE TO ASSEMBLE VARIABLE DAMPING SELECTOR VALVE ASSEMBLY….12998
REMOVE AND INSTALL REAR SUSPENSION CYLINDER ASSEMBLY….13000
PROCEDURE TO REMOVE REAR SUSPENSION CYLINDER ASSEMBLY….13000
PROCEDURE TO INSTALL REAR SUSPENSION CYLINDER ASSEMBLY….13000
DISASSEMBLE AND ASSEMBLE OF REAR SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER RING)….13001
PROCEDURE TO DISASSEMBLE REAR SUSPENSION CYLINDER ASSEMBLY….13001
PROCEDURE TO ASSEMBLE REAR SUSPENSION CYLINDER ASSEMBLY….13003
DISASSEMBLE AND ASSEMBLE OF FRONT WHEEL HUB ASSEMBLY….13006
PROCEDURE TO DISASSEMBLE FRONT WHEEL HUB ASSEMBLY….13006
PROCEDURE TO ASSEMBLE FRONT WHEEL HUB ASSEMBLY….13007
HYDRAULIC SYSTEM….13011
REMOVE AND INSTALL HOIST VALVE ASSEMBLY….13011
PROCEDURE TO REMOVE HOIST VALVE ASSEMBLY….13011
PROCEDURE TO INSTALL HOIST VALVE ASSEMBLY….13014
DISASSEMBLE AND ASSEMBLE OF HOIST CYLINDER ASSEMBLY….13018
PROCEDURE TO DISASSEMBLE HOIST CYLINDER ASSEMBLY….13019
PROCEDURE TO ASSEMBLE HOIST CYLINDER ASSEMBLY….13022
WORK EQUIPMENT….13029
REMOVE AND INSTALL DUMP BODY ASSEMBLY….13029
PROCEDURE TO REMOVE DUMP BODY ASSEMBLY….13029
PROCEDURE TO INSTALL DUMP BODY ASSEMBLY….13030
CAB AND ITS ATTACHMENTS….13033
REMOVE AND INSTALL AIR CONDITIONER ASSEMBLY….13033
PROCEDURE TO REMOVE AIR CONDITIONER ASSEMBLY….13033
PROCEDURE TO INSTALL AIR CONDITIONER UNIT ASSEMBLY….13041
REMOVE AND INSTALL OPERATOR'S SEAT ASSEMBLY….13048
PROCEDURE TO REMOVE OPERATOR'S SEAT ASSEMBLY….13048
PROCEDURE TO INSTALL OPERATOR'S SEAT ASSEMBLY….13050
REMOVE AND INSTALL SEAT BELT….13053
PROCEDURE TO REMOVE SEAT BELT….13053
PROCEDURE TO INSTALL SEAT BELT….13054
ELECTRICAL SYSTEM….13055
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY….13055
PROCEDURE TO REMOVE ENGINE CONTROLLER ASSEMBLY….13055
PROCEDURE TO INSTALL ENGINE CONTROLLER ASSEMBLY….13056
REMOVE AND INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY….13059
PROCEDURE TO REMOVE RETARDER AND HOIST CONTROLLER ASSEMBLY….13059
PROCEDURE TO INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY….13060
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY….13061
PROCEDURE TO REMOVE TRANSMISSION CONTROLLER ASSEMBLY….13061
PROCEDURE TO INSTALL TRANSMISSION CONTROLLER ASSEMBLY….13062
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY….13063
PROCEDURE TO REMOVE MACHINE MONITOR ASSEMBLY….13063
PROCEDURE TO INSTALL MACHINE MONITOR ASSEMBLY….13065
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY….13068
PROCEDURE TO REMOVE MONITOR CONTROLLER ASSEMBLY….13068
PROCEDURE TO INSTALL MONITOR CONTROLLER ASSEMBLY….13069
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR….13070
PROCEDURE TO REMOVE MASS AIR FLOW AND TEMPERATURE SENSOR….13070
PROCEDURE TO INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR….13071
REMOVE AND INSTALL SCR TEMPERATURE SENSOR….13073
PROCEDURE TO REMOVE SCR TEMPERATURE SENSOR….13073
PROCEDURE TO INSTALL SCR TEMPERATURE SENSOR….13075
REMOVE AND INSTALL KOMTRAX CONTROLLER ASSEMBLY….13077
PROCEDURE TO REMOVE KOMTRAX CONTROLLER ASSEMBLY….13077
PROCEDURE TO INSTALL KOMTRAX CONTROLLER ASSEMBLY….13078
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR….13079
PROCEDURE TO REMOVE KCCV CRANKCASE PRESSURE SENSOR….13079
PROCEDURE TO INSTALL KCCV CRANKCASE PRESSURE SENSOR….13080
60 MAINTENANCE STANDARD….13082
CONTENTS….13083
ABBREVIATIONS….13084
ENGINE AND COOLING SYSTEM….13089
MAINTENANCE STANDARD OF ENGINE MOUNT….13089
MAINTENANCE STANDARD OF OUTPUT SHAFT….13090
MAINTENANCE STANDARD OF COOLING FAN AND HOIST PUMP….13092
MAINTENANCE STANDARD OF SERVO VALVE OF COOLING FAN AND HOIST PUMP….13093
MAINTENANCE STANDARD OF COOLING FAN MOTOR….13094
POWER TRAIN….13096
MAINTENANCE STANDARD OF DRIVE SHAFT….13096
MAINTENANCE STANDARD OF TORQUE CONVERTER AND TRANSMISSION MOUNT….13097
MAINTENANCE STANDARD OF TORQUE CONVERTER AND PTO….13098
MAINTENANCE STANDARD OF TORQUE CONVERTER VALVE….13101
MAINTENANCE STANDARD OF TRANSMISSION….13102
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE….13107
MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV….13108
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV….13109
MAINTENANCE STANDARD OF FRONT AXLE….13110
MAINTENANCE STANDARD OF REAR AXLE….13111
MAINTENANCE STANDARD OF DIFFERENTIAL….13112
MAINTENANCE STANDARD OF FINAL DRIVE….13113
STEERING SYSTEM….13114
MAINTENANCE STANDARD OF STEERING COLUMN….13114
MAINTENANCE STANDARD OF STEERING CONTROL LINKAGE….13115
MAINTENANCE STANDARD OF DEMAND VALVE….13118
MAINTENANCE STANDARD OF STEERING CYLINDER….13120
BRAKE SYSTEM….13121
MAINTENANCE STANDARD OF SLACK ADJUSTER….13121
MAINTENANCE STANDARD OF FRONT BRAKE….13122
MAINTENANCE STANDARD OF REAR BRAKE….13123
MAINTENANCE STANDARD OF PARKING BRAKE….13124
UNDERCARRIAGE AND FRAME….13126
MAINTENANCE STANDARD OF FRONT SUSPENSION CYLINDER….13126
MAINTENANCE STANDARD OF REAR SUSPENSION CYLINDER….13128
MAINTENANCE STANDARD OF REAR AXLE SUPPORT….13130
HYDRAULIC SYSTEM….13131
MAINTENANCE STANDARD OF STEERING AND HOIST PUMP….13131
MAINTENANCE STANDARD OF SERVO VALVE OF STEERING AND HOIST PUMP….13132
MAINTENANCE STANDARD OF POWER TRAIN AND BRAKE CONTROL DUPLEX PUMP….13134
MAINTENANCE STANDARD OF BRAKE COOLING DUPLEX PUMP….13136
MAINTENANCE STANDARD OF HOIST VALVE….13138
WORK EQUIPMENT….13140
MAINTENANCE STANDARD OF HOIST CYLINDER….13140
CAB AND ITS ATTACHMENTS….13141
MAINTENANCE STANDARD OF CAB MOUNT….13141
80 THE OTHER INFORMATION….13142
CONTENTS….13143
ABBREVIATIONS….13145
AIR CONDITIONER SYSTEM….13150
PRECAUTIONS FOR REFRIGERANT….13150
AIR CONDITIONER COMPONENT….13151
SPECIFICATIONS OF AIR CONDITIONER….13153
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE….13154
OUTLINE OF REFRIGERATION CYCLE….13155
COMPONENT PARTS OF AIR CONDITIONER SYSTEM….13157
AIR CONDITIONER UNIT….13157
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT….13157
FUNCTION OF AIR CONDITIONER UNIT….13158
COMPONENT PARTS OF AIR CONDITIONER UNIT….13160
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT….13160
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT….13161
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT….13161
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT….13161
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT….13162
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT….13162
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT….13162
FUNCTION OF DUAL PRESSURE SWITCH….13163
AIR CONDITIONER CONTROLLER….13164
STRUCTURE OF AIR CONDITIONER CONTROLLER….13164
COMPRESSOR….13165
STRUCTURE OF COMPRESSOR….13165
SPECIFICATIONS OF COMPRESSOR….13165
FUNCTION OF COMPRESSOR….13165
CONDENSER….13166
STRUCTURE OF CONDENSER….13166
SPECIFICATIONS OF CONDENSER….13166
FUNCTION OF CONDENSER….13166
SENSORS FOR AIR CONDITIONER SYSTEM….13168
STRUCTURE OF AMBIENT TEMPERATURE SENSOR….13168
FUNCTION OF AMBIENT TEMPERATURE SENSOR….13168
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER….13169
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER….13171
AIR CONDITIONER SYSTEM DIAGRAM….13173
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER….13174
FUNCTION OF AIR CONDITIONER CONTROLLER….13175
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS….13176
TESTING AIR LEAKAGE (DUCT)….13179
METHOD FOR TESTING AIR LEAKAGE (DUCT)….13179
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION….13182
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR….13184
TEST VENT (MODE) CHANGEOVER….13186
METHOD FOR TESTING VENT (MODE) CHANGEOVER….13186
TESTING FRESH/RECIRC AIR CHANGEOVER….13187
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER….13187
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT….13188
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT….13188
TEST RELAYS….13189
METHOD FOR TESTING RELAYS….13189
AIR CONDITIONER TROUBLESHOOTING CHART 1….13190
AIR CONDITIONER TROUBLESHOOTING CHART 2….13191
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE….13194
FAILURE CODE [879AKA]….13195
FAILURE CODE [879AKB]….13196
FAILURE CODE [879BKA]….13197
FAILURE CODE [879BKB]….13198
FAILURE CODE [879CKA]….13199
FAILURE CODE [879CKB]….13200
FAILURE CODE [879EMC]….13201
FAILURE CODE [879FMC]….13202
FAILURE CODE [879GKX]….13203
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)….13204
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)….13206
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)….13209
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER….13211
TROUBLESHOOTING USING GAUGE PRESSURE….13213
CONNECTION OF SERVICE TOOL….13216
METHOD FOR CONNECTING SERVICE TOOL….13216
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS….13217
HANDLE COMPRESSOR OIL….13219
METHOD FOR REPLACING DESICCANT….13221
90 CIRCUIT DIAGRAMS….13224
CONTENTS….13225
ABBREVIATIONS….13226
HYDRAULIC CIRCUIT DIAGRAM….13231
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM….13231
HYDRAULIC CIRCUIT DIAGRAM….13236
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM….13236
ELECTRICAL CIRCUIT DIAGRAM….13238
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM….13238
INTERNAL CAB ELECTRICAL DIAGRAM (1/9)….13242
INTERNAL CAB ELECTRICAL DIAGRAM (2/9)….13243
INTERNAL CAB ELECTRICAL DIAGRAM (3/9)….13244
INTERNAL CAB ELECTRICAL DIAGRAM (4/9)….13245
INTERNAL CAB ELECTRICAL DIAGRAM (5/9)….13246
INTERNAL CAB ELECTRICAL DIAGRAM (6/9)….13247
INTERNAL CAB ELECTRICAL DIAGRAM (7/9)….13248
INTERNAL CAB ELECTRICAL DIAGRAM (8/9)….13249
INTERNAL CAB ELECTRICAL DIAGRAM (9/9)….13250
EXTERNAL CAB ELECTRICAL DIAGRAM (1/8)….13251
EXTERNAL CAB ELECTRICAL DIAGRAM (2/8)….13252
EXTERNAL CAB ELECTRICAL DIAGRAM (3/8)….13253
EXTERNAL CAB ELECTRICAL DIAGRAM (4/8)….13254
EXTERNAL CAB ELECTRICAL DIAGRAM (5/8)….13255
EXTERNAL CAB ELECTRICAL DIAGRAM (6/8)….13256
EXTERNAL CAB ELECTRICAL DIAGRAM (7/8)….13257
EXTERNAL CAB ELECTRICAL DIAGRAM (8/8)….13258
ELECTRICAL CIRCUIT DIAGRAM OF ENGINE….13259
INDEX….13260
TEN00041-05 – Dump Truck HD325-6, HD405-6 Operation & Maintenance Manual….13276
COVER….13276
FOREWORD….13277
FOREWORD….13278
SAFETY INFORMATION….13281
INTENDED USE….13283
DIRECTIONS OF MACHINE….13283
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….13284
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….13284
ENGINE SERIAL NO. PLATE POSITION….13284
SERVICE METER POSITION….13285
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….13285
CONTENTS….13286
SAFETY….13291
SAFETY….13292
SAFETY LABELS….13294
POSITION FOR ATTACHING SAFETY LABELS….13294
SAFETY LABELS….13295
GENERAL PRECAUTIONS….13300
PRECAUTIONS DURING OPERATION….13308
STARTING ENGINE….13308
OPERATION….13310
TRANSPORTATION….13313
BATTERY….13314
TOWING….13316
PRECAUTIONS FOR MAINTENANCE….13317
PRECAUTIONS WITH TIRES….13323
OPERATION….13325
GENERAL VIEW….13326
GENERAL VIEW OF MACHINE….13326
GENERAL VIEW OF CONTROLS AND GAUGES….13327
EXPLANATION OF COMPONENTS….13329
MACHINE MONITOR….13329
SWITCHES….13347
CONTROL LEVERS AND PEDALS….13356
MECHATRONICS EQUIPMENT CONTROLLER….13360
BODY PIVOT PIN….13361
DUST INDICATOR….13361
LOCATION OF FIRE EXTINGUISHER….13362
LOCATION OF FIRST AID KIT….13362
FUSES….13362
CAR RADIO….13365
CAR STEREO….13371
AIR CONDITIONER….13379
OPERATION….13384
CHECK BEFORE STARTING ENGINE….13384
STARTING ENGINE….13400
OPERATIONS, CHECKS AFTER STARTING ENGINE….13404
STOPPING ENGINE….13405
CHECKS AFTER STOPPING ENGINE….13405
MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING….13406
SHIFTING GEAR….13411
TRAVELING DOWNHILL….13412
STEERING THE MACHINE….13421
LOADING OPERATIONS….13421
DUMP OPERATIONS….13422
PRECAUTIONS FOR OPERATION….13423
PARKING MACHINE….13424
CHECKS AFTER COMPLETION OF WORK….13425
DRAIN WATER FROM AIR TANK….13425
LOCKING….13425
HANDLING TIRES….13426
DETERMINING AND MAINTAINING TRAVEL ROAD….13430
DETERMINING TRAVEL ROAD….13430
MAINTAINING TRAVEL ROAD….13430
TRANSPORTATION….13431
PRECAUTIONS WHEN TRANSPORTING….13431
STEPS FOR TRANSPORTATION….13431
METHOD OF SECURING MACHINE….13431
METHOD OF LIFTING MACHINE….13432
COLD WEATHER OPERATION….13434
PRECAUTIONS FOR LOW TEMPERATURE….13434
PRECAUTIONS AFTER COMPLETION OF WORK….13435
AFTER COLD WEATHER….13436
LONG-TERM STORAGE….13437
BEFORE STORAGE….13437
DURING STORAGE….13437
AFTER STORAGE….13437
PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE….13437
TROUBLESHOOTING….13438
AFTER RUNNING OUT OF FUEL….13438
METHOD OF TOWING MACHINE….13440
IF BATTERY IS DISCHARGED….13445
OTHER TROUBLE….13449
MAINTENANCE….13457
GUIDES TO MAINTENANCE….13458
OUTLINE OF SERVICE….13460
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….13460
OUTLINE OF ELECTRIC SYSTEM….13464
WEAR PARTS….13465
WEAR PARTS LIST….13465
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….13466
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….13467
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….13471
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….13472
TORQUE LIST….13472
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….13473
SAFETY CRITICAL PARTS….13473
MAINTENANCE SCHEDULE CHART….13474
MAINTENANCE SCHEDULE CHART….13474
ADJUST INJECTOR….13477
SERVICE PROCEDURE….13478
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)….13478
WHEN REQUIRED….13479
CHECK BEFORE STARTING….13496
EVERY 50 HOURS SERVICE….13497
EVERY 100 HOURS SERVICE….13499
EVERY 250 HOURS SERVICE….13500
EVERY 500 HOURS SERVICE….13511
EVERY 1000 HOURS SERVICE….13518
EVERY 2000 HOURS SERVICE….13527
EVERY 4000 HOURS SERVICE….13532
EVERY 8000 HOURS SERVICE….13534
EVERY 15000 HOURS SERVICE….13535
SPECIFICATIONS….13537
SPECIFICATIONS….13538
ATTACHMENTS, OPTIONS….13539
HANDLING PAYLOAD METER….13540
NAME OF PARTS….13540
EXTERNAL DISPLAY LAMPS….13541
OPERATING PAYLOAD METER….13544
SELECTING DUMP BODY….13552
TACHOGRAPH (TCO 15-6)….13553
EXPLANATION OF COMPONENTS….13553
METHOD OF USING KEY….13555
METHOD OF USE….13556
REVO TACHOGRAPH (TCO 15-7)….13558
EXPLANATION OF COMPONENTS….13558
METHOD OF USE….13561
USING DIFFERENTIAL LOCK….13563
DIFFERENTIAL LOCK PEDAL….13563
PRECAUTIONS AND METHOD OF USE….13564
OPERATION OF ABS AND ABS/ASR….13565
EXPLANATION OF COMPONENTS….13565
OPERATION METHOD….13567
PRECAUTIONS FOR USE….13568
TROUBLESHOOTING….13568
HANDLING AUTO-GREASING SYSTEM….13569
METHOD OF OPERATING AUTO-GREASING SYSTEM….13569
PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM….13575
TROUBLESHOOTING….13575
ARSC (AUTOMATIC RETARDER SPEED CONTROL)….13576
EXPLANATION OF COMPONENTS….13576
METHOD OF OPERATION….13578
TROUBLESHOOTING….13580
ASR-II (AUTOMATIC SPIN REGULATOR II)….13583
EXPLANATION OF COMPONENTS….13583
ACTUATION OF ASR-II SYSTEM….13584
PRECAUTIONS WHEN USING….13584
TROUBLESHOOTING….13585
HANDLING OIL FILTER CAUTION….13587
METHOD OF USE….13587
INDEX….13589
TEN00137-09 – Dump Truck HD325-7, HD405-7 Operation & Maintenance Manual….13593
COVER….13593
FOREWORD….13594
BEFORE READING THIS MANUAL….13595
SAFETY INFORMATION….13598
INTENDED USE….13599
USE OF MACHINE….13599
DIRECTIONS OF MACHINE….13599
VISIBILITY FROM OPERATOR'S SEAT….13599
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….13600
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….13600
EPA REGULATIONS, ENGINE NUMBER PLATE….13600
SERVICE METER POSITION….13601
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….13601
CONTENTS….13602
SAFETY….13606
SAFETY….13607
SAFETY LABELS….13610
POSITION FOR ATTACHING SAFETY LABELS….13611
SAFETY LABELS….13612
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE….13617
PRECAUTIONS BEFORE STARTING OPERATION….13617
PREPARATIONS FOR SAFE OPERATION….13617
FIRE PREVENTION….13619
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE….13620
DO NOT GET CAUGHT IN DUMP BODY….13622
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES….13622
UNAUTHORIZED MODIFICATION….13622
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS….13623
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING….13623
PRECAUTIONS FOR OPERATION….13624
PRECAUTIONS FOR JOBSITE….13624
STARTING ENGINE….13626
OPERATION….13628
TRANSPORTATION….13632
TOWING….13633
PRECAUTIONS FOR MAINTENANCE….13634
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE….13634
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….13638
TIRES….13643
OPERATION….13646
GENERAL VIEW….13647
GENERAL VIEW OF MACHINE….13647
GENERAL VIEW OF CONTROLS AND GAUGES….13648
EXPLANATION OF COMPONENTS….13650
MACHINE MONITOR….13650
OTHER FUNCTIONS OF MACHINE MONITOR….13671
SWITCHES….13675
CONTROL LEVERS AND PEDALS….13684
BODY PIVOT PIN….13689
LOCATION OF FIRE EXTINGUISHER….13689
DUST INDICATOR….13690
FUSES….13691
CAR RADIO….13694
CAR STEREO….13700
AIR CONDITIONER….13709
OPERATION….13714
CHECK BEFORE STARTING ENGINE….13714
STARTING ENGINE….13733
OPERATIONS, CHECKS AFTER STARTING ENGINE….13735
STOPPING ENGINE….13736
CHECKS AFTER STOPPING ENGINE….13736
MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING….13737
SHIFTING GEAR….13742
TRAVELING DOWNHILL….13744
STEERING THE MACHINE….13753
LOADING OPERATIONS….13753
DUMP OPERATIONS….13754
PRECAUTIONS FOR OPERATION….13755
PARKING MACHINE….13756
CHECKS AFTER COMPLETION OF WORK….13757
LOCKING….13757
HANDLING TIRES….13758
DETERMINING AND MAINTAINING TRAVEL ROAD….13761
DETERMINING TRAVEL ROAD….13761
MAINTAINING TRAVEL ROAD….13761
TRANSPORTATION….13762
PRECAUTIONS WHEN TRANSPORTING….13762
STEPS FOR TRANSPORTATION….13762
METHOD OF SECURING MACHINE….13762
METHOD OF LIFTING MACHINE….13763
COLD WEATHER OPERATION….13766
PRECAUTIONS FOR LOW TEMPERATURE….13766
PRECAUTIONS AFTER COMPLETION OF WORK….13767
AFTER COLD WEATHER….13768
LONG-TERM STORAGE….13769
BEFORE STORAGE….13769
DURING STORAGE….13769
AFTER STORAGE….13769
PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE….13769
TROUBLESHOOTING….13770
AFTER RUNNING OUT OF FUEL….13770
IF TRANSMISSION HAS TROUBLE….13771
METHOD OF LOWERING DUMP BODY IN EMERGENCY….13772
METHOD OF TOWING MACHINE….13774
IF BATTERY IS DISCHARGED….13778
OTHER TROUBLE….13781
MAINTENANCE….13788
GUIDES TO MAINTENANCE….13789
OUTLINE OF SERVICE….13792
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….13792
OUTLINE OF ELECTRIC SYSTEM….13796
WEAR PARTS….13797
WEAR PARTS LIST….13797
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….13798
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….13799
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….13800
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….13801
TORQUE LIST….13801
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….13802
SAFETY CRITICAL PARTS….13803
MAINTENANCE SCHEDULE CHART….13804
MAINTENANCE SCHEDULE CHART….13804
SERVICE PROCEDURE….13807
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)….13807
WHEN REQUIRED….13808
CHECK BEFORE STARTING….13829
EVERY 250 HOURS SERVICE….13830
EVERY 500 HOURS SERVICE….13842
EVERY 1000 HOURS SERVICE….13848
EVERY 2000 HOURS SERVICE….13860
EVERY 4000 HOURS SERVICE….13864
EVERY 8000 HOURS SERVICE….13867
EVERY 15000 HOURS SERVICE….13868
SPECIFICATIONS….13870
SPECIFICATIONS….13871
ATTACHMENTS, OPTIONS….13872
SELECTING DUMP BODY….13873
HANDLING AIR SUSPENSION SEAT….13874
SEAT ADJUSTMENT….13874
REMOVAL AND INSTALLATION OF HEADREST….13876
HANDLING AUTOMATIC SPIN REGULATOR (ASR)….13877
EXPLANATION OF COMPONENTS….13877
ACTUATION OF ASR SYSTEM….13878
PRECAUTIONS WHEN USING….13878
BLEEDING AIR FROM ASR CIRCUIT….13879
HANDLING ABS….13880
EXPLANATION OF COMPONENTS….13880
ABS SYSTEM CHECK AFTER STARTING ENGINE….13882
OPERATION OF ABS….13882
PRECAUTIONS WHEN USING….13883
HANDLING PAYLOAD METER II (CARD TYPE)….13884
METHOD OF USING ACCURATELY….13885
GENERAL LOCATIONS….13886
CONTENT OF DISPLAY (CONTROLLER, EXTERNAL DISPLAY LAMPS)….13891
EXTERNAL DISPLAY LAMPS….13895
DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER….13897
OPERATION OF SWITCHES….13902
PROBLEM AND WARNING DISPLAY (ERROR CODE)….13924
WHEN ERROR CODE F-09 IS DISPLAYED (PROCEDURE FOR REPLACING BATTERY)….13931
OPERATION WHEN ERROR CODE F.CAL IS DISPLAYED OR CONTROLLER HAS BEEN REPLACED….13934
ARSC (AUTOMATIC RETARDER SPEED CONTROL)….13937
EXPLANATION OF COMPONENTS….13938
METHOD OF OPERATION….13941
USE OF REAR VIEW MONITOR….13944
NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR….13944
SETTING OF REAR VIEW MONITOR….13947
CAUTIONS WHEN USING REAR VIEW MONITOR….13947
HANDLING DUMPING COUNTER….13948
HANDLING MACHINES EQUIPPED WITH KOMTRAX….13949
BASIC PRECAUTIONS….13949
INDEX….13950
TEN00331-00 – Dump Truck HD325-7, HD405-7 Operation & Maintenance Manual….13954
COVER….13954
FOREWORD….13955
BEFORE READING THIS MANUAL….13956
SAFETY INFORMATION….13957
INTENDED USE….13958
USE OF MACHINE….13958
DIRECTIONS OF MACHINE….13958
VISIBILITY FROM OPERATOR'S SEAT….13958
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….13959
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….13959
EPA REGULATIONS, ENGINE NUMBER PLATE….13959
SERVICE METER POSITION….13960
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….13960
CONTENTS….13961
SAFETY….13965
SAFETY….13966
SAFETY LABELS….13969
POSITION FOR ATTACHING SAFETY LABELS….13970
SAFETY LABELS….13971
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE….13976
PRECAUTIONS BEFORE STARTING OPERATION….13976
PREPARATIONS FOR SAFE OPERATION….13976
FIRE PREVENTION….13978
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE….13979
DO NOT GET CAUGHT IN DUMP BODY….13981
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES….13981
UNAUTHORIZED MODIFICATION….13981
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS….13982
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING….13982
PRECAUTIONS FOR OPERATION….13983
PRECAUTIONS FOR JOBSITE….13983
STARTING ENGINE….13985
OPERATION….13987
TRANSPORTATION….13991
TOWING….13992
PRECAUTIONS FOR MAINTENANCE….13993
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE….13993
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….13997
TIRES….14002
OPERATION….14005
GENERAL VIEW….14006
GENERAL VIEW OF MACHINE….14006
GENERAL VIEW OF CONTROLS AND GAUGES….14007
EXPLANATION OF COMPONENTS….14009
MACHINE MONITOR….14009
OTHER FUNCTIONS OF MACHINE MONITOR….14030
SWITCHES….14034
CONTROL LEVERS AND PEDALS….14043
BODY PIVOT PIN….14048
LOCATION OF FIRE EXTINGUISHER….14048
DUST INDICATOR….14049
FUSES….14050
CAR RADIO….14053
CAR STEREO….14059
AIR CONDITIONER….14068
OPERATION….14073
CHECK BEFORE STARTING ENGINE….14073
STARTING ENGINE….14092
OPERATIONS, CHECKS AFTER STARTING ENGINE….14094
STOPPING ENGINE….14095
CHECKS AFTER STOPPING ENGINE….14095
MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING….14096
SHIFTING GEAR….14101
TRAVELING DOWNHILL….14103
STEERING THE MACHINE….14112
LOADING OPERATIONS….14112
DUMP OPERATIONS….14113
PRECAUTIONS FOR OPERATION….14114
PARKING MACHINE….14115
CHECKS AFTER COMPLETION OF WORK….14116
LOCKING….14116
HANDLING TIRES….14117
DETERMINING AND MAINTAINING TRAVEL ROAD….14120
DETERMINING TRAVEL ROAD….14120
MAINTAINING TRAVEL ROAD….14120
TRANSPORTATION….14121
PRECAUTIONS WHEN TRANSPORTING….14121
STEPS FOR TRANSPORTATION….14121
METHOD OF SECURING MACHINE….14121
METHOD OF LIFTING MACHINE….14122
COLD WEATHER OPERATION….14125
PRECAUTIONS FOR LOW TEMPERATURE….14125
PRECAUTIONS AFTER COMPLETION OF WORK….14126
AFTER COLD WEATHER….14127
LONG-TERM STORAGE….14128
BEFORE STORAGE….14128
DURING STORAGE….14128
AFTER STORAGE….14128
PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE….14128
TROUBLESHOOTING….14129
AFTER RUNNING OUT OF FUEL….14129
IF TRANSMISSION HAS TROUBLE….14130
METHOD OF LOWERING DUMP BODY IN EMERGENCY….14131
METHOD OF TOWING MACHINE….14132
IF BATTERY IS DISCHARGED….14136
OTHER TROUBLE….14139
MAINTENANCE….14145
GUIDES TO MAINTENANCE….14146
OUTLINE OF SERVICE….14150
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….14150
OUTLINE OF ELECTRIC SYSTEM….14154
WEAR PARTS….14155
WEAR PARTS LIST….14155
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….14156
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….14157
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….14158
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….14159
TORQUE LIST….14159
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….14160
SAFETY CRITICAL PARTS….14161
MAINTENANCE SCHEDULE CHART….14162
MAINTENANCE SCHEDULE CHART….14162
SERVICE PROCEDURE….14165
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)….14165
WHEN REQUIRED….14166
CHECK BEFORE STARTING….14187
EVERY 250 HOURS SERVICE….14188
EVERY 500 HOURS SERVICE….14200
EVERY 1000 HOURS SERVICE….14206
EVERY 2000 HOURS SERVICE….14219
EVERY 4000 HOURS SERVICE….14223
EVERY 8000 HOURS SERVICE….14226
EVERY 15000 HOURS SERVICE….14227
SPECIFICATIONS….14229
SPECIFICATIONS….14230
ATTACHMENTS, OPTIONS….14231
SELECTING DUMP BODY….14232
HANDLING AIR SUSPENSION SEAT….14233
SEAT ADJUSTMENT….14233
REMOVAL AND INSTALLATION OF HEADREST….14235
HANDLING AUTOMATIC SPIN REGULATOR (ASR)….14236
EXPLANATION OF COMPONENTS….14236
ACTUATION OF ASR SYSTEM….14237
PRECAUTIONS WHEN USING….14237
BLEEDING AIR FROM ASR CIRCUIT….14238
HANDLING ABS….14239
EXPLANATION OF COMPONENTS….14239
ABS SYSTEM CHECK AFTER STARTING ENGINE….14241
OPERATION OF ABS….14241
PRECAUTIONS WHEN USING….14242
HANDLING PAYLOAD METER II (CARD TYPE)….14243
METHOD OF USING ACCURATELY….14244
GENERAL LOCATIONS….14245
CONTENT OF DISPLAY (CONTROLLER, EXTERNAL DISPLAY LAMPS)….14250
EXTERNAL DISPLAY LAMPS….14254
DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER….14256
OPERATION OF SWITCHES….14261
PROBLEM AND WARNING DISPLAY (ERROR CODE)….14283
WHEN ERROR CODE F-09 IS DISPLAYED (PROCEDURE FOR REPLACING BATTERY)….14290
OPERATION WHEN ERROR CODE F.CAL IS DISPLAYED OR CONTROLLER HAS BEEN REPLACED….14293
ARSC (AUTOMATIC RETARDER SPEED CONTROL)….14296
EXPLANATION OF COMPONENTS….14297
METHOD OF OPERATION….14300
USE OF REAR VIEW MONITOR….14303
NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR….14303
SETTING OF REAR VIEW MONITOR….14306
CAUTIONS WHEN USING REAR VIEW MONITOR….14306
HANDLING DUMPING COUNTER….14307
HANDLING MACHINES EQUIPPED WITH KOMTRAX….14308
BASIC PRECAUTIONS….14308
INDEX….14309
TEN00348-02 – Dump Truck HD325-7, HD405-7 Operation & Maintenance Manual….14313
COVER….14313
FOREWORD….14314
BEFORE READING THIS MANUAL….14315
SAFETY INFORMATION….14316
INTENDED USE….14317
USE OF MACHINE….14317
DIRECTIONS OF MACHINE….14317
VISIBILITY FROM OPERATOR'S SEAT….14317
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….14318
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….14318
EPA REGULATIONS, ENGINE NUMBER PLATE….14318
SERVICE METER POSITION….14319
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….14319
CONTENTS….14320
SAFETY….14324
SAFETY….14325
SAFETY LABELS….14328
POSITION FOR ATTACHING SAFETY LABELS….14329
SAFETY LABELS….14330
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE….14335
PRECAUTIONS BEFORE STARTING OPERATION….14335
PREPARATIONS FOR SAFE OPERATION….14335
FIRE PREVENTION….14337
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE….14338
DO NOT GET CAUGHT IN DUMP BODY….14340
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES….14340
UNAUTHORIZED MODIFICATION….14340
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS….14341
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING….14341
PRECAUTIONS FOR OPERATION….14342
PRECAUTIONS FOR JOBSITE….14342
STARTING ENGINE….14344
OPERATION….14346
TRANSPORTATION….14350
TOWING….14351
PRECAUTIONS FOR MAINTENANCE….14352
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE….14352
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….14356
TIRES….14361
OPERATION….14364
GENERAL VIEW….14365
GENERAL VIEW OF MACHINE….14365
GENERAL VIEW OF CONTROLS AND GAUGES….14366
EXPLANATION OF COMPONENTS….14368
MACHINE MONITOR….14368
OTHER FUNCTIONS OF MACHINE MONITOR….14389
SWITCHES….14393
CONTROL LEVERS AND PEDALS….14402
BODY PIVOT PIN….14407
LOCATION OF FIRE EXTINGUISHER….14407
DUST INDICATOR….14408
FUSES….14409
CAR RADIO….14412
CAR STEREO….14418
AIR CONDITIONER….14427
OPERATION….14432
CHECK BEFORE STARTING ENGINE….14432
STARTING ENGINE….14450
OPERATIONS, CHECKS AFTER STARTING ENGINE….14452
STOPPING ENGINE….14453
CHECKS AFTER STOPPING ENGINE….14453
MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING….14454
SHIFTING GEAR….14459
TRAVELING DOWNHILL….14461
STEERING THE MACHINE….14470
LOADING OPERATIONS….14470
DUMP OPERATIONS….14471
PRECAUTIONS FOR OPERATION….14472
PARKING MACHINE….14473
CHECKS AFTER COMPLETION OF WORK….14474
LOCKING….14474
HANDLING TIRES….14475
DETERMINING AND MAINTAINING TRAVEL ROAD….14478
DETERMINING TRAVEL ROAD….14478
MAINTAINING TRAVEL ROAD….14478
TRANSPORTATION….14479
PRECAUTIONS WHEN TRANSPORTING….14479
STEPS FOR TRANSPORTATION….14479
METHOD OF SECURING MACHINE….14479
METHOD OF LIFTING MACHINE….14480
COLD WEATHER OPERATION….14483
PRECAUTIONS FOR LOW TEMPERATURE….14483
PRECAUTIONS AFTER COMPLETION OF WORK….14484
AFTER COLD WEATHER….14485
LONG-TERM STORAGE….14486
BEFORE STORAGE….14486
DURING STORAGE….14486
AFTER STORAGE….14486
PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE….14486
TROUBLESHOOTING….14487
AFTER RUNNING OUT OF FUEL….14487
IF TRANSMISSION HAS TROUBLE….14488
METHOD OF LOWERING DUMP BODY IN EMERGENCY….14489
METHOD OF TOWING MACHINE….14490
IF BATTERY IS DISCHARGED….14494
OTHER TROUBLE….14497
MAINTENANCE….14504
GUIDES TO MAINTENANCE….14505
OUTLINE OF SERVICE….14509
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….14509
OUTLINE OF ELECTRIC SYSTEM….14513
WEAR PARTS….14514
WEAR PARTS LIST….14514
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….14515
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….14516
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….14517
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….14518
TORQUE LIST….14518
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….14519
SAFETY CRITICAL PARTS….14520
MAINTENANCE SCHEDULE CHART….14521
MAINTENANCE SCHEDULE CHART….14521
SERVICE PROCEDURE….14524
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)….14524
WHEN REQUIRED….14525
CHECK BEFORE STARTING….14545
EVERY 250 HOURS SERVICE….14546
EVERY 500 HOURS SERVICE….14558
EVERY 1000 HOURS SERVICE….14564
EVERY 2000 HOURS SERVICE….14576
EVERY 4000 HOURS SERVICE….14580
EVERY 8000 HOURS SERVICE….14583
EVERY 15000 HOURS SERVICE….14584
SPECIFICATIONS….14586
SPECIFICATIONS….14587
ATTACHMENTS, OPTIONS….14588
SELECTING DUMP BODY….14589
HANDLING AIR SUSPENSION SEAT….14590
SEAT ADJUSTMENT….14590
REMOVAL AND INSTALLATION OF HEADREST….14592
HANDLING AUTOMATIC SPIN REGULATOR (ASR)….14593
EXPLANATION OF COMPONENTS….14593
ACTUATION OF ASR SYSTEM….14594
PRECAUTIONS WHEN USING….14594
BLEEDING AIR FROM ASR CIRCUIT….14595
HANDLING ABS….14596
EXPLANATION OF COMPONENTS….14596
ABS SYSTEM CHECK AFTER STARTING ENGINE….14598
OPERATION OF ABS….14598
PRECAUTIONS WHEN USING….14599
HANDLING PAYLOAD METER II (CARD TYPE)….14600
METHOD OF USING ACCURATELY….14601
GENERAL LOCATIONS….14602
CONTENT OF DISPLAY (CONTROLLER, EXTERNAL DISPLAY LAMPS)….14607
EXTERNAL DISPLAY LAMPS….14611
DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER….14613
OPERATION OF SWITCHES….14618
PROBLEM AND WARNING DISPLAY (ERROR CODE)….14640
WHEN ERROR CODE F-09 IS DISPLAYED (PROCEDURE FOR REPLACING BATTERY)….14647
OPERATION WHEN ERROR CODE F.CAL IS DISPLAYED OR CONTROLLER HAS BEEN REPLACED….14650
ARSC (AUTOMATIC RETARDER SPEED CONTROL)….14653
EXPLANATION OF COMPONENTS….14654
METHOD OF OPERATION….14657
USE OF REAR VIEW MONITOR….14660
NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR….14660
SETTING OF REAR VIEW MONITOR….14663
CAUTIONS WHEN USING REAR VIEW MONITOR….14663
EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER….14664
SOCKET FOR ENGINE HEATER….14664
CONNECTING EXTERNAL POWER SOURCE….14664
RESTARTING ENGINE….14665
HANDLING EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER….14666
HANDLING DUMPING COUNTER….14672
HANDLING MACHINES EQUIPPED WITH KOMTRAX….14673
BASIC PRECAUTIONS….14673
INDEX….14674
TEN00425-07 – Dump Truck HD325-7, HD405-7 Operation & Maintenance Manual….14678
COVER….14678
FOREWORD….14679
BEFORE READING THIS MANUAL….14680
SAFETY INFORMATION….14681
INTENDED USE….14682
USE OF MACHINE….14682
DIRECTIONS OF MACHINE….14682
VISIBILITY FROM OPERATOR'S SEAT….14683
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….14684
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….14684
EPA REGULATIONS, ENGINE NUMBER PLATE….14684
SERVICE METER POSITION….14685
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….14685
CONTENTS….14686
SAFETY….14691
SAFETY….14692
SAFETY LABELS….14695
POSITION FOR ATTACHING SAFETY LABELS….14696
SAFETY LABELS….14697
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE….14702
PRECAUTIONS BEFORE STARTING OPERATION….14702
PREPARATIONS FOR SAFE OPERATION….14702
FIRE PREVENTION….14704
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE….14705
DO NOT GET CAUGHT IN DUMP BODY….14707
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES….14707
UNAUTHORIZED MODIFICATION….14707
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS….14708
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING….14708
PRECAUTIONS FOR OPERATION….14709
PRECAUTIONS FOR JOBSITE….14709
STARTING ENGINE….14711
OPERATION….14713
TRANSPORTATION….14717
TOWING….14718
PRECAUTIONS FOR MAINTENANCE….14719
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE….14719
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….14723
TIRES….14728
OPERATION….14731
GENERAL VIEW….14732
GENERAL VIEW OF MACHINE….14732
GENERAL VIEW OF CONTROLS AND GAUGES….14733
EXPLANATION OF COMPONENTS….14735
MACHINE MONITOR….14735
OTHER FUNCTIONS OF MACHINE MONITOR….14756
SWITCHES….14760
CONTROL LEVERS AND PEDALS….14769
BODY PIVOT PIN….14774
LOCATION OF FIRE EXTINGUISHER….14774
DUST INDICATOR….14775
FUSES….14776
CAR RADIO….14779
CAR STEREO….14785
AIR CONDITIONER….14794
OPERATION….14799
CHECK BEFORE STARTING ENGINE….14799
STARTING ENGINE….14819
OPERATIONS, CHECKS AFTER STARTING ENGINE….14821
STOPPING ENGINE….14822
CHECKS AFTER STOPPING ENGINE….14822
MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING….14823
SHIFTING GEAR….14828
TRAVELING DOWNHILL….14830
STEERING THE MACHINE….14839
LOADING OPERATIONS….14839
DUMP OPERATIONS….14840
PRECAUTIONS FOR OPERATION….14841
PARKING MACHINE….14842
CHECKS AFTER COMPLETION OF WORK….14843
LOCKING….14843
HANDLING TIRES….14844
DETERMINING AND MAINTAINING TRAVEL ROAD….14847
DETERMINING TRAVEL ROAD….14847
MAINTAINING TRAVEL ROAD….14847
TRANSPORTATION….14848
PRECAUTIONS WHEN TRANSPORTING….14848
STEPS FOR TRANSPORTATION….14848
METHOD OF SECURING MACHINE….14848
METHOD OF LIFTING MACHINE….14849
COLD WEATHER OPERATION….14852
PRECAUTIONS FOR LOW TEMPERATURE….14852
PRECAUTIONS AFTER COMPLETION OF WORK….14853
AFTER COLD WEATHER….14854
LONG-TERM STORAGE….14855
BEFORE STORAGE….14855
DURING STORAGE….14855
AFTER STORAGE….14855
PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE….14855
TROUBLESHOOTING….14856
AFTER RUNNING OUT OF FUEL….14856
IF TRANSMISSION HAS TROUBLE….14857
METHOD OF LOWERING DUMP BODY IN EMERGENCY….14858
METHOD OF TOWING MACHINE….14859
IF BATTERY IS DISCHARGED….14863
OTHER TROUBLE….14866
MAINTENANCE….14873
GUIDES TO MAINTENANCE….14874
OUTLINE OF SERVICE….14878
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….14878
OUTLINE OF ELECTRIC SYSTEM….14882
WEAR PARTS….14883
WEAR PARTS LIST….14883
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….14884
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….14885
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….14886
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….14887
TORQUE LIST….14887
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….14888
SAFETY CRITICAL PARTS….14889
MAINTENANCE SCHEDULE CHART….14890
MAINTENANCE SCHEDULE CHART….14890
SERVICE PROCEDURE….14893
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)….14893
WHEN REQUIRED….14894
CHECK BEFORE STARTING….14914
EVERY 250 HOURS SERVICE….14915
EVERY 500 HOURS SERVICE….14927
EVERY 1000 HOURS SERVICE….14933
EVERY 2000 HOURS SERVICE….14946
EVERY 4000 HOURS SERVICE….14951
EVERY 8000 HOURS SERVICE….14954
EVERY 15000 HOURS SERVICE….14955
SPECIFICATIONS….14957
SPECIFICATIONS….14958
ATTACHMENTS, OPTIONS….14961
SELECTING DUMP BODY….14962
HANDLING AIR SUSPENSION SEAT….14963
SEAT ADJUSTMENT….14963
REMOVAL AND INSTALLATION OF HEADREST….14965
HANDLING AUTOMATIC SPIN REGULATOR (ASR)….14966
EXPLANATION OF COMPONENTS….14966
ACTUATION OF ASR SYSTEM….14967
PRECAUTIONS WHEN USING….14967
BLEEDING AIR FROM ASR CIRCUIT….14968
HANDLING ABS….14969
EXPLANATION OF COMPONENTS….14969
ABS SYSTEM CHECK AFTER STARTING ENGINE….14971
OPERATION OF ABS….14971
PRECAUTIONS WHEN USING….14972
HANDLING PAYLOAD METER II (CARD TYPE)….14973
METHOD OF USING ACCURATELY….14974
GENERAL LOCATIONS….14975
CONTENT OF DISPLAY (CONTROLLER, EXTERNAL DISPLAY LAMPS)….14980
EXTERNAL DISPLAY LAMPS….14984
DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER….14986
OPERATION OF SWITCHES….14991
PROBLEM AND WARNING DISPLAY (ERROR CODE)….15013
WHEN ERROR CODE F-09 IS DISPLAYED (PROCEDURE FOR REPLACING BATTERY)….15020
OPERATION WHEN ERROR CODE F.CAL IS DISPLAYED OR CONTROLLER HAS BEEN REPLACED….15023
ARSC (AUTOMATIC RETARDER SPEED CONTROL)….15026
EXPLANATION OF COMPONENTS….15027
METHOD OF OPERATION….15030
USE OF REAR VIEW MONITOR….15033
NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR….15033
SETTING OF REAR VIEW MONITOR….15036
CAUTIONS WHEN USING REAR VIEW MONITOR….15036
EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER….15037
SOCKET FOR ENGINE HEATER….15037
CONNECTING EXTERNAL POWER SOURCE….15037
RESTARTING ENGINE….15038
HANDLING EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER….15039
HANDLING DUMPING COUNTER….15045
HANDLING MACHINES EQUIPPED WITH KOMTRAX….15046
BASIC PRECAUTIONS….15046
INDEX….15047
Komatsu Dump Trucks HD325, HD405, HD465, HD605, HD785 Workshop Service Repair Manuals