DUMP TRUCK
SERIAL NUMBERS
-8E0
HD325-55001 and up
HD405-55001 and up
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00 INDEX AND FOREWORD
INDEX 00 INDEX AND FOREWORD
INDEX
00 INDEX AND FOREWORD
ABBREVIATIONS
FOREWORD, SAFETY, BASIC INFORMATION-
-00-25
-00-30 HOW TO READ THE SHOP MANUAL-
SAFETY NOTICE FOR OPERATION-
PRECAUTIONS TO PREVENT FIRE-
FOR DEF
STORE DEF
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT-
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS -
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT -
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT-
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT
PRACTICAL USE OF KOMTRAX -
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER-
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS-
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR- -
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL - - -
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH- - -
-00-44
-00-45
-00-47
-00-53
-00-55
-00-58
-00-62
-00-66
-00-67
- - -00-68
-00-69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE- - - - -00-71
HOW TO READ ELECTRICAL WIRE CODE
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD-
STANDARD TIGHTENING TORQUE TABLE
CONVERSION TABLE
01 SPECIFICATIONS
ABBREVIATIONS
SPECIFICATIONS-
SPECIFICATION DRAWING-
SPECIFICATIONS
FUEL, COOLANT, AND LUBRICATING
10 STRUCTURE AND FUNCTION-
ABBREVIATIONS
UREA SCR SYSTEM-
LAYOUT DRAWING OF UREA SCR
FUNCTION OF UREA SCR SYSTEM
COMPONENT PARTS OF UREA SCR SYSTEM
BOOT-UP SYSTEM-
LAYOUT DRAWING OF BOOT-UP SYSTEM (For machines equipped with KOMTRAX terminal)
-00-72
-00-76
-10-1
-10-7
-10-12
-10-15
-10-16
-10-27
- -10-36
-10-36
LAYOUT DRAWING OF BOOT-UP SYSTEM (For machines equipped with emergency engine stop switch) (For machines equipped with KOMTRAX terminal)-
-10-38
LAYOUT DRAWING OF BOOT-UP SYSTEM (For machines equipped with gateway function controller) - - - -10-40
LAYOUT DRAWING OF BOOT-UP SYSTEM (For machines equipped with emergency engine stop switch) (For machines equipped with gateway function controller)-
10-42
OF COOLING SYSTEM
RADIATOR FAN CONTROL SYSTEM
COMPONENT PARTS OF COOLING SYSTEM-
SYSTEM
LAYOUT DRAWING OF CONTROL SYSTEM (For machines equipped with KOMTRAX terminal)
LAYOUT DRAWING OF CONTROL SYSTEM (For machines equipped with gateway function controller)
10-99 RETARDER AND HOIST CONTROL SYSTEM
MACHINE MONITOR SYSTEM
REARVIEW MONITOR SYSTEM
KOMTRAX SYSTEM-
DRAWING OF HYDRAULIC SYSTEM
DRAWING
TRANSMISSION CONTROL SYSTEM-
FRONT SUSPENSION-
STANDARD VALUE TABLE FOR ENGINE: HD325-8E0
STANDARD VALUE TABLE FOR ENGINE: HD405-8E0 -
STANDARD VALUE TABLE FOR MACHINE
STANDARD VALUE TABLE FOR MACHINE: HD325-8E0
STANDARD VALUE TABLE FOR MACHINE: HD405-8E0
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE
30 TESTING AND ADJUSTING-
PRECAUTIONS BEFORE WORK-
ABBREVIATIONS
RELATED INFORMATION TO TEST AND ADJUST-
TOOLS TO TEST AND ADJUST
DIAGRAM FOR TEST AND ADJUST TOOLS-
ENGINE AND COOLING SYSTEM-
TEST ENGINE SPEED-
TEST BOOST PRESSURE-
TEST EXHAUST GAS TEMPERATURE-
TEST EXHAUST GAS COLOR
TEST AND ADJUST VALVE CLEARANCE-
TEST COMPRESSION PRESSURE
TEST BLOWBY PRESSURE
TEST ENGINE OIL PRESSURE
TEST EGR VALVE AND VGT OIL PRESSURE-
TEST FUEL PRESSURE
TEST FUEL RETURN RATE AND LEAKAGE-
BLEED AIR FROM FUEL SYSTEM-
TEST FUEL CIRCUIT LEAK
CYLINDER CUT-OUT MODE
NO-INJECTION CRANKING-
-20-8
-20-11
-20-14
-20-14
-20-28
-20-42
-30-8
-30-46
-30-48
-30-60
00 INDEX AND FOREWORD INDEX
ADJUST TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR -
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR
CHECK AFTER ADJUSTING TRANSMISSION SPEED SENSOR
MOVE MACHINE WITH ELECTRICAL SYSTEM PROBLEMS
STEERING SYSTEM
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE-
TEST SUPPLY PRESSURE
BLEED AIR FROM STEERING CYLINDER CIRCUIT-
BRAKE SYSTEM-
RELEASE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT-
TEST WHEEL BRAKE OIL PRESSURE
TEST AND ADJUST BRAKE ACCUMULATOR PRESSURE-
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR AND CHARGE NITROGEN GAS
TEST BRAKE PERFORMANCE- -
BLEED AIR FROM BRAKE CIRCUIT -
TEST PARKING BRAKE OIL PRESSURE-
RELEASE PARKING BRAKE MANUALLY-
TEST THE AMOUNT OF FRONT BRAKE PAD WEAR-
TEST THE AMOUNT OF REAR BRAKE DISC WEAR
TEST AND ADJUST PARKING BRAKE PAD- -
HYDRAULIC SYSTEM-
TEST AND ADJUST HOIST CIRCUIT OIL PRESSURE -
TEST HOIST CYLINDER SUPPLY PRESSURE -
TEST OIL PRESSURE OF HOIST EPC VALVE CIRCUIT-
TEST RADIATOR FAN CIRCUIT OIL PRESSURE-
TEST AND ADJUST FRONT SUSPENSION CYLINDER -
30-155
30-158
30-174
30-177
30-181
30-184
30-185
30-188
30-188
30-190
30-192
30-194
- 30-196
TEST AND ADJUST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION) - - 30-202
TEST AND ADJUST REAR SUSPENSION CYLINDER
TEST KTCS CIRCUIT OIL PRESSURE (FOR MACHINE WITH KTCS)-
WORK EQUIPMENT
TEST AND ADJUST DUMP BODY POSITIONER SENSOR-
30-204
30-210
30-212
30-212 LOWER THE BODY MANUALLY
LIFT THE
CAB AND ITS ATTACHMENTS-
RATTLING
SET AND ADJUST EACH EQUIPMENT-
SET AND OPERATE OF MACHINE MONITOR-
30-221
PROCEDURE TO START UP KOMTRAX TERMINAL (For machines equipped with KOMTRAX terminal) - - 30-359
PROCEDURE TO FINISH KOMTRAX TERMINAL (For machines equipped with KOMTRAX terminal)-
30-363
PROCEDURE TO START UP KOMTRAX SYSTEM (For machines equipped with gateway function controller)30-365
PROCEDURE TO FINISH KOMTRAX SYSTEM (For machines equipped with gateway function controller) - 30-369
SET DRIVER STATUS MONITOR -
ADJUST REARVIEW CAMERA ANGLE
SET REGION OF BLUETOOTH® COMPATIBLE RADIO
ADJUST OPTICAL AXIS OF HEAD LAMP
VOLTAGE CIRCUIT OF ENGINE CONTROLLER WORK-
BATTERY DISCONNECT SWITCH WORK (For machines equipped with KOMTRAX terminal)
HD325-8E0, HD405-8E0
30-371
30-381
30-382
30-388
BATTERY DISCONNECT SWITCH WORK (For machines equipped with gateway function controller)-
TEST DIODES-
Pm CLINIC-
Pm CLINIC SERVICE-
40 TROUBLESHOOTING
RELATED INFORMATION ON TROUBLESHOOTING
GENERAL TROUBLESHOOTING POINTS
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM
SEQUENCE OF EVENTS IN TROUBLESHOOTING- -
CHECKS BEFORE TROUBLESHOOTING-
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING-
TESTING IN ACCORDANCE WITH TESTING PROCEDURE
ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION -
PROCEDURE FOR TESTING AND TROUBLESHOOTING- -
SYMPTOM AND TROUBLESHOOTING NUMBERS-
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE-
CONNECTORS LIST AND LAYOUT
CONNECTOR CONTACT IDENTIFICATION
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE-
FUSE LOCATION TABLE (For machines equipped with KOMTRAX terminal)
FUSE LOCATION TABLE (For machines equipped with gateway function controller)
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR -
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT
-40-18
-40-23
-40-64
-40-74
-40-81
-40-84
-40-111
-40-157
-40-163
-40-169
-40-172
-40-174
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] and [CA3135])
FAILURE CODES TABLE
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)
FAILURE CODE [1500L0]-
FAILURE CODE [15B0NX]
FAILURE CODE [15F0KM] -
FAILURE CODE [15F0MB]
FAILURE CODE [15F7KM]
FAILURE CODE [15G0MW]
FAILURE CODE [15G7KM]-
FAILURE CODE [15H0MW]
FAILURE CODE [15J0MW]-
FAILURE CODE [15K0MW]
FAILURE CODE [15L0MW]-
FAILURE CODE [15M0MW]
FAILURE CODE [15N0MW]
FAILURE CODE [15SBL1]
FAILURE CODE [15SBMA]-
FAILURE CODE [15SCL1]
FAILURE CODE [15SCMA]-
FAILURE CODE [15SDL1]
FAILURE CODE [15SDMA]-
FAILURE CODE [15SEL1]
-40-180
-40-182
-40-209
00 INDEX AND FOREWORD INDEX
FAILURE CODE [15SEMA]
FAILURE CODE [15SFL1]-
FAILURE CODE [15SFMA]
FAILURE CODE [15SGL1]-
FAILURE CODE [15SGMA]
FAILURE CODE [15SHL1]-
FAILURE CODE [15SHMA] -
FAILURE CODE [15SJMA]
FAILURE CODE [2C4MNX]
FAILURE CODE [2F00KM]
FAILURE CODE [2G42ZG]
FAILURE CODE [2G43ZG]
FAILURE CODE [6014NX]-
FAILURE CODE [879AKA]-
FAILURE CODE [879AKB]-
FAILURE CODE [879BKA]-
FAILURE CODE [879BKB]-
FAILURE CODE [879CKA]-
FAILURE CODE [879CKB]-
FAILURE CODE [879EMC]
FAILURE CODE [879FMC]
FAILURE CODE [879GKX]
FAILURE CODE [989D00]-
FAILURE CODE [989L00]
FAILURE CODE [989M00]-
FAILURE CODE [989N00]-
FAILURE CODE [989X00]
FAILURE CODE [98A000]
FAILURE CODE [98A100]
FAILURE CODE [98A200]
FAILURE CODE [98A300]
FAILURE CODE [98A400]
FAILURE CODE [98A500]
FAILURE CODE [98A600]
FAILURE CODE [A1U0N3]
FAILURE CODE [A1U0N4]
FAILURE CODE [AA10NX]
FAILURE CODE [AB00KE]
FAILURE CODE [AB00KY]
FAILURE CODE [AQ10N3]
FAILURE CODE [AS00N3]-
FAILURE CODE [AS00R2]-
FAILURE CODE [AS00R3]-
FAILURE CODE [AS00R4]-
FAILURE CODE [AS00R5]-
FAILURE CODE [AS00R6]-
FAILURE CODE [AS00ZK]-
FAILURE CODE [AS10KM]
FAILURE CODE [AS10NR]
FAILURE CODE [AS10NT]
HD325-8E0, HD405-8E0
FAILURE CODE [B@BAZG]
FAILURE CODE [B@BAZK]
FAILURE CODE [B@BCNS]-
FAILURE CODE [B@BCQA]-
FAILURE CODE [B@BCZK]
FAILURE CODE [B@C7NS]
FAILURE CODE [B@CENS]-
FAILURE CODE [B@JANS]
FAILURE CODE [CA115]
FAILURE CODE [CA122]
FAILURE CODE [CA123]
FAILURE CODE [CA131]
FAILURE CODE [CA132]
FAILURE CODE [CA135]
FAILURE CODE [CA141]
FAILURE CODE [CA144]
FAILURE CODE [CA145]
FAILURE CODE [CA153]
FAILURE CODE [CA154]
FAILURE CODE [CA187]
FAILURE CODE [CA221]
FAILURE CODE [CA222]
FAILURE CODE [CA227] -
FAILURE CODE [CA234]
FAILURE CODE [CA238]
FAILURE CODE [CA239]
FAILURE CODE [CA249]
FAILURE CODE [CA256]
FAILURE CODE [CA271]
FAILURE CODE [CA272]
FAILURE CODE [CA273]
FAILURE CODE [CA274]
FAILURE CODE [CA322]
FAILURE CODE [CA323]
FAILURE CODE [CA324]
FAILURE CODE [CA325]
FAILURE CODE [CA331]
FAILURE CODE [CA332]
FAILURE CODE [CA343]
FAILURE CODE [CA351]
FAILURE CODE [CA352]
FAILURE CODE [CA356]
FAILURE CODE [CA357]
FAILURE CODE [CA386]
FAILURE CODE [CA431]
FAILURE CODE [CA432]
FAILURE CODE [CA441]
FAILURE CODE [CA442]
FAILURE CODE [CA449]
FAILURE CODE [CA451]
00 INDEX AND FOREWORD INDEX
FAILURE CODE [CA452]-
FAILURE CODE [CA515]-
FAILURE CODE [CA516]-
FAILURE CODE [CA553]-
FAILURE CODE [CA555]-
FAILURE CODE [CA556]-
FAILURE CODE [CA559]-
FAILURE CODE [CA595]-
FAILURE CODE [CA687]-
FAILURE CODE [CA689]-
FAILURE CODE [CA691]-
FAILURE CODE [CA692]-
FAILURE CODE [CA697]-
FAILURE CODE [CA698]-
FAILURE CODE [CA731]-
FAILURE CODE [CA778]-
FAILURE CODE [CA1117]
FAILURE CODE [CA1664]-
FAILURE CODE [CA1669]-
FAILURE CODE [CA1673]-
FAILURE CODE [CA1677]-
FAILURE CODE [CA1678]-
FAILURE CODE [CA1682]- -
FAILURE CODE [CA1683]- -
FAILURE CODE [CA1684]-
FAILURE CODE [CA1686]-
FAILURE CODE [CA1691]-
FAILURE CODE [CA1694]-
FAILURE CODE [CA1695]-
FAILURE CODE [CA1696]-
FAILURE CODE [CA1712]-
FAILURE CODE [CA1713]- -
FAILURE CODE [CA1714]-
FAILURE CODE [CA1715]-
FAILURE CODE [CA1776]-
FAILURE CODE [CA1777]-
FAILURE CODE [CA1843]-
FAILURE CODE [CA1844]-
FAILURE CODE [CA1879]-
FAILURE CODE [CA1881]-
FAILURE CODE [CA1883]-
FAILURE CODE [CA1885]-
FAILURE CODE [CA1887]-
FAILURE CODE [CA1921]-
FAILURE CODE [CA1922]-
FAILURE CODE [CA1923]-
FAILURE CODE [CA1924]-
FAILURE CODE [CA1925]-
FAILURE CODE [CA1927]-
FAILURE CODE [CA1928]-
HD325-8E0, HD405-8E0
FAILURE CODE [CA1942]
FAILURE CODE [CA1963]
FAILURE CODE [CA1977]
FAILURE CODE [CA1993]
FAILURE CODE [CA2185]
FAILURE CODE [CA2186]
FAILURE CODE [CA2249]
FAILURE CODE [CA2265]
FAILURE CODE [CA2266]
FAILURE CODE [CA2271]
FAILURE CODE [CA2272]
FAILURE CODE [CA2349]
FAILURE CODE [CA2353]
FAILURE CODE [CA2357] -
FAILURE CODE [CA2381] -
FAILURE CODE [CA2382]
FAILURE CODE [CA2383] -
FAILURE CODE [CA2386] -
FAILURE CODE [CA2387]
FAILURE CODE [CA2555]
FAILURE CODE [CA2556] -
FAILURE CODE [CA2637] -
FAILURE CODE [CA2639] -
FAILURE CODE [CA2732]
FAILURE CODE [CA2733] -
FAILURE CODE [CA2741]
FAILURE CODE [CA2765]
FAILURE CODE [CA2771]
FAILURE CODE [CA2777]
FAILURE CODE [CA2878]
FAILURE CODE [CA2881]
FAILURE CODE [CA2976]
FAILURE CODE [CA3133]
FAILURE CODE [CA3134]
FAILURE CODE [CA3135]
FAILURE CODE [CA3142]
FAILURE CODE [CA3143]
FAILURE CODE [CA3144]
FAILURE CODE [CA3146]
FAILURE CODE [CA3147]
FAILURE CODE [CA3148]
FAILURE CODE [CA3151]
FAILURE CODE [CA3165]
FAILURE CODE [CA3167]
FAILURE CODE [CA3229]
FAILURE CODE [CA3231]
FAILURE CODE [CA3232]
FAILURE CODE [CA3235]
FAILURE CODE [CA3239]
FAILURE CODE [CA3241]
00 INDEX AND FOREWORD INDEX
FAILURE CODE [CA3242]-
FAILURE CODE [CA3251]-
FAILURE CODE [CA3253]-
FAILURE CODE [CA3254]-
FAILURE CODE [CA3255]-
FAILURE CODE [CA3256]-
FAILURE CODE [CA3311]-
FAILURE CODE [CA3312]-
FAILURE CODE [CA3313]-
FAILURE CODE [CA3314]-
FAILURE CODE [CA3315]-
FAILURE CODE [CA3316]-
FAILURE CODE [CA3317]-
FAILURE CODE [CA3318]-
FAILURE CODE [CA3319]- -
FAILURE CODE [CA3321]-
FAILURE CODE [CA3322]-
FAILURE CODE [CA3419]-
FAILURE CODE [CA3421]-
FAILURE CODE [CA3497]-
FAILURE CODE [CA3498]-
FAILURE CODE [CA3543]-
FAILURE CODE [CA3545]- -
FAILURE CODE [CA3547]- -
FAILURE CODE [CA3558]-
FAILURE CODE [CA3559]-
FAILURE CODE [CA3562]-
FAILURE CODE [CA3563]-
FAILURE CODE [CA3567]-
FAILURE CODE [CA3568]- -
FAILURE CODE [CA3571]- -
FAILURE CODE [CA3572]-
FAILURE CODE [CA3574]-
FAILURE CODE [CA3575]-
FAILURE CODE [CA3577]-
FAILURE CODE [CA3578]-
FAILURE CODE [CA3582]-
FAILURE CODE [CA3583]-
FAILURE CODE [CA3596]-
FAILURE CODE [CA3649]-
FAILURE CODE [CA3681]-
FAILURE CODE [CA3682]-
FAILURE CODE [CA3713]-
FAILURE CODE [CA3717]-
FAILURE CODE [CA3718]-
FAILURE CODE [CA3725]-
FAILURE CODE [CA3748]-
FAILURE CODE [CA3751]-
FAILURE CODE [CA3755]-
FAILURE CODE [CA3866]-
HD325-8E0, HD405-8E0
FAILURE CODE [CA3867]
FAILURE CODE [CA3868]
FAILURE CODE [CA3899]
FAILURE CODE [CA3911]
FAILURE CODE [CA3912]
FAILURE CODE [CA3932]
FAILURE CODE [CA3933]
FAILURE CODE [CA3934]
FAILURE CODE [CA3935] -
FAILURE CODE [CA3936]
FAILURE CODE [CA4151]
FAILURE CODE [CA4152]
FAILURE CODE [CA4155]
FAILURE CODE [CA4156] -
FAILURE CODE [CA4157]
FAILURE CODE [CA4158]
FAILURE CODE [CA4159] -
FAILURE CODE [CA4161]
FAILURE CODE [CA4162] -
FAILURE CODE [CA4163]
FAILURE CODE [CA4164]
FAILURE CODE [CA4165] -
FAILURE CODE [CA4166] -
FAILURE CODE [CA4168]
FAILURE CODE [CA4169]
FAILURE CODE [CA4171]
FAILURE CODE [CA4249]
FAILURE CODE [CA4251]
FAILURE CODE [CA4259]
FAILURE CODE [CA4261]
FAILURE CODE [CA4277]
FAILURE CODE [CA4281]
FAILURE CODE [CA4459] -
FAILURE CODE [CA4461]
FAILURE CODE [CA4658]
FAILURE CODE [CA4731]
FAILURE CODE [CA4732]
FAILURE CODE [CA4739]
FAILURE CODE [CA4768]
FAILURE CODE [CA4769]
FAILURE CODE [CA4842] -
FAILURE CODE [CA4952] (For machines equipped with KOMTRAX terminal)
FAILURE CODE [CA4952] (For machines equipped with gateway function controller)
FAILURE CODE [CA5115]
FAILURE CODE [CA5179]
FAILURE CODE [CA5181]
FAILURE CODE [CA5383]
FAILURE CODE [D018KB]
FAILURE CODE [D018KY]
FAILURE CODE [D019KB]
-40-794
00 INDEX AND FOREWORD INDEX
FAILURE CODE [D019KY]-
FAILURE CODE [D150KB]-
FAILURE CODE [D150KZ]-
FAILURE CODE [D164KY]-
FAILURE CODE [D19HKZ]
FAILURE CODE [D19JKZ]-
FAILURE CODE [D19QKZ] -
FAILURE CODE [D1EHKA]
FAILURE CODE [D1EHKB] -
FAILURE CODE [D1EHKY]
FAILURE CODE [D1EMKA]-
FAILURE CODE [D1EMKB]-
FAILURE CODE [D1EMKY]-
FAILURE CODE [D1FBKB] -
FAILURE CODE [D5WNKZ]-
FAILURE CODE [D5ZHL6]-
FAILURE CODE [D5ZKKZ] -
FAILURE CODE [D811MC] (For machines equipped with KOMTRAX terminal)
FAILURE CODE [D811MC] (For machines equipped with gateway function controller)
FAILURE CODE [D862KA] (For machines equipped with KOMTRAX terminal)-
FAILURE CODE [D862KA] (For machines equipped with gateway function controller)-
FAILURE CODE [D8ALKA] (For machines equipped with KOMTRAX terminal)-
FAILURE CODE [D8ALKA] (For machines equipped with gateway function controller)
FAILURE CODE [D8ALKB] (For machines equipped with KOMTRAX terminal)-
FAILURE CODE [D8ALKB] (For machines equipped with gateway function controller)
FAILURE CODE [D8AQK4] (For machines equipped with KOMTRAX terminal)
FAILURE CODE [D8AQK4] (For machines equipped with gateway function controller)
FAILURE CODE [D8AQKR] (For machines equipped with KOMTRAX terminal)
FAILURE CODE [D8AQKR] (For machines equipped with gateway function controller)
FAILURE CODE [D8G1KT]
FAILURE CODE [D8G6KT] -
FAILURE CODE [DAF0KT] -
FAILURE CODE [DAF0MB]
FAILURE CODE [DAF0MC]-
FAILURE CODE [DAF3KK]
FAILURE CODE [DAF8KB] -
FAILURE CODE [DAFDKB]
FAILURE CODE [DAFGMC] (For machines equipped with KOMTRAX terminal)-
FAILURE CODE [DAFGMC] (For machines equipped with gateway function controller)-
FAILURE CODE [DAFLKA] (For machines equipped with KOMTRAX terminal)
FAILURE CODE [DAFLKA] (For machines equipped with gateway function controller)
FAILURE CODE [DAFLKB] (For machines equipped with KOMTRAX terminal)
FAILURE CODE [DAFLKB] (For machines equipped with gateway function controller)
FAILURE CODE [DAFQKR] (For machines equipped with KOMTRAX terminal)
FAILURE CODE [DAFQKR] (For machines equipped with gateway function controller)-
FAILURE CODE [DAQ0KK]
FAILURE CODE [DAQ0KT]
FAILURE CODE [DAQ0MC]-
FAILURE CODE [DAQ1KA]
FAILURE CODE [DAQ2KK]
40-866
40-867
40-868
40-870
40-872
40-874
40-876
HD325-8E0, HD405-8E0 00-13
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE
FAILURE CODE [DAQ9KQ]
FAILURE CODE [DAQLKA] (For machines equipped with KOMTRAX terminal)-
FAILURE CODE [DAQLKA] (For machines equipped with gateway function controller)-
FAILURE CODE [DAQLKB] (For machines equipped with KOMTRAX terminal)-
FAILURE CODE [DAQLKB] (For machines equipped with gateway function controller)-
FAILURE CODE [DAQQKR] -
FAILURE CODE [DAQRKR]
FAILURE CODE [DAQRMA]
FAILURE CODE [DAQV00]-
FAILURE CODE [DAQW00]
FAILURE CODE [DAZ9KQ]-
FAILURE CODE [DAZQKR]
FAILURE CODE [DB10KT]
FAILURE CODE [DB10MC]-
FAILURE CODE [DB11KA] -
FAILURE CODE [DB11KA] (For machines equipped with emergency engine
FAILURE CODE [DB12KK]-
FAILURE CODE [DB13KK]-
FAILURE CODE [DB19KQ]-
FAILURE CODE [DB1LKA] (For machines equipped with KOMTRAX terminal)
FAILURE CODE [DB1LKA] (For machines equipped with gateway function controller)
FAILURE CODE [DB1LKB] (For machines equipped with KOMTRAX terminal)
FAILURE CODE [DB1LKB] (For machines equipped with gateway function controller)
FAILURE CODE [DB1QKR]
FAILURE CODE [DB1QMA]
FAILURE CODE [DB1RKR]-
FAILURE CODE [DB2QKR] (For machines equipped with KOMTRAX terminal)-
-40-889
-40-890
-40-892
-40-894
-40-896
-40-898
-40-899
-40-925
-40-932
FAILURE CODE [DB2QKR] (For machines equipped with KOMTRAX terminal and Drowsiness Detection system)
FAILURE CODE [DB2QKR] (For machines equipped with gateway function controller)
-40-944
FAILURE CODE [DB2QKR] (For machines equipped with gateway function controller and Drowsiness Detection system)-
FAILURE CODE [DB2RKR]-
FAILURE CODE [DB2RKR] (For machines equipped with Drowsiness Detection system)-
FAILURE CODE [DBS0KK]-
FAILURE CODE [DBS6KP]-
FAILURE CODE [DBSQKQ]
FAILURE CODE [DBSQKR]
FAILURE CODE [DBSRKR]
FAILURE CODE [DCR0MC]
FAILURE CODE [DCR2KK]-
FAILURE CODE [DCR8L4]-
FAILURE CODE [DCR9KQ]
FAILURE CODE [DCRLKA]-
FAILURE CODE [DCRLKB]-
FAILURE CODE [DCRQKR]
FAILURE CODE [DCRRKR]
FAILURE CODE [DDAAL6]-
FAILURE CODE [DDAAL6] (For machines equipped with emergency engine stop switch)
FAILURE CODE [DDD7KX]-
-40-956
-40-961
-40-1002
00 INDEX AND FOREWORD INDEX
FAILURE CODE [DDTHKA]-
FAILURE CODE [DDTJKA]
FAILURE CODE [DDTKKA]
FAILURE CODE [DDTLKA]
FAILURE CODE [DDTMKA]-
FAILURE CODE [DDTNKA]-
FAILURE CODE [DDTPKA] -
FAILURE CODE [DF10KA]
FAILURE CODE [DF10KB]
FAILURE CODE [DGF1KX]
FAILURE CODE [DGR2KB]-
FAILURE CODE [DGR6KB]-
FAILURE CODE [DGR6L8]
FAILURE CODE [DGT1KX] -
FAILURE CODE [DHA4KA]
FAILURE CODE [DHAAMA]-
FAILURE CODE [DHACMA]-
FAILURE CODE [DHP4KY]
FAILURE CODE [DHP4KZ]
FAILURE CODE [DHP5KY]
FAILURE CODE [DHP5KZ]
FAILURE CODE [DHP6KA]
FAILURE CODE [DHP6KX] -
FAILURE CODE [DHP6KY]
FAILURE CODE [DHP6KZ]
FAILURE CODE [DHP7KA]
FAILURE CODE [DHP7KX]
FAILURE CODE [DHP7KY]
FAILURE CODE [DHP7KZ]
FAILURE CODE [DHQ4KX]-
FAILURE CODE [DHT5KX]
FAILURE CODE [DHT5L6]-
FAILURE CODE [DHT8KX]
FAILURE CODE [DHT8ZG]
FAILURE CODE [DHU2KX]
FAILURE CODE [DHU3KX]
FAILURE CODE [DHUCKX]-
FAILURE CODE [DHUDKX]-
FAILURE CODE [DHUHKX]-
FAILURE CODE [DHULKX]
FAILURE CODE [DHUMKX]-
FAILURE CODE [DHUPKX]-
FAILURE CODE [DJF1KA]-
FAILURE CODE [DK30KX]
FAILURE CODE [DK51L5]-
FAILURE CODE [DK52KX]
FAILURE CODE [DK53L8]-
FAILURE CODE [DK54KX]
FAILURE CODE [DK60KX]
FAILURE CODE [DKD0L6]
HD325-8E0, HD405-8E0 00-15
-40-1120
FAILURE CODE [DKH0KX]-
FAILURE CODE [DKH1KX]-
FAILURE CODE [DLF1KA]
FAILURE CODE [DLF1LC]
FAILURE CODE [DLF2KA]
FAILURE CODE [DLF2LC]
FAILURE CODE [DLF8KA]
FAILURE CODE [DLF8LC]
FAILURE CODE [DLF9KA]
FAILURE CODE [DLF9LC]
FAILURE CODE [DLM3KA]-
FAILURE CODE [DLM3LC]-
FAILURE CODE [DLM3MB]
FAILURE CODE [DLT3KA] -
FAILURE CODE [DLT3LC] -
FAILURE CODE [DPQ1KR]
FAILURE CODE [DPQ2KR]
FAILURE CODE [DPQ3KR]
FAILURE CODE [DR81KR]-
FAILURE CODE [DR81MA]-
FAILURE CODE [DSJ0KR]-
FAILURE CODE [DV00KB]-
FAILURE CODE [DV03KB]-
FAILURE CODE [DV03KY]-
FAILURE CODE [DW2AKA]
FAILURE CODE [DW2AKB]
FAILURE CODE [DW2AKY]
FAILURE CODE [DW2AL1]-
FAILURE CODE [DW2ALH]
FAILURE CODE [DW35KZ]-
FAILURE CODE [DW36KZ]-
FAILURE CODE [DW4BK4]
FAILURE CODE [DW4BMA]
FAILURE CODE [DW72KZ]-
FAILURE CODE [DW73KA]
FAILURE CODE [DW73KB]
FAILURE CODE [DW73KY]
FAILURE CODE [DW78KZ]-
FAILURE CODE [DW7BKB]
FAILURE CODE [DW7BKY]
FAILURE CODE [DW7BKZ]
FAILURE CODE [DW7MKB]
FAILURE CODE [DW7MKY]
FAILURE CODE [DW7MKZ]
FAILURE CODE [DW7NKZ]
FAILURE CODE [DWNMKZ]-
FAILURE CODE [DX11K4]
FAILURE CODE [DX11KA]
FAILURE CODE [DX11KB]
FAILURE CODE [DX11KY]
00-16
00 INDEX AND FOREWORD INDEX
FAILURE CODE [DX11MA]
FAILURE CODE [DX13KA]
FAILURE CODE [DX13KB]
FAILURE CODE [DX13KY]
FAILURE CODE [DX16KA]
FAILURE CODE [DX16KB]
FAILURE CODE [DX16KY]
FAILURE CODE [DX37K4]-
FAILURE CODE [DX37KA]
FAILURE CODE [DX37KB]
FAILURE CODE [DX37KY]
FAILURE CODE [DX37MA]
FAILURE CODE [DX38K4]-
FAILURE CODE [DX38KA]
FAILURE CODE [DX38KB]
FAILURE CODE [DX38KY] -
FAILURE CODE [DX38MA]
FAILURE CODE [DXH1KA]
FAILURE CODE [DXH1KB]
FAILURE CODE [DXH1KY]
FAILURE CODE [DXH2KA]
FAILURE CODE [DXH2KB]
FAILURE CODE [DXH2KY]
FAILURE CODE [DXH3KA]
FAILURE CODE [DXH3KB]
FAILURE CODE [DXH3KY]
FAILURE CODE [DXH4KA]
FAILURE CODE [DXH4KB]
FAILURE CODE [DXH4KY]
FAILURE CODE [DXH5KA]
FAILURE CODE [DXH5KB]
FAILURE CODE [DXH5KY]
FAILURE CODE [DXH6KA]
FAILURE CODE [DXH6KB]
FAILURE CODE [DXH6KY]
FAILURE CODE [DXH7KA]
FAILURE CODE [DXH7KB]
FAILURE CODE [DXH7KY]
FAILURE CODE [DXHHKA]-
FAILURE CODE [DXHHKB]-
FAILURE CODE [DXHHKY]-
FAILURE CODE [DY30MA]
FAILURE CODE [DY30MC]
FAILURE CODE [DY30ME]
FAILURE CODE [F313KA]-
FAILURE CODE [F313KB]-
FAILURE CODE [F318KB]-
FAILURE CODE [F318KY]-
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)-
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)
40-1307
40-1308
HD325-8E0, HD405-8E0 00-17
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK -
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK - - - -
INDEX AND FOREWORD
- -40-1317
- -40-1320
- -40-1322
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP- - -
E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING- - - - -40-1323
E-6 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING (For machines equipped with emergency engine stop switch) - -
E-7 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING- -
- -40-1326
- - -40-1329
E-8 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS)
E-9 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY-
E-10 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL- -
E-11 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL- -
E-12 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL- -
-40-1331
-40-1333
-40-1335
-40-1338
- -40-1341
E-13 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY- - - - - -
-40-1344
E-14 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION - -40-1346
E-15 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL -
- -40-1348
E-16 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY- -
E-17 DEF LEVEL IS NOT DISPLAYED PROPERLY - -
E-18 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS-
E-19 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY -
E-20 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED-
E-21 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL- -
-40-1350
- -40-1351
-40-1354
-40-1358
-40-1362
- -40-1365
E-22 REARVIEW MONITOR DOES NOT DISPLAY IMAGES WHILE REVERSE LINKED DISPLAY FUNCTION IS ENABLED-
-40-1367
E-23 GUIDE LINE ON REARVIEW MONITOR IS NOT DISPLAYED WHILE GUIDE LINE IS SET- - - - - - - - -40-1370
E-24 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL- -
E-25 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL- -
E-26 MACHINE MONITOR CANNOT BE OPERATED WHEN STARTING SWITCH IS
E-27 ALARM BUZZER DOES NOT SOUND- -
E-28 ALARM BUZZER DOES NOT STOP SOUNDING- -
E-29 ENGINE MODE SELECTOR FUNCTION DOES NOT OPERATE PROPERLY
E-30 AISS FUNCTION DOES NOT OPERATE PROPERLY-
E-31 HOIST LEVER DOES NOT OPERATE PROPERLY - -
E-32 FUEL FEED PUMP DOES NOT OPERATE OR DOES NOT STOP AUTOMATICALLY-
-40-1374
-40-1377
-40-1379
-40-1381
-40-1383
-40-1385
-40-1387
E-33 TURN SIGNAL LAMP AND WINKER LAMP (HAZARD LAMP) DO NOT OPERATE PROPERLY- - - - - -40-1390
E-34 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS-
E-35 SMALL LAMP (CLEARANCE LAMP) DOES NOT LIGHT UP-
E-36 TAIL LAMP DOES NOT LIGHT UP - -
E-37 (LOW BEAM) HEAD LAMP DOES NOT LIGHT UP-
E-38 (HIGH BEAM) HEAD LAMP DOES NOT LIGHT UP
E-39 NEITHER (LOW BEAM) NOR (HIGH BEAM) HEAD LAMPS LIGHTS UP
E-40 HIGH BEAMS DO NOT LIGHT UP WHILE PASSING SWITCH IS OPERATED
- -40-1394
-40-1397
-40-1400
-40-1403
-40-1405
-40-1407
- -40-1409
E-41 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY (For machines equipped with KOMTRAX terminal)
-40-1411
E-41 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY (For machines equipped with gateway function controller)
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)
-40-1413
-40-1415
-40-1415
00-18 HD325-8E0, HD405-8E0
00 INDEX AND FOREWORD INDEX
FAILURE MODE AND CAUSE TABLE
H-1 MACHINE DOES NOT START-
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE HUNTS)
H-3 LOCKUP IS NOT RELEASED
H-4 ABNORMALLY LARGE SHOCKS RESULT
40-1416
40-1424
40-1429
H-10 OIL TEMPERATURE OF TORQUE CONVERTER IS
H-11 OIL PRESSURE OF TORQUE CONVERTER IS
H-12 STEERING WHEEL IS HEAVY TO OPERATE- -
H-13 STEERING WHEEL CANNOT BE OPERATED -
H-14 STEERING WHEEL WAGGLES-
H-15 FRONT BRAKE DOES NOT WORK ENOUGH
H-16 REAR BRAKE DOES NOT WORK ENOUGH
H-17 DUMP BODY RISING SPEED IS LOW- -
H-18 HYDRAULIC DRIFT OF DUMP BODY IS LARGE
H-19 DUMP BODY DOES NOT MOVE- -
H-20 RADIATOR FAN SPEED IS UNUSUAL (EXCESSIVELY HIGH OR LOW, OR FAN STOPS)-
H-21 UNUSUAL NOISE IS HEARD FROM AROUND RADIATOR FAN -
40-1445
40-1452
- 40-1454
40-1455 TROUBLESHOOTING OF ENGINE (S-MODE)-
40-1456 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)-
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION-
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT
40-1456
40-1457
- 40-1458
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)
S-4 ENGINE STARTABILITY IS POOR-
S-5 ENGINE DOES NOT PICK UP SMOOTHLY -
S-6 ENGINE STOPS DURING OPERATION-
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE
S-8 ENGINE LACKS POWER
S-9 KDPF GETS CLOGGED IN A SHORT TIME-
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE
S-11 OIL BECOMES CONTAMINATED QUICKLY
S-12 FUEL CONSUMPTION IS EXCESSIVE
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)
S-14 OIL PRESSURE DROPS-
S-15 FUEL MIXES INTO ENGINE OIL
S-16 WATER MIXES INTO ENGINE OIL (MILKY)
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)
S-18 UNUSUAL NOISE IS HEARD-
S-19 VIBRATION IS EXCESSIVE-
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT-
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY
S-22 ACTIVE REGENERATION TAKES TIME-
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION
40-1459
40-1460
- 40-1462
40-1466
40-1467
40-1469
40-1471
40-1473
- 40-1474
40-1475
40-1476
40-1477
40-1478
40-1479
40-1480
40-1481
40-1482
40-1484
40-1485
HD325-8E0, HD405-8E0 00-19
S-24 DEF CONSUMPTION IS EXCESSIVE-
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)
S-26 FOREIGN MATERIALS ENTER DEF (DEF INCREASES)
50 DISASSEMBLY AND ASSEMBLY
PRECAUTIONS BEFORE WORK-
ABBREVIATIONS
DISASSEMBLE AND ASSEMBLE-RELATED
ENGINE AND COOLING SYSTEM-
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY
REMOVE AND INSTALL INJECTOR ASSEMBLY-
REMOVE AND INSTALL FUEL DOSER ASSEMBLY-
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY-
REMOVE AND INSTALL EGR VALVE ASSEMBLY
REMOVE AND INSTALL EGR COOLER ASSEMBLY -
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY -
REMOVE AND INSTALL ALTERNATOR BELT
REMOVE AND INSTALL RADIATOR- -
REMOVE AND INSTALL COOLER ASSEMBLY
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY- -
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY- - - -
REMOVE AND INSTALL GRILLE GUARD ASSEMBLY-
REMOVE AND INSTALL ENGINE ASSEMBLY-
REMOVE AND INSTALL ENGINE FRONT OIL SEAL
REMOVE AND INSTALL ENGINE REAR OIL SEAL
REMOVE AND INSTALL OUTPUT SHAFT ASSEMBLY -
DISASSEMBLE AND ASSEMBLE OF OUTPUT SHAFT ASSEMBLY
REMOVE AND INSTALL DEF TANK ASSEMBLY -
REMOVE AND INSTALL DEF TANK SENSOR FLANGE ASSEMBLY-
REMOVE AND INSTALL DEF TANK SENSOR-
REMOVE AND INSTALL DEF TANK STRAINER
REMOVE AND INSTALL KDPF, SCR ASSEMBLY
REMOVE AND INSTALL KDPF ASSEMBLY- -
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY -
REMOVE AND INSTALL SCR ASSEMBLY-
REMOVE AND INSTALL KCCV ASSEMBLY
REMOVE AND INSTALL DEF MIXING TUBE-
REMOVE AND INSTALL DEF INJECTOR
REMOVE AND INSTALL DEF PUMP-
REMOVE AND INSTALL DEF HOSE-
REMOVE AND INSTALL AIR CLEANER ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY
-40-1486
-40-1488
-40-1489
-50-1
-50-8
-50-9
-50-35
-50-40
-50-40
-50-45
-50-77
-50-126
-50-138
-50-153
-50-176
-50-185
-50-188
-50-221
-50-224
-50-232
-50-235
-50-238
-50-251
-50-299
-50-310
-50-318
-50-326
50-346
-50-358
-50-367
-50-390
-50-395 POWER TRAIN-
REMOVE AND INSTALL TORQUE CONVERTER AND TRANSMISSION ASSEMBLY-
DISCONNECT AND CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY
DISASSEMBLE AND ASSEMBLE OF TORQUE CONVERTER ASSEMBLY-
DISASSEMBLE AND ASSEMBLE OF TRANSMISSION ASSEMBLY -
-50-397
-50-425
-50-451
-50-468
00 INDEX AND FOREWORD INDEX
REMOVE AND INSTALL DIFFERENTIAL ASSEMBLY- -
DISASSEMBLE AND ASSEMBLE OF DIFFERENTIAL ASSEMBLY
REMOVE AND INSTALL FRONT BRAKE CALIPER PAD-
REMOVE AND INSTALL FRONT BRAKE CALIPER ASSEMBLY
DISASSEMBLE AND ASSEMBLE OF FRONT BRAKE CALIPER ASSEMBLY-
REMOVE AND INSTALL FINAL DRIVE AND REAR BRAKE ASSEMBLY
REMOVE AND INSTALL PARKING BRAKE PAD ASSEMBLY
REMOVE AND INSTALL PARKING BRAKE CALIPER ASSEMBLY-
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE CARRIER ASSEMBLY
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE ASSEMBLY-
REMOVE AND INSTALL SLACK ADJUSTER ASSEMBLY
STEERING SYSTEM
REMOVE AND INSTALL STEERING VALVE ASSEMBLY-
DISASSEMBLE AND ASSEMBLE OF STEERING CYLINDER ASSEMBLY-
REMOVE AND INSTALL SECONDARY STEERING MOTOR PUMP ASSEMBLY-
UNDERCARRIAGE AND FRAME
REMOVE AND INSTALL FRONT WHEEL ASSEMBLY-
REMOVE AND INSTALL REAR WHEEL ASSEMBLY- -
REMOVE AND INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY-
DISASSEMBLE AND ASSEMBLE OF FRONT SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER RING)
REMOVE AND INSTALL KING PIN
DISASSEMBLE AND ASSEMBLE OF VARIABLE DAMPING SELECTOR VALVE ASSEMBLY
REMOVE AND INSTALL REAR SUSPENSION CYLINDER ASSEMBLY
50-584
50-588
50-590
- 50-594
DISASSEMBLE AND ASSEMBLE OF REAR SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER RING)
DISASSEMBLE AND ASSEMBLE OF FRONT WHEEL HUB ASSEMBLY
HYDRAULIC SYSTEM-
REMOVE AND INSTALL HOIST VALVE ASSEMBLY-
DISASSEMBLE AND ASSEMBLE OF HOIST CYLINDER ASSEMBLY
EQUIPMENT
REMOVE AND INSTALL DUMP BODY ASSEMBLY-
CAB AND ITS ATTACHMENTS-
REMOVE AND INSTALL AIR CONDITIONER ASSEMBLY-
REMOVE AND INSTALL OPERATOR'S SEAT ASSEMBLY
REMOVE AND INSTALL SEAT BELT
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY-
REMOVE AND INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY-
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY-
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR-
REMOVE AND INSTALL SCR TEMPERATURE SENSOR -
REMOVE AND INSTALL KOMTRAX CONTROLLER ASSEMBLY-
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS-
REMOVE AND INSTALL COMMUNICATION TERMINAL-
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR- -
REMOVE AND INSTALL DRIVER STATUS MONITOR- - -
HD325-8E0, HD405-8E0
50-600
50-605
50-662
50-664
REMOVE AND INSTALL TRANSLATOR CONTROLLER- -
REMOVE AND INSTALL DROWSINESS DETECTION CAMERA- -
REMOVE AND INSTALL DROWSINESS ALARM BUZZER- -
REMOVE AND INSTALL DROWSINESS DETECTION WIRING HARNESS
60 MAINTENANCE STANDARD
ABBREVIATIONS
ENGINE AND COOLING SYSTEM-
MAINTENANCE STANDARD OF ENGINE MOUNT
MAINTENANCE STANDARD OF OUTPUT SHAFT-
MAINTENANCE STANDARD OF COOLING FAN AND HOIST PUMP
MAINTENANCE STANDARD OF COOLING FAN MOTOR -
-50-719
-50-722
-50-725
-60-9
-60-13 POWER TRAIN- -
MAINTENANCE STANDARD OF DRIVE SHAFT
MAINTENANCE STANDARD OF TORQUE CONVERTER AND TRANSMISSION MOUNT
MAINTENANCE STANDARD OF TORQUE CONVERTER AND PTO-
MAINTENANCE STANDARD OF TRANSMISSION- -
MAINTENANCE STANDARD OF FORWARD AND REVERSE
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV
MAINTENANCE STANDARD OF FRONT AXLE-
MAINTENANCE STANDARD OF REAR AXLE
MAINTENANCE STANDARD OF DIFFERENTIAL-
MAINTENANCE STANDARD OF FINAL DRIVE
STEERING SYSTEM-
MAINTENANCE STANDARD OF STEERING COLUMN
MAINTENANCE STANDARD OF STEERING CONTROL LINKAGE-
MAINTENANCE STANDARD OF DEMAND VALVE-
MAINTENANCE STANDARD OF STEERING CYLINDER
BRAKE SYSTEM
MAINTENANCE STANDARD OF SLACK ADJUSTER-
MAINTENANCE STANDARD OF FRONT BRAKE-
MAINTENANCE STANDARD OF REAR BRAKE-
MAINTENANCE STANDARD OF PARKING BRAKE-
UNDERCARRIAGE AND FRAME- -
MAINTENANCE STANDARD OF FRONT SUSPENSION CYLINDER-
MAINTENANCE STANDARD OF REAR SUSPENSION CYLINDER-
MAINTENANCE STANDARD OF REAR AXLE SUPPORT-
HYDRAULIC SYSTEM-
MAINTENANCE STANDARD OF STEERING AND HOIST PUMP
MAINTENANCE STANDARD OF POWER TRAIN AND BRAKE CONTROL DUPLEX PUMP
MAINTENANCE STANDARD OF BRAKE COOLING DUPLEX PUMP
MAINTENANCE STANDARD OF HOIST VALVE-
-60-15
-60-15
-60-16
-60-17
-60-40
-60-41
-60-49
-60-50
-60-50
-60-53
-60-55
-60-57 WORK EQUIPMENT-
-60-59
-60-59
MAINTENANCE STANDARD OF HOIST CYLINDER
CAB AND ITS ATTACHMENTS
MAINTENANCE STANDARD OF CAB MOUNT
00 INDEX AND FOREWORD INDEX
PRECAUTIONS FOR REFRIGERANT
SPECIFICATIONS OF AIR CONDITIONER-
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE
OUTLINE OF REFRIGERATION CYCLE
SENSORS FOR AIR CONDITIONER SYSTEM-
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER-
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER-
AIR CONDITIONER SYSTEM DIAGRAM- -
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS-
TESTING AIR LEAKAGE (DUCT) -
METHOD FOR TESTING AIR LEAKAGE (DUCT) -
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION-
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF
MACHINE MONITOR-
TEST VENT (MODE) CHANGEOVER -
METHOD FOR TESTING VENT (MODE) CHANGEOVER
TESTING FRESH/RECIRC AIR CHANGEOVER -
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT
TEST RELAYS- -
METHOD FOR TESTING RELAYS-
AIR CONDITIONER TROUBLESHOOTING CHART 1-
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE-
FAILURE CODE [879AKA]
FAILURE CODE [879AKB]
FAILURE CODE [879BKA]
FAILURE CODE [879BKB]
FAILURE CODE [879CKA]
FAILURE CODE [879CKB]
FAILURE CODE [879EMC]-
FAILURE CODE [879FMC]-
FAILURE CODE [879GKX]
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) - - - 80-64
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) - - - - 80-66
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER
TROUBLESHOOTING USING GAUGE PRESSURE-
CONNECTION OF SERVICE TOOL
METHOD FOR CONNECTING SERVICE TOOL
HD325-8E0, HD405-8E0
- 80-69
- 80-71
80-73
80-76
80-76
INDEX AND FOREWORD
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS
HANDLE COMPRESSOR OIL
METHOD FOR REPLACING DESICCANT
90 CIRCUIT DIAGRAMS-
ABBREVIATIONS
HYDRAULIC CIRCUIT DIAGRAM-
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM-
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM- -
ELECTRICAL CIRCUIT DIAGRAM-
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM-
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (1/9)
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (2/9)
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (3/9)
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (4/9)
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (5/9) -
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (6/9) -
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (7/9)
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (8/9)
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (9/9)
- -80-77
-80-79
-80-81
-90-1
-90-3
-90-8
-90-13
-90-15
-90-17
-90-17
- -90-21
- -90-23
- -90-25
-90-27
- -90-29
- -90-31
- -90-33
- -90-35
-90-37
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (1/10) -90-39
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (2/10) -90-41
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (3/10) -90-43
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (4/10) -90-45
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (5/10) -90-47
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (6/10) -90-49
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (7/10) -90-51
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (8/10) -90-53
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (9/10) -90-55
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (10/10)90-57
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (1/8)- - - - - - -90-59
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (2/8)- - - - - - -90-61
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (3/8)- - -
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (4/8)- -
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (5/8)- -
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (6/8)- -
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (7/8)- - -
-90-63
-90-65
-90-67
-90-69
-90-71
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (8/8)- - - - - - -90-73
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (1/8)- -90-75
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (2/8)- -90-77
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (3/8)- -90-79
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (4/8)- -90-81
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (5/8)- -90-83
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (6/8)- -90-85
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (7/8)- -90-87
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (8/8)- -90-89
ELECTRICAL CIRCUIT DIAGRAM OF ENGINE-
INDEX-
ELECTRICAL CIRCUIT DIAGRAM (DROWSINESS DETECTION SYSTEM (DDS))
-90-91
-90-93
00-24 HD325-8E0, HD405-8E0
ABBREVIATIONS
00 INDEX AND FOREWORD
ABBREVIATIONS
q These abbreviations include those used in the shop manual for parts, components, and functions which are not easily understood. The abbreviation is shown and defined in full.
q The list may not include general usage abbreviations.
q Special abbreviations are identified in the text.
q This list of abbreviations is in two parts. One part is abbreviations used in the text of the manual, and the second is abbreviations used in the circuit diagram.
List of abbreviations used in the text
AbbreviationTerms shown completely Function (major applicable machine (*), or component and system)
Travel and brake
ABSAntilock Brake System
Explanation
When the tires slide (wheels do not turn), the brakes are released, and when the wheels start to turn, the brakes are applied again. (HD, HM)
AISS Automatic Idle Setting System Engine
Steering
AJSS Advanced Joystick Steering System
ARAC Automatic Retarder Accelerator Control
ARSC Automatic Retarder Speed Control
This function automatically sets the idle speed.
A lever is used to perform the steering operations. It shifts gear and changes direction (FORWARD or REVERSE). (WA)
Travel and brake
When the accelerator pedal is released while the machine travels downhill, this function automatically applies the retarder with a constant brake force. (HD, HM)
Travel and brake
When the accelerator pedal is released while the machine travels downhill, this function automatically applies the retarder. It ensures that the machine speed does not accelerate above the speed set by the operator. (HD, HM)
ASRAutomatic Spin Regulator Travel and brake
When the tires slip on soft ground surfaces, this function automatically uses the brake force to power each wheel. (HD, HM)
ATTAttachment Work equipment
BCV Brake Cooling oil control Valve Brake
A device attached onto the standard machine, to let it do different operations.
When the retarder is not used, this valve bypasses part of the brake cooling oil to reduce the load on the hydraulic pump. (HD)
CANController Area Network Communication and electronic control
CDR Crankcase Depression Regulator Engine
CLSS Closed-center Load Sensing System Hydraulic system
CRICommon Rail InjectionEngine
ECMElectronic Control ModuleElectronic control system
One of the communication standards that is used in the circuits on the machine.
A valve installed in the KCCV. It is written as CDR valve and it is not used independently.
This system can actuate several actuators at the same time regardless of the load (Improves mixed operations over OLSS).
Engine controller electronically controls supply pump, common rail, and injector. This function correctly maintains fuel injection quantity and timing.
Electronic control device which uses the signals from the sensors on the machine. These signals indicate the actuators to function for the best operation. (Same as ECU)
HD325-8E0, HD405-8E0 00-25
ABBREVIATIONS
AbbreviationTerms shown completely Function (major applicable machine (*), or component and system)
ECMV Electronic Control Modulation Valve
ECSS Electronically Controlled Suspension System
00 INDEX AND FOREWORD
Explanation
TransmissionElectromagnetic valve that gradually proportions oil pressure to engage clutches and decrease transmission shock. (D, HD, WA, etc)
TravelThis system absorbs machine vibration during high speed to ensure smooth travel, using hydraulic spring effect of the accumulator. (WA)
ECUElectronic Control Unit Electronic control system
EGR Exhaust Gas Recirculation Engine
EMMS Equipment Management Monitoring System Machine monitor
EPC Electromagnetic Proportional Control Hydraulic system
FOPS Falling Object Protection Structure Cab and canopy
Electronic control device which uses the signals from the sensors on the machine. These signals indicate the actuators to function for the best operation. (Same as ECM)
This function recirculates part of exhaust gas back to the combustion chamber to reduce temperature and control NOx emissions.
This system allows monitor check of each sensor of the machine. (Data includes oil and filter replacement intervals, machine malfunctions, failure codes, and failure records)
This mechanism allows actuators to be operated in proportion to the current supplied.
This structure protects the operator from objects that fall.
This performance is standardized as ISO 3449.
F-N-RForward-Neutral-ReverseOperationForward - Neutral - Reverse
GPS Global Positioning System Communication
Global Positioning System: This system uses satellites to determine the machine’s present location. (KOMTRAX, KOMTRAX Plus)
GNSS Global Navigation Satellite System Communication
HSS Hydrostatic Steering System
HST Hydro Static Transmission
Global Navigation Satellite System: This system uses satellites to determine the present machine location. (KOMTRAX, KOMTRAX Plus)
SteeringThis function uses the hydraulic motor and bevel shaft to control the difference in travel speed of right and left tracks. Therefore the machine can turn without using steering clutches. (D)
TransmissionThis function uses the hydraulic pump and motor together, to shift the speed range without using gears. (D, WA)
ICT Information and Communication Technology Communication and electronic control
IMAInlet Metering ActuatorEngine
IMUInertial Measurement UnitEngine
IMVInlet Metering ValveEngine
00-26
A generally accepted term for engineered and applied technology of information procedures and communication.
This valve is installed at the inlet port of the pump, and adjusts fuel intake quantity to control fuel volume of the supply pump. (Same as IMV)
This is a device to detect the angle and speed of the 3 pivot points that control movements.
This valve is installed at the inlet port of the pump, and it adjusts fuel intake quantity to control fuel release volume of supply pump. (Same as IMA)
00 INDEX AND FOREWORD
AbbreviationTerms shown completely Function (major applicable machine (*), or component and system)
KCCV KOMATSU Closed Crankcase Ventilation Engine
KCSF KOMATSU Catalyzed Soot Filter Engine
KDOC KOMATSU Diesel Oxidation Catalyst Engine
KDPF KOMATSU Diesel Particulate Filter Engine
Explanation
ABBREVIATIONS
This mechanism causes the separation of oil in blowby gas and puts it in the intake side to be burned in the engine. It is primarily made up of filters.
This filter captures soot in exhaust gas.
It is assembled in the KDPF.
This component is used to purify exhaust gas. It is assembled in to KDPF or assembled with the muffler.
This component is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are part of it.
It is installed in the same location as a standard muffler.
KTCS KOMATSU Traction Control System Travel and brakeThis function recovers the traction of the wheels by using the brakes automatically with the necessary force. At the same time, it activates the inter-axle differential lock when the wheels idle while the machine travels on soft ground. (HM)
LCDLiquid Crystal DisplayMachine monitor Liquid crystal elements assembled into components such as a monitor.
LEDLight Emitting DiodeElectronic parts Refers to a semiconductor element that emits light when energized in the forward direction.
LIN Local Interconnect Network Communication and electronic control
LSLoad SensingHydraulic system
LVDS Low Voltage Differential Signaling Communication and electronic control
MAFMass Air FlowEngine
MMS Multimedia Messaging Service Communication
One of the communication standards that is used in the circuits on the machine.
Function that senses pressure differences of the pump and controls output volume corresponding to load.
One of the communication standards that is used in the circuits on the machine.
This indicates airflow of the engine intake. It is used together with a MAF sensor.
Service that allows transmission and reception of short text or voice messages, or pictures between cell phones.
NCNormally Closed Electrical system, Hydraulic system Properties of electrical or hydraulic circuits. Circuit is closed when it is not activated, and opens when it is activated.
NONormally Open Electrical system, Hydraulic system Properties of electrical or hydraulic circuits. Circuit is open when it is not activated, and closes when it is activated.
OLSS Open-center Load Sensing System Hydraulic system
PC Pressure CompensationHydraulic system
Hydraulic system that can operate more than one actuator at the same time regardless of the load.
A function used to correct oil pressure.
ABBREVIATIONS
AbbreviationTerms shown completely Function (major applicable machine (*), or component and system)
00 INDEX AND FOREWORD
Explanation
PCCS Palm Command Control System Steering System in which a controller examines data from each lever, pedal, and knob, and performs necessary electronic control of the engine and transmission. (D)
PCVPre-stroke Control ValveEngine
PPC Proportional Pressure Control Hydraulic system
This valve is installed at the inlet port of pump, and it adjusts fuel intake quantity to control fuel volume of supply pump.
This system is used for controlling pressures. It moves actuators in proportion to oil pressure.
PPMPiston Pump and Motor Hydraulic system Piston hydraulic pump and motor. (D, PC, etc)
PTOPower Take Off Power train system Power take-off mechanism.
PTP Power Tilt and power Pitch dozer Work equipment
This function performs hydraulic control of the tilt and angle of the Bulldozer blade. (D)
ROPS Roll-Over Protective Structure Cab and canopy
SCR Selective Catalytic Reduction Urea SCR system
SI Le Systeme International d' Unites (International unit system) Unit
If a machine tilts over, this structure protects the operator who wears a seat belt from injury.
(Operator protection structure)
This performance is standardized as ISO 3471 or ISO 12117-2.
It is an exhaust gas conditioner, using urea water which converts nitrogen oxides (NOx) to harmless nitrogen and water. It is also known part of the name of related devices.
Abbreviation for "Le Systeme International d' Unites". It is the accepted unit system and "one unit for one quantity" is the basic principle applied,
SOLSolenoid Electrical system Refers to an actuator that moves by magnetic force when the solenoid is energized.
TOPS Tip-Over Protective Structure Cab and canopy
If a machine tilts over, this structure protects the operator who wears a seat belt from injury.
(Protective function for compact excavators against overturning)
This performance is standardized as ISO 12117.
TWV2-Way Valve Hydraulic system Solenoid valve that switches direction of flow.
VGT Variable Geometry Turbocharger Engine A turbocharger which can change the pattern of the exhaust flow area.
VHPC Variable HorsePower Control Engine control
*: Code for applicable machine model
D: Bulldozer
HD: Dump truck
HM: Articulate dump truck
PC: Hydraulic excavator
WA: Wheel loader
00-28
Function providing both high production and low fuel consumption by fine control of the maximum power of the machine.
ABBREVIATIONS
INDEX AND FOREWORD
00
List of abbreviations used in the circuit diagrams
AbbreviationTerms shown completely
A/CAir Conditioner
A/DAnalogue-to-Digital
A/MAir Mix damper
ACCAccessory
ADDAdditional
AUXAuxiliary
BRBattery Relay
CWClockwise
CCWCounter Clockwise
ECUElectronic Control Unit
ECMElectronic Control Module
ENGEngine
EXGNDExternal Ground
F.G.Frame Ground
GNDGround
IMAInlet Metering Actuator
NCNo Connection
S/T Steering
STRG
SIGSignal
SOLSolenoid
STDStandard
OPT Option
OP
PRESSPressure
SPECSpecification
SWSwitch
TEMPTemperature
T/CTorque Converter
T/MTransmission
FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE
SHOP MANUAL
q Some of the attachments and options described in this shop manual may not be available in some areas. If they are required, consult your Komatsu distributor.
q The materials and specifications are subject to change without notice.
q Shop Manuals are available for "machine part" and "engine part". For the engine unit, see the shop manual for the machine which has the same engine model.
q Actual machine may differ from the images which are contained in this manual. A typical model is shown in the illustrations of this shop manual.
q All "AdBlue/DEF" shown on the machine monitor is referred to as "DEF" in the shop manual. Some machine monitors installed to the product show "DEF" as "AdBlue/DEF" in the service mode. Thus, be sure to recognize that "DEF" and "AdBlue/DEF" are the same when you read the shop manual.
REMARK
The illustrations in the shop manual reproduce the display of the machine monitor. They are not always the same as the terminology in the shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. "STRUCTURE AND FUNCTION" is helpful in not only understanding the structure of each component but performing troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described in "STANDARD VALUE TABLE".
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure. Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows the criteria and remedies for disassembly and assembly.
00 INDEX AND FOREWORD FOREWORD, SAFETY, BASIC INFORMATION
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
Symbols
Important safety and quality portions are marked with the following symbols so that shop manual is used effectively.
Remark
Symbol Item
Danger This signal indicates an extremely hazardous situation which will result in death or serious injury if it is not avoided.
Warning This signal indicates a potentially hazardous situation which will result in death or serious injury if it is not avoided.
Caution This signal indicates a potentially hazardous situation which will result in injury or property damage around the machine if it is not avoided.
Weight
This symbol shows the weight of parts and components. Refer to this symbol when you handle heavy object for selection of the required equipment such as crane and lifting tools, and for what kind of working posture to take.
Tightening torque This signal indicates the tightening torque for portions which requires special care in assembling work.
Coat This signal indicates a place to be coated with adhesive, grease, etc. in assembling work.
Oil and coolantThis signal indicates a place to supply oil, coolant, etc. and the quantity.
DrainingThis signal indicates a place to drain oil, coolant, etc. and the quantity.
Signal word
Signal word for notice and remark describes the following.
Symbol Item
NOTICE Notice
Unit
Remark
If the precaution of this signal word is not observed, the machine damage or shortening of service life may occur.
REMARK RemarkThis signal word contains useful information to know.
International System of Units (SI) is used in this manual. For reference, units that have been used in the past are given in { }.
SAFETY NOTICE FOR OPERATION
q Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of the servicing and repair methods require the use of special tools designed by Komatsu for special purposes.
q The symbol mark is indicated for such matters that require specia precautions. The work indicated with this warning mark should be performed according to the instructions with special attention. Should a hazardous situation occurs or be anticipated during such work, be sure to keep safe first and take every necessary measures.
Safety matters
q Well organized work place
q Correct work clothes
q Observance of work standard
q Enforcement of hand signals
q Prohibition against unlicensed persons operating and handling the machine
q Safety check before starting work
q Wear of dust glasses (for cleaning or grinding work)
q Wear of welding goggles and protectors (for welding work)
q Being in good physical condition, and good preparation
q Always be alert and careful.
General precautions
k If the machine is handled incorrectly, it is dangerous. Read and understand what is described in the operation and maintenance manual before operation. Read and understand what is described in this manual before operation.
q Read and understand the meaning of all the safety labels stuck to the machine before performing any greasing or repairs. For the locations of the safety labels and detailed explanation of precautions, see Operation and Maintenance Manual.
q Tools and removed parts in the workshop should be well organized. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dust, dirt, oil, or water on the floor. Smoke only in the designated areas. Never smoke while working.
q Keep all tools in good condition, learn the correct way to use them, and use the proper ones. Check the tools, machine, forklift truck, service car, etc. thoroughly before starting the work.
q Always wear safety shoes and helmet when performing any operation. Do not wear loose clothes, or clothes with buttons missing.
00 INDEX AND FOREWORD
q Always wear the protective eyeglasses when hitting parts with a hammer.
q Always wear the protective eyeglasses when grinding parts with a grinder, etc.
q When performing any operation with multiple workers, always agree on the operating procedure before starting. Be clear in verbal communication, and observe hand signals. Hang "UNDER REPAIR" warning tag in the operator's compartment before starting work.
q Only the approved personnel can do the work in a closed environment or in a prohibited area.
q Work and operation which require license or qualification should be performed by qualified workers.
q Welding repairs should be performed by trained and experienced welders. When performing welding work, always wear welding gloves, apron, welding goggles, cap and other clothes suited for welding work.
q Warm up before starting the work with exercise which increases alertness and the range of motion in order to prevent injury.
q Avoid prolonged work, and take a rest at times to keep up a good condition. Take a rest at designated safe area.
q When you work in high places, use a platform.
q Before you start the work, use the personal fall-arrest equipment to prevent falling. There is a danger of personal accident that you fall by slipping.
q Always do the work correctly. If you find the unsafe behavior of co-worker, give him/her a notice and stop it.
q Because there is a danger that you are caught, be very careful when the work is done in dangerous areas such as: when you go in the range where the lifted load possibly falls, or when you stand directly in front of tire, or when you are near the sliding parts.
q When you handle chemical materials (such as nitrogen gas), see the MSDS (safety data sheet) and local guidelines, and get the important information (such as a safe handling method). Also, put on applicable protective equipment (such as protective goggles, gloves, and masks).
q If necessary, cut out all the power sources (electricity, oil pressure, compressed air, etc.) before you start the work. If the machine has a lock mechanism, set it to the LOCK position and install the warning tag in a position where it is easy to see. Do not release the lock until the work is completed.
Precautions for preparatory work
q Place the machine on a firm and level ground, and apply the parking brake and chock the wheels or tracks to prevent the machine from moving before adding oil or making any repairs.
q Lower the work equipment (blade, ripper, bucket, etc.) to the ground before starting work. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang "UNDER REPAIR" warning tag on them.
q When performing the disassembling or assembling work, support the machine securely with blocks, jacks, or stands before starting the work.
q Remove all mud and oil from the steps or other places for going up and down on the machine. Always use the handrails, ladders or steps when for going up and down on the machine. Never jump on or off the machine. When the scaffold is not provided, use steps or stepladder to secure your footing. Do not use handrails, ladders, or steps if they are damaged or deformed. Repair it or replace it immediately.
Precautions during work
q For the machine with the battery disconnect switch, check before starting the work that the system operating lamp is not lit. Then, turn the battery disconnect switch to OFF (○) position.
REMARK
Remove the key after it is turned to OFF (○) position if the battery disconnect switch is a switch key type. For the machine without the battery disconnect switch, turn the starting switch to OFF position, wait for two minutes or more before starting the work. Disconnect the battery cable by starting from the negative (-) terminal first.
q For the machine with the quick release battery terminal (-), check before starting the work that the system operating lamp is not lit. Then, disconnect the quick release battery terminal (-).
REMARK
For the machine without the system operating lamp, turn the starting switch to OFF position, wait for two minutes or more before starting the work. Disconnect the quick release battery terminal (-).
q Release the remaining pressure from the circuit before starting the work of disconnecting and removing of oil, fuel, water, or air from the circuit. When removing the cap of oil filter, drain plug, or oil pressure plug, it should be done slowly otherwise the oil spills.
q When removing or installing the checking plug or the piping in the fuel circuit, wait 30 seconds or longer after the engine is shut down and start the work after the remaining pressure is released from the fuel circuit.
q The coolant and oil in the circuits are hot when the engine is shut down. Be careful not to get scalded. Wait for the oil and coolant to cool before performing any work on the oil or coolant circuits.
q Before starting work, shut down the engine. When working on or around a rotating part, in particular, shut down the engine. When checking the machine without shutting down the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get caught in rotating parts or moving parts.
q When raising a heavy component (heavier than 20 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, webbing slings, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.
q When removing a part which is under internal pressure or under reaction force of a spring, always leave 2 bolts in diagonal positions. Loosen those 2 bolts gradually and alternately to release the pressure, and then remove the part.
q When removing components, do not break or damage the electrical wiring. Damaged wiring may cause a fire.
q When removing piping, do not spill the fuel or oil. If any fuel or oil drips onto the floor, wipe it off immediately. Fuel or oil on the floor can cause you to slip and can even cause fires.
q Do not use gasoline to wash parts as a general rule. Do not use gasoline to clean electrical parts, in particular.
q Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wiring harnesses, be sure that they will not be damaged by contact with other parts when the machine is operated.
q When installing high pressure hoses and tubes, make sure that they are not twisted. Damaged hoses and tubes are dangerous, so be extremely careful when installing hoses and tubes for high pressure circuits. In addition, check that high pressure hoses and tubes are correctly installed.
q When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, check again that they are installed correctly.
q Never insert your fingers or hand when aligning 2 holes. Be careful not to get your fingers caught in a hole.
q Check that the measuring tools are correctly installed when measuring hydraulic pressure.
q Take care when removing or installing the tracks of track-type machines. Since the track shoe may separate suddenly when you remove it, never let anyone stand at either end of the track shoe.
q If the engine is operated for a long time in a closed place with poor ventilation, it may cause gas poisoning. Open the windows and doors to ventilate the place well.
Precautions for slinging work and making signals
q Only one appointed worker must make signals and co-workers must communicate with each other frequently. The appointed signaler must make specified signals clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The signaler must always stand in front of the load and guide the operator safely.
k Do not do the work while the lifted load is in the range where it possibly falls. It is not allowed to go in the range where the lifted load possibly falls.
k Do not move a load over a person.
k Never step on the load.
k Do not prevent the load from swinging or falling down by holding it simply with the hands.
k The sling workers and assistant workers other than the guide must move to a place where they are not caught between the load and materials or equipment on the ground or hit by the load even if the crane starts abruptly.
q When you lift or fix the machine, see “Operation and Maintenance Manual” or “Field Assembly Instruction”.
k Do not lift or fix the machine by the positions where the name plate is not attached.
q When you lift the machine for the disassembly and assembly, follow the instructions on the Disassembly and Assembly.
q Check the slings before starting sling work.
q Keep putting on gloves during sling work. (Put on leather gloves, if available.)
q Measure the weight of the load by the eye and check its center of gravity.
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FOREWORD, SAFETY, BASIC INFORMATION00 INDEX AND FOREWORD
q Use proper sling corresponding to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall.
q Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically.
k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original slinging position on the load, which can result in a dangerous accident.
q Hanging angle must be 60 °or smaller as a rule.
q When slinging a heavy load (20 kg or heavier), the hanging angle of the rope must be narrower than that of the hook.
REMARK
When slinging a load with 2 or more ropes, the force subjected to each rope increases with the hanging angle. The figure below shows the variation of allowable load in kN {kg} when slinging is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, they can sling up to 2000 kg of total weight. This weight is reduced to 1000 kg when the 2 ropes make a hanging angle of 120 °. If the 2 ropes sling a 2000 kg load at a hanging angle of 150 °, each rope is subjected to a force as large as 39.2 kN {4000 kg} .
q When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping.
q Use the specified eye bolts and fix wire ropes, chains, etc. to them with shackles, etc.
q Apply wire ropes to the middle part of the hook.
k Do not use hooks if it does not have a latch system.
k Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting.
REMARK
The strength of the hook is maximum at its central part.
q Never use a wire rope which has breaks in strands (A), reduced diameter (B), or kinks (C). There is a danger that the rope may break during the towing operation.
Precautions for slinging up
q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught.
q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.
q If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again.
q Do not lift up the load at an angle.
Precautions for slinging down
q When slinging down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly.
q Check that the load is stable, and then remove the sling.
q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.
00-36
FOREWORD, SAFETY, BASIC INFORMATION
00 INDEX AND FOREWORD
Precautions for using mobile crane
REMARK
Read Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely.
Precautions for using overhead traveling crane
k When raising a heavy component (heavier than 20 kg), use a hoist or crane.
Weight of component whose weight is heavier than 20 kg is shown with symbol in "DISASSEMBLY AND ASSEMBLY".
REMARK
The symbol shows the weight of the parts with weight of 20kg or more for convenience of workers. But the weight can possibly be shown even if it is less than 20kg in accordance with the work environment.
Do the work safely in response to the work environment and the physical build, preexisting condition, and physical condition of the operator. And obey the laws and regulations of each country.
q Before starting work, check the wire ropes, brake, clutch, controller, rails, over winding prevention device, ground fault circuit interrupter for electric shock prevention, crane collision prevention device, and energizing caution lamp, and check the following safety items.
q Be sure not to touch the lifting tool and lifted load directly. Use push-pull sticks or tagline ropes.
q Observe the signals for sling work.
q Operate the hoist at a safe place.
q Be sure to check the directions of the direction indication plate (north, south, east and west) and the operating button.
q Do not sling a load at an angle. Do not move the crane while the slung load is swinging.
q Do not raise or lower a load while the crane is moving longitudinally or laterally.
q Do not drag a sling.
q When lifting up a load, stop it just after it becomes off the ground, check the safety, and then lift it up.
q Consider the travel route in advance and lift up a load to a safe height.
q Place the control switch in a position where it is not an obstacle to work and passage.
q After operating the hoist, do not swing the control switch.
q Remember the position of the main switch so that you can turn off the power immediately in an emergency.
q If the hoist stops because of a power failure, turn off the main switch. When turning on a switch after it is turned off by the ground fault circuit interrupter, check that the devices related to that switch are not in operating condition.
q If you find an obstacle around the hoist, stop the operation.
q After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.
Selecting wire ropes
Select adequate ropes depending on the weight of the parts to be hoisted referring to the table below.
REMARK
The allowable load is calculated with one sixth (safety factor 6) of the breaking load of the rope.
Wire rope (JIS G3525 6x37-A type) (Standard Z twist wire ropes without galvanizing)
Nominal diameter of rope (mm) Allowable load (kN {t})
FOREWORD, SAFETY, BASIC INFORMATION00 INDEX AND FOREWORD
Precautions for disconnecting air conditioner piping
NOTICE When replacing the air conditioner unit, air conditioner compressor, condenser or receiver drier, etc., collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before disconnecting the air conditioner hoses.
REMARK
q Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas: R134a).
q Never release the refrigerant (air conditioner gas: R134a) to the atmosphere.
k Put on the protective eyeglasses, gloves and working clothes with long sleeves while you are collecting or filling the refrigerant. Otherwise, when refrigerant gas (R134a) gets in your eyes, you may lose your sight, and when it touches your skin, you may suffer from frostbite.
q When loosening the nuts fixing air conditioner hoses and tubes, be sure to use 2 wrenches; use one wrench to fix and use the other one to loosen the nut.
Precautions for air conditioner piping
q When installing the air conditioner piping, be careful so that dirt, dusts and water do not enter the hose.
q Check that the O-rings are fitted to the joints when connecting the air conditioner piping.
q Do not reuse an O-ring because it is deformed and deteriorated if it is used once.
q When removing the O-rings, use a soft tool so that the piping is not damaged.
q Check that the O-ring is not damaged or deteriorated.
q Apply compressor oil for refrigerant (R134a) to O-ring.
REMARK
Do not apply oil to the threaded portion of a bolt, nut or union.
3079.6 {8.1} 40141.6 {14.4} 50221.6 {22.6} 60318.3 {32.4} Nominal diameter of rope (mm)Allowable load (kN {t}) Manufacturer Part name
DENSO ND-OIL8
VALEO THERMAL SYSTEMS ZXL100PG (PAG46 or equivalent)
SANDEN SP-10
When tightening nuts of the air conditioner hoses and tubes, be sure to use 2 wrenches. Use one wrench to fix and tighten the nut with the other wrench to the specified torque (Use a torque wrench for tightening).
REMARK
q The figure shows an example of fitting of O-ring.
q An O-ring is fitted to every joint of the air conditioner piping. For tightening torques, see THE OTHER INFORMATION, "Precautions for disconnection and connection of air conditioner piping".
HD325-8E0, HD405-8E0
00-38
PRECAUTIONS TO PREVENT FIRE
Fire caused by fuel, oil, coolant or window washer fluid
Do not bring any open flame close to fuel, oil, coolant or window washer fluid. Always observe the following.
q Do not smoke or use any open flame near fuel or other flammable substances.
q Shut down the engine before adding fuel.
q Do not leave the machine when adding fuel or oil.
q Tighten all the fuel and oil caps securely.
q Be careful not to spill fuel on overheated surfaces or on parts of the electrical system.
q After adding fuel or oil, wipe up any spilled fuel or oil.
q Put greasy rags and other flammable materials into a safe container to maintain safety at the workplace.
q When washing parts with oil, use a non-flammable oil. Do not use diesel oil or gasoline. There is danger that they may catch fire.
q Do not weld or use a cutting torch to cut any pipes or tubes that contain flammable liquids.
q Determine well-ventilated areas for storing oil and fuel. Keep the oil and fuel in the specified place and do not allow unauthorized persons to enter.
q When performing grinding or welding work on the machine, move any flammable materials to a safe place before starting.
Fire caused by accumulation or attachment of flammable material
q Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or attached to or around the engine exhaust manifold, muffler, or battery, or on the undercovers.
q To prevent fires from being caught, remove any flammable materials such as dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated around the cooling system (radiator, oil cooler) or on the undercover.
Fire coming from electric wiring
Short circuits in the electrical system can cause fire. Always observe the following.
q Keep all the electric wiring connections clean and securely tightened.
q Check the wiring every day for looseness or damage. Reconnect any loose connectors or refasten wiring clamps. Repair or replace any damaged wiring.
Fire caused by piping
Check that all the clamps for the hoses and tubes, guards, and cushions are securely fixed in position.
If they are loose, they may vibrate during operation and rub against other parts. There is danger that this may lead to damage to the hoses and cause high-pressure oil to spurt out, leading to fire and serious personal injury or death.
Fire around the machine due to highly heated exhaust gas
This machine is equipped with KDPF (Komatsu Diesel Particulate Filter).
KDPF is a system for purifying exhaust gas by removing soot in exhaust gas. In the process of purification (regeneration), the temperature of discharged exhaust gas may be higher than that of conventional models. Do not bring any flammable materials close to exhaust pipe outlet.
q When there are thatched houses, dry leaves or pieces of paper near the work site, set the system to disable the regeneration before starting work to prevent fire hazards due to highly heated exhaust gas caused by KDPF regeneration.
See the Operation and Maintenance Manual for the setting procedure.
Explosion caused by lighting equipment
q When checking fuel, oil, battery electrolyte, or coolant, always use lighting equipment with anti-explosion specifications.
q When taking the electrical power for the lighting equipment from the machine, follow the instructions in the Operation and Maintenance Manual.
ACTIONS IF FIRE OCCURS
q Turn the starting switch to OFF position to stop the engine.
q Use the handrails and steps to get off the machine.
q Do not jump off the machine. You may fall and suffer serious injury.
q The fumes generated by a fire contain harmful materials which have a bad influence on your body when they are inhaled.
Do not breathe the fumes.
q After a fire, there may be harmful compounds left. If they touch your skin they may have a bad influence on your body.
Be sure to wear rubber gloves when handling the materials left after the fire.
The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in the lower temperature environment).
When wearing cotton work gloves, wear rubber gloves under them.
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS
To prevent pollution, pay full attention to the way to dispose of waste materials.
q Always drain the oil from your machine in containers. Never drain the oil and coolant directly onto the ground or dump into the sewage system, rivers, seas, or lakes.
q Obey appropriate laws and regulations when disposing of harmful objects such as oil, fuel, coolant, solvent, filters, batteries, and DEF.
Avoid exposure to burning rubber or plastics which produce a toxic gas that is harmful to people.
q When disposing of parts made of rubber or plastics (hoses, cables, and harnesses), always comply with the local regulations for disposing industrial waste products.
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS
This machine conforms to either regulation of Tier4 Final (North America), Stage IV (Europe, until 2018), or Stage V (Europe, 2019 and after).
This machine is equipped with the following two exhaust gas treatment systems:
q Komatsu Diesel Particulate Filter (hereafter KDPF): A device which captures soot in the exhaust gas to purify exhaust gas. This process performs the combustion of soot referred to as "regeneration".
q Urea SCR system: A device which decomposes the toxic nitrogen oxides (NOx) mixed in the exhaust gas into harmless nitrogen and water. Spraying aqueous urea solution into the exhaust gas produces a reaction between the nitrogen oxides and ammonia generated from the urea solution and decomposes the nitrogen oxides into nitrogen and water.
Either AdBlue® or DEF may be used as the aqueous urea solution for the SCR system.
AdBlue® is a registered trade-mark of VDA (Verband der Automobilindustrie e.V.: Automobile Association of Germany).
DEF is the abbreviation for Diesel Exhaust Fluid.
Commercial DEF that is API approved and meets all the requirements defined in ISO 22241-1. This solution will be represented as DEF throughout this manual.
About DEF
DEF is necessary for the urea SCR system. DEF is a colorless transparent 32.5% aqueous urea solution. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical products, and fertilizer, etc.
If you add any additional additive agents or water to DEF and use it, the devices will not function properly, and conformance to the exhaust gas regulations will be lost. In addition, it will cause failure of the machine.
q In Europe, use AdBlue®
q In North America, use DEF (Diesel Exhaust Fluid) which is certified by API (American Petroleum Institute). The certified DEF has the API DEF Certification Mark shown as follows. Look for the API DEF Certification Mark when purchasing DEF. API Diesel Exhaust Fluid Certification Mark is the trade mark of API (American Petroleum Institute).
00
PRECAUTIONS FOR DEF
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING
DEF is a colorless transparent 32.5% aqueous urea solution. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical products, and fertilizer, etc. The following situations require immediate action:
q If it gets on your skin, it may cause inflammation. Immediately take the contaminated clothes or shoes off and wash it off with water. In addition, use a soap to wash it off thoroughly. If your skin becomes irritated or begins to hurt, immediately consult a doctor for treatment.
q Do not induce vomiting if swallowed. If swallowed, thoroughly rinse mouth with water and consult a doctor for treatment.
q Avoid contact with the eyes. If there is contact, flush with clean water for several minutes and consult a doctor for treatment
q Wear protective eyeglasses when exposed to DEF to protect from solution splashing in your eyes. Wear rubber gloves when you perform work handling DEF to avoid skin contact.
PRECAUTIONS FOR ADDING
Do not put fluid other than DEF into DEF tank. If diesel fuel or gasoline is added into the tank, it can cause a fire. Some fluids or agents added can create and emit a toxic gas.
When opening the cap of DEF tank of the machine, the ammonia vapor may escape. Keep your face away from the filler port during opening or refilling.
PRECAUTIONS FOR STORING
If the temperature of DEF becomes high, harmful ammonia gas may be generated. Completely seal up its container for storage.
When opening the container, perform it where there is good ventilation. For storage, see “STORE DEF”.
Store DEF avoiding direct sunlight. Always use the original container at the time of purchase. Do not exchange the container of DEF with another one. If DEF is stored in an iron or aluminum container, toxic gas may develop and a chemical reaction may corrode the container.
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE
DEF is non-flammable; however, in the case of a fire it may generate an ammonia gas. Act on the base of “Actions if fire occurs”. If DEF is spilled, immediately wipe and wash the area with water. If spilled DEF is left unattended and the area is not wiped and cleaned, toxic gas or corrosive substance may be produced by chemical reactions.
THE OTHER PRECAUTIONS
When disposing of DEF, treat it as an industrial waste. For the waste treating method, refer to “Precautions for disposing of waste materials”. The container of DEF must be treated as an industrial waste as well. It should be treated in the same way.
Never use an iron or aluminum container when disposing DEF fluid, because toxic gas may develop and a chemical reaction may corrode the container. Use a container made of resin (PP, PE) or stainless steel when handling the fluid waste of DEF.
Do not touch any fluid discharged from urea SCR. This fluid becomes acid by the influence of sulphur in the fuel or built-in oxidation catalyzer. If it gets on your skin, thoroughly wash it off with water.
Never relocate or modify the exhaust gas after-treatment device. The harmful gas may be exhausted and it can cause serious damage to the environment as well as violation of laws.
FOREWORD, SAFETY, BASIC INFORMATION00 INDEX AND FOREWORD
STORE DEF
q If the temperature of DEF becomes high, harmful ammonia gas may be generated. Completely seal up its container for storage. When opening the container, perform it where there is good ventilation.
q Store DEF avoiding direct sunlight. Always use the original container at the time of purchase. Do not exchange the container of DEF with another one. If DEF is stored in an iron or aluminum container, toxic gas may develop and a chemical reaction may corrode the container.
q DEF freezes at –11 °C. The recommended temperature for storage is -5 °C or above. The relation between the upper limit of storage temperature and the storage period of DEF is shown in the table.
Temperature of storage areaStorage period
Max. 10 °C Up to 36 months
Max. 25 °C Up to 18 months
Max. 30 °C Up to 12 months
Max. 35 °C Up to 6 months
*: Do not store DEF in the temperature of 35 °C or above.
Handling DEF in cold weather
q DEF freezes at –11 °C.
DEF may freeze and expand to break the devices and parts in the tank. The parts inside the tank may be affected. Add DEF to the specified amount for cold weather (below the level of when DEF may freeze).
q In cold weather, keep DEF or the machine installed with DEF in the indoors where the temperature is at –11 °C or higher to prevent DEF in the tank from freezing. If DEF or the machine installed with DEF cannot be stored in the indoors where the temperature is at –11 °C or higher (if they are left outdoors in cold weather), DEF in the tank may freeze. Drain DEF to prevent it from freezing.
00
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT
Because of the higher pressure and more precise hydraulic components, the most common cause of a failure is dust (foreign material) in the hydraulic circuit. The special care must be taken when adding hydraulic oil, or when disassembling, or assembling the hydraulic components.
Select an appropriate workplace
q In rain or high winds, or in dusty environment, avoid adding hydraulic oil, replacing filters, or repairing the machine.
Disassembly and maintenance work in the field
q In the field, there is a risk of dust entering the component during disassembling or maintenance work, and performance check is hardly performed. Replacement of the assembly is recommended.
q Perform disassembling and maintenance work in the dust proof area.
Sealing of openings (prevention of flowing out of oil)
Plug the openings of the piping and the device which have been removed to prevent foreign material from entering and oil from flowing out.
NOTICE
Do not expose the openings or stuff it, otherwise foreign material may enter or leaked oil may pollute the environment.
Do not discard the oil inconsiderately. Ask the customer for disposal or bring it back to dispose it appropriately.
REMARK
Cover the places tightly with caps, tapes, or plastic bags if it is hard to provide the plugs.
Preventing intrusion of foreign materials during refilling
q During refilling with the hydraulic oil, do not let water enter the electrical components.
q Clean the oil filler port and its around, refilling pump, oil jug, or etc.
q Refilling by using an oil cleaning device is better method since it can filtrate the contaminants accumulated in the oil during storage.
FOREWORD, SAFETY, BASIC INFORMATION00 INDEX AND FOREWORD
Replacing hydraulic oil while its temperature is high
q The higher the oil temperature is, the softer the oil is, and the smoother the oil runs. Also, the sludges are easily discharged from the circuit. Perform the replacement while oil temperature is high.
q Old hydraulic oil needs to be drained as much as possible when replacing.
NOTICE
Old hydraulic oil contaminates the new one if it is mixed since it contains contaminants and sludges, and the service life of the hydraulic oil is shortened.
REMARK
Drain the old hydraulic oil not only from the hydraulic tank but also from the filter and drain plug in the circuit.
Flushing operation
q Flushing is required to completely dislodge the contaminants and sludges, and existing oil containing those inside the hydraulic circuit after disassembling and assembling, and when replacing the oil with the new one.
q Normally, flushing is performed twice. Primary flushing is performed by using the flushing oil (1) and the secondary flushing is performed by using the specified hydraulic oil.
Cleaning operation
Perform oil cleaning to remove the contaminants and sludges in the hydraulic circuit after repair of the hydraulic device (pump or control valve) or during operation of the machine.
REMARK
The oil cleaning equipment can remove the ultra fine (approximately 3 μm) particles that the filter built in the hydraulic equipment cannot remove. So, it is very effective device.
00
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS
When performing "testing and adjusting" of the machine, "removal and installation" and "disassembly and assembly" of the components, observe the following precautions.
Precautions for removal and disassembling work
q If the cooling water contains coolant, dispose of it correctly as chemicals. Do not drain it to the sewage rashly.
q After disconnecting the hoses or tubes, plug them to prevent dust from entering.
q When draining oil, prepare a container with sufficient capacity.
q Check the matchmarks which indicate the installing position, and put matchmarks on the places where they seem necessary before removal of the components to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires.
q Attach the tags to wires and hoses so that installation is done to the correct installing positions.
q Check the thickness and number of shims when storing shims.
q When hoisting the components, prepare the slings with sufficient strength.
q When using forcing screws to remove any component, tighten the forcing screws uniformly and alternately.
q Before removing any component, clean the surrounding area and cover the component to prevent any foreign material from entering after removal.
q After disconnecting the piping or removing a pipe joint, install the following plugs.
NOTICE When disassembling the machine, check the part number by referring to the Parts Book and use the appropriate parts according to the usage conditions.
REMARK
The part numbers of O-ring shown in the table indicate the temporary part number when disassembling and transporting the machine.
Introduction of parts for the disassembly of the face seal type hoses and tubes
Nominal
0207376-7021002789-0021002896-11008
0307376-7031502789-0031502896-11009
0407376-7042202789-0042202896-11012
0507376-7052202789-0052202896-11015
0607376-7062802789-0062802896-11018
FOREWORD, SAFETY, BASIC INFORMATION00 INDEX AND FOREWORD
Introduction of parts for the disconnection of the taper seal type hoses and tubes
Nominal No. Hose sidePipe joint side Plug (1)Nut (2)
02 07376-50210
03 07376-50315
04 07376-50422
05 07376-50522
06 07376-50628
10 07376-51034
12 07376-51234
14 07376-51443
07222-00210
07222-00312
07222-00414
07222-00515
07222-00616
07222-01018
07222-01219
07222-01422
Introduction of parts for the disconnection of the split flange type hoses and tubes
Nominal No. Bolt pitch (mm)Hose sideTube side O-ring (4)Bolt (5)Washer (6) abFlange (1)Split flange (2) Sleeve head (3)
0438.117.507379-0040007371-3040007378-1040007000-1202101010-8082501643-50823 0542.919.807379-0050007371-3050007378-1050007000-1302201010-8083001643-50823 0647.622.207379-0064007371-3064007378-1060007000-1302507372-5103501643-51032 1052.426.207379-0104407371-3104907378-1100007000-1303207372-5103501643-51032 12 58.730.207379-0125007371-3125507378-1120007000-1303807372-5103501643-51032 66.731.807379-0126007371-5126007378-1121007000-1303801010-8124501643-51232
00-48 HD325-8E0, HD405-8E0
14 69.935.807379-0146007371-3146507378-1140007000-1304807372-5124001643-51232
79.436.507379-0147007371-5147007378-1141007000-1304801010-8145501643-31445
20 77.842.807379-0207107371-3207607378-1200007000-1206007372-5124001643-51232
96.844.507379-0208007371-5208007378-1201007000-1206001010-8186501643-31845 2488.950.807379-0248407371-1248407378-1240007000-1207007372-5124001643-51232 30106.46207379-0301007371-1301007378-1300007000-1208507372-5165001643-51645 34120.669.807379-0341107371-1341107378-1340007000-1210007372-5165001643-51645 40130.277.807379-0401207371-1401207378-1400007000-1211007372-5165001643-51645 50152.49207379-0501107371-1501107378-1500007000-1213507372-5165501643-51645
Introduction of parts for the removal of O-ring boss type joint
FOREWORD, SAFETY, BASIC INFORMATION00 INDEX AND FOREWORD
Introduction of parts for the removal of taper pipe thread type joint
Nominal No. Nominal thread size
Plug (1)
Square head type (A)Hexagonal socket head (B)
01 R1/8 07042-00108
02 R1/4 07042-00211
03 R3/8 07042-00312
04 R1/2 07042-00415
06 R3/4 07042-00617
10 R1 07042-01019
12 R11/4 07042-01222
14 R11/2 07042-01422
20 R2 07042-02026
Precautions for installation and assembling work
07043-00108
07043-00211
07043-00312
07043-00415
07043-00617
07043-01019
07043-01222
07043-01422
07043-02026
q Tighten the bolts and nuts (sleeve nuts) to the specified torque (KES) unless otherwise specified.
q Install the hoses without twist and interference. If there is any in-between clamp, securely fasten it.
q Replace all of the gaskets, O-rings, cotter pins, and lock plates with new ones.
q Bend the cotter pins and lock plates securely.
q When applying adhesive, clean and degrease the surface to apply, and apply 2 to 3 drops of adhesive to the threaded portion.
q When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that the surface is free from dust or damage.
q Clean all of the parts. If there is any damage, dents, burrs, or rust found on them, repair it.
q Apply engine oil to the rotating parts and sliding surface.
q Apply molybdenum disulfide lubricant (LM-P) to the surfaces of the press-fitting parts.
q After installing the snap ring, check that the snap ring is settled in the ring groove completely.
q When connecting wiring harness connectors, clean the connectors to remove oil, dust, or water, then connect them securely.
q Use the eye bolts without fatigue and deformation and screw them in securely. Match the directions of the eyes and the hook.
q When installing split flanges, tighten the bolts uniformly and alternately to prevent uneven tightening.
q As a rule, apply liquid gasket (LG-5) or liquid sealant (LS-2) to the threaded portion of each taper male screws which receive pressure.
00-50
HD325-8E0, HD405-8E0
00
REMARK
If the threaded portion is difficult to degrease, you may use a seal tape.
When winding a seal tape onto a right-handed taper male screw, start winding the screw clockwise from the third thread in the advancing direction of the threads seeing from the screw end.
NOTICE If the seal tape is wound counterclockwise, it may become loose when screwed in, and it may come off. If the sealed tip is pushed outside, it may cause oil leakage.
NOTICE
When assembling the hydraulic equipment such as cylinders, pumps and pipings which are removed, be sure to bleed air from the hydraulic circuit before operating it for the first time according to the following procedure.
1.Start the engine, and run it at low idle.
2.Perform the operation to extend and retract each cylinder of the work equipment and stop it at approximately 100 mm before the stroke end for 4 or 5 times.
3.Perform the operation to extend and retract each cylinder of the work equipment and stop it at the stroke end for 3 or 4 times.
NOTICE
After repair is finished, when operating the machine which has been stored for a long period, bleed air from the hydraulic circuit according to the same procedure.
Precautions at the time of completion of work
Refilling of coolant or water or oil, greasing, and adding of DEF
q For machines with urea SCR system, fill DEF to the specified level before starting the engine.
q Supply the specified amount of grease to the work equipment parts.
q When the coolant is drained, be sure that the drain valve is securely tightened, then refill the coolant reservoir with the coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping, and add the coolant to the specified level again.
q When the hydraulic components are removed and installed, refill the tank with the oil Komatsu recommends to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the specified level again.
q If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system after rebuilding the parts, by referring to TESTING AND ADJUSTING.
Testing installed condition of cylinder heads and manifolds
q Check the cylinder head and intake and exhaust manifold mountings for looseness.
q If there is any looseness, retighten the part.
REMARK
For the tightening torques, see "DISASSEMBLY AND ASSEMBLY".
Test engine piping for damage and looseness
Intake and exhaust system
Check that there is no damage on the pipings, or no looseness on mounting bolts, nuts and clamps, or no leak of air or exhaust gas from connecting portion.
If there is any looseness, damage, or gas leak, retighten or repair the part.
Cooling system
Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no water leak from connecting portion.
If there is any looseness, damage, or water leak, retighten or repair the part.
Fuel system
Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no fuel leak from connecting portion.
If there is any looseness, damage, or fuel leak, retighten or repair the part.
Check the exhaust equipment and its installation portion for looseness and damage.
REMARK
When an equipment is described as an exhaust equipment, it is one of the followings. (The applications or components of equipment are different depending on its models or specifications.)
q KDPF
q DEF mixing tube
q SCR assembly
q KDOC muffler
q Muffler
q Exhaust pipe
q Parts which connects the above, or etc.
Visually check that there is no crack or no damage on the exhaust equipment and its installation portion. If there is any damage, replace the part.
Check that there is no looseness on the exhaust equipment and mounting bolts, nuts, and clamps on the installation portion.
If there is any looseness, retighten the part.
Check of function of muffler in exhaust system
REMARK
When an equipment is described as an muffler in exhaust system, it is one of the followings. (The applications or components of equipment are different depending on its models or specifications.)
q KDPF
q DEF mixing tube
q SCR assembly
q KDOC muffler
q Muffler
q Exhaust pipe
q Parts which connects the above, or etc.
Check that there is no unusual noise by comparing to it of the time when the machine was new.
If there is any unusual noise, repair KDPF or muffler, referring to "TROUBLESHOOTING" and "DISASSEMBLY AND ASSEMBLY".
00
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT
To maintain the performance of the machine over a long period, and to prevent failures or troubles before they occur, correct "operation", "maintenance and inspection" "troubleshooting", and "repairs" must be performed. This section deals particularly with correct repair procedures for mechatronics components and is aimed at improving the quality of repairs. For this purpose, it describes the working procedures in "Handling of electrical equipment".
Handling wiring harnesses and connectors
q Wiring harnesses consist of wires connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wires.
q Compared with other electrical components fitted in boxes or cases, wiring harnesses are likely to be directly affected by rain water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling and maintenance of the wiring harnesses.
q If DEF is spilled over wiring harness and connectors, it may cause corrosion and defective contact. Be careful not to spill it over electrical equipment, wiring harness and connectors since DEF is strongly corrosive to metal.
Main causes of failure in wiring harness
Defective contact of connectors (defective contact between male and female connectors)
Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of connectors are deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connectors approximately 10 times.
Defective crimping or soldering of connectors
The pins of the male and female connectors are attached to wires by crimping or soldering. If excessive force is applied to the wire, the jointed portion (1) may become loose, and it may result in a defective connection or breakage.
HD325-8E0, HD405-8E0
Disconnection in wiring
If the wiring harness is pulled to disconnect the connector, or the components are lifted with a crane while the wiring harness is still connected, or a heavy object hits the wiring harness, it may separate the crimping of the connector, or damage the soldering, or break the wiring harness.
Water entering the connector by high-pressure jetting
The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet.
Do not spray water directly on the connector.
If the connector is waterproof, intruded water is hardly drained. Once water enters into the connector, water goes through pins to cause short-circuit. Drying the drenched connector or take appropriate actions before providing electricity.
Entry of water, dirt, or dust when disconnecting a connector
If any water, mud or dust is stuck to the outside surface of a connector, it can enter inside the connector when the connector is disconnected. Before disconnecting the connector, wipe off any stuck water or dirt by using a dry cloth or blow it with compressed air.
Oil, mud, or dust stuck to connector
If any oil or grease is stuck to the connector and an oil film is formed on the mating surface of the male and female pins, the oil prevents electricity from passing through resulting in defective contact. If any oil, grease, dirt or dust is stuck to the connector, wipe it off with a dry cloth or blow it with compressed air, and wash it with electrical contact restorer.
NOTICE
q When wiping the jointed portion of the connector, do not apply excessive force or deform the pins.
q If there is oil or water in the compressed air, it causes the contacts to become dirtier. Use clean air which any oil and water has been removed from.
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT
The machines equipped with common rail fuel injection system (CRI) consists of more precise parts than the parts used in the conventional fuel injection pump and nozzle. If foreign material enters this system, it may cause a failure. Use special care to prevent entry of the foreign material when servicing the fuel system.
Select an appropriate workplace
Avoid the work of adding hydraulic oil, replacing filters, or repairing the machine in rainy or windy weather, or in dusty environment.
Sealing the opening
Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to prevent foreign material from entering.
NOTICE
Do not expose the openings or stuff it, otherwise foreign material may enter or leaked oil may pollute the environment.
Do not discard the oil inconsiderately. Ask the customer for disposal or bring it back to dispose it appropriately.
How to clean parts when dirt is stuck
If any dirt or dust sticks the parts of the fuel system, clean it off thoroughly with clean fuel.
Precautions for replacing fuel filter cartridge
Be sure to use the Komatsu genuine fuel filter cartridge.
NOTICE
The machine equipped with common rail fuel injection system (CRI) consists of more precise parts than the parts used in the conventional fuel injection pump and nozzle. In order to prevent foreign material from entering this system, the filter employs a specially high performance of filter element. If a filter other than a Komatsu genuine filter is used, fuel system contamination and damage may occur. Therefore Komatsu recommends using only Komatsu fuel filters and install them following the procedures in the shop manual.
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT
The machines equipped with Komatsu Variable Geometry Turbocharger (VGT) consists of more precise parts (variable system) than the parts used in the conventional turbocharger. If foreign material enters this system, it may cause a failure. Use special care to prevent entry of the foreign material when servicing the intake system.
Select an appropriate workplace
Avoid the work of adding hydraulic oil, replacing filters, or repairing the machine in rainy or windy weather, or in dusty environment.
Sealing the opening
Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to prevent foreign material from entering.
NOTICE
Do not expose the openings or stuff it, otherwise foreign material may enter it.
PRACTICAL USE OF KOMTRAX
Various information which KOMTRAX system transmits by using the radio communication is useful for KOMTRAX operator to provide various services for the customers.
When KOMTRAX system is installed to the machine and it is enabled, machine information can be checked by KOMTRAX system, and it is used for testing and troubleshooting to be performed efficiently.
Large-sized models are equipped with KOMTRAX Plus which can use more detailed information.
REMARK
KOMTRAX may not be installed to the machine in some countries or areas.
Merit of using KOMTRAX
q The location where the machine is working at can be checked on the map in a personal computer.
q Operation information such as service meter, operating hours, fuel consumption, and occurred caution as well as failure code can be checked.
q The operator can check the hours used and replacement interval of consumable parts of the machine such as fuel filter, hydraulic oil filter, hydraulic oil and engine oil.
q Information of how machine is operated (idling time, traveling time, digging time, relieving time, etc.) can be checked, and it is used to presume the machine operating condition.
q Various reports such as “Fuel saving operation support”, “Operation summary”, etc. is generated, and it is utilized as an advice tool for the user and operator.
q KOMTRAX Plus can record the data of abnormality record, trend data, snap shot data, etc. to grasp the soundness of machine, in addition to KOMTRAX function described above. These data can be used on personal computer screens.
How to make a full use of KOMTRAX
Making use of KOMTRAX enables the following activities.
q Quick response to a request for immediate repair
1)To check the displayed caution and failure code, etc. through KOMTRAX upon receiving a repair request from a user.
2)To immediately arrange necessary tools, replacement parts, etc, immediately in accordance with the displayed failure code.
3)To find the location of the failed machine by using the map of KOMTRAX, to visit the customer there.
q Proactive maintenance
1)To check the service summary screen of KOMTRAX, to find the machine which has high priority failure code indicated by a red or yellow flag.
2)To check the condition of the machine with the customer and to make a plan to visit.
3)To immediately arrange necessary tools, replacement parts, etc, immediately in accordance with the displayed failure code.
q Practice of periodic maintenance and periodic inspection service
1)To check the service summary screen of KOMTRAX, and to find the machine of which the usage limits for the consumable parts indicated by red flags are over.
2)To submit an estimate sheet for the consumable parts to be replaced and the labor cost for the replacement work to the customer.
3)To propose the periodic inspection (Pm clinic, etc.) according to the service meter reading.
How to operate KOMTRAX
For the operating method of each screen of KOMTRAX, ask KOMTRAX key person in your Komatsu distributor.
FOREWORD, SAFETY, BASIC INFORMATION00 INDEX AND FOREWORD
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER
REMARK
q Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the hydraulic tank.
q Provide an oil container to receive oil since some hydraulic oi flows out when the hose is disconnected even after the remaining pressure is released from the hydraulic tank.
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER
Disconnection
1.Hold adapter (1), and push hose joint (2) into mating adapter (3).
REMARK
q Push it in approximately 3.5 mm.
q Do not hold rubber cap portion (4).
2.While having adapter (3) inserted into hose side joint (2), insert rubber cap (4) to adapter (3) side until it clicks.
3.Hold hose adapter (1) or hose (5), and pull it out.
REMARK
Provide an oil container to receive a quantity of hydraulic oil which may flow out.
Connection
1.Hold hose adapter (1) or hose (5), and insert it in mating adapter (3), aligning the axis.
REMARK
Do not hold rubber cap portion (4).
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00 INDEX AND FOREWORD
2.After inserting the hose in the mating adapter perfectly, pull it back to check the connecting condition.
REMARK
When the hose fitting is pulled back, the rubber cap moves approximately 3.5 mm toward the hose, but it is not a problem.
SAFETY, BASIC INFORMATION
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER
Disconnection
1.Hold the tightening adapter part and push body (2) straight until sliding prevention ring (1) contacts contact surface (a) of the hexagonal part at the male end.
2.While keeping the condition of step 1, turn lever (3) to the right (clockwise).
3.While keeping the conditions of steps 1 and 2, pull out whole body (2) to disconnect it.
REMARK
Provide an container to receive a quantity of hydraulic oil which may flow out.
FOREWORD, SAFETY, BASIC INFORMATION00 INDEX AND FOREWORD
Connection Hold the tightening adapter part and push body (2) straight until sliding prevention ring (1) contacts contact surface (a) of the hexagonal part at the male end.
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER
Disconnection
1.Hold the tightening adapter part and push body (2) straight until sliding prevention ring (1) contacts contact surface (a) of the hexagonal part at the male end.
2.While keeping the condition of step 1, push cover (3) straight until it contacts contact surface (a) of the hexagonal portion on the male side.
3.While keeping the conditions of steps 1 and 2, pull out whole body (2) to disconnect it. REMARK
Provide an container to receive a quantity of hydraulic oil which may flow out.
00
Connection
Hold the tightening adapter part and push body (2) straight until sliding prevention ring (1) contacts contact surface (a) of the hexagonal part at the male end.
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS
Disconnecting connectors
1.Hold the connectors when disconnecting.
When disconnecting the connectors, always hold the connecting portion. If the connector is fixed with screw, loosen the screw of the connector completely, hold the both of male and female connectors, and pull them out in parallel.
NOTICE
Do not pull the connectors with one hand.
REMARK
If it is a lock stopper type connector, pull it out as pushing the stopper (1) with your thumb.
2.When removing a connector from a clip
q Both of the connector and clip have stoppers (2), which are engaged with each other when the connector is connected.
q When removing a connector from a clip, pull the connector in parallel with the clip as removing stoppers.
NOTICE
If the connector is pried up and down or to the right or left, it may break the housing.
3.Action to be taken after removing connectors
After removing the connector, cover it with plastic bags to prevent entry of dust, dirt, oil, or water in the contact portion.
NOTICE
Be sure to cover the connector with plastic bags when leaving the machine disassembled for a long time, otherwise defective contact may occur.
00 INDEX AND FOREWORD FOREWORD, SAFETY, BASIC INFORMATION
Connecting connectors
1.Check the connector visually.
q Check that there is no dust, dirt, oil, or water stuck to the connector pins (joint portion).
q Check that there is no deformation, defective contact, corrosion, or damage on the connector pins.
q Check that there is no damage or crack on the external surfaces of the connectors.
NOTICE
q If there is any dust, dirt, oil, or water stuck to the connector, wipe it off with a dry cloth. If there is any water intrusion into the connector, warm the inside of the connector and harness with a dryer. Do not overheat the connector, otherwise short circuit may occur.
q If there is any damage or breakage, replace the connector.
2.Connecting the connector securely Position connector (1) correctly, and fit it in securely.
REMARK If the connector is lock stopper type, insert it until it clicks.
3.Correct the protrusion of the boot and misalignment of the wiring harness.
q If the connector is with the boot, correct any extrusion of the boot. In addition, if the wiring harness is misaligned or the clamp is out of position, adjust it to its correct position.
NOTICE If the protrusion of the boot and misalignment of the wiring harness cannot be fixed, remove the clamp to adjust them.
q If the connector clamp is removed, be sure to return it to its original position. Check that there is no looseness.
HD325-8E0,
FOREWORD, SAFETY, BASIC INFORMATION00 INDEX AND FOREWORD
Drying wiring harness
REMARK
If the wiring harness is dirty with oil and dust, wipe it off with a dry cloth. Avoid water washing or steam washing. If water washing is unavoidable, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector do as follows.
1.Disconnect the connector and wipe off the water with a dry cloth.
NOTICE
If the connector is to be blown with dry compressed air, there is the risk that oil in the air may cause defective contact, remove oil and water in the air before starting air blow.
2.Dry the inside of the connector with a dryer. If water enters inside the connector, use a dryer to dry the connector.
NOTICE
Hot air from a dryer can be used, but limit the time of using a dryer to prevent the connector or related parts from becoming too hot, as this will cause deformation or damage to the connector.
3.Perform a continuity test on the connector.
After drying, leave the wiring harness disconnected, connect T-adapter (1), and perform a continuity test to check for any short circuits between pins caused by water or etc.
REMARK
After the connector is completely dried, blow the contact restorer, and reassemble them.
FOREWORD, SAFETY, BASIC INFORMATION
00 INDEX AND FOREWORD
Handling controller
k When performing arc welding on the machine body, disconnect all of the wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.
NOTICE
q Controller has been assembled with electronic circuits for control including microcomputers. These electronic circuits inside of the controller must be handled with care since they control the machine.
q Do not leave things on the controller.
q Cover the connector portion of the controller with a tape and a plastic bag. Do not touch the connecting portion of connector.
q Do not leave the controller in a place where it is exposed to rain.
q Do not place the controller on oil, water, soil or any places where the temperature is likely to be high even for a short period of time (Place it on a suitable dry stand).
Precautions for troubleshooting electrical circuits
q Be sure to turn the starting switch to OFF position before disconnecting or connecting the connectors.
q Before performing troubleshooting, check all the related connectors for loose connection.
REMARK
Check the related connectors for their performance by disconnecting and connecting them several times.
q Be sure to connect all the disconnected connectors before proceeding to the next step.
NOTICE
If the starting switch is turned to ON position while the connectors are disconnected, an unrelated failure beside the actual failed part may be displayed.
q When performing the troubleshooting for the circuit (measurement of voltage, resistance,continuity, current, etc.), shake the related wiring harnesses and connectors several times and check that the multimeter reading does not change.
NOTICE
If the value changes on the multimeter, there may be a defective contact in the circuit.
HD325-8E0,
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR
Method for disconnecting Deutsch connector While pressing locks (a) and (b) from each side respectively, pull out female connector (2).
Method for connecting Deutsch connector
1.Push in female connector (2) horizontally, and insert it straight until it clicks. (Arrow: x)
2.In order to check whether locks (a) and (b) are completely inserted, insert female connector (2) by rocking it vertically (in the arrow z direction). (Arrow: x, y, z)
REMARK Lock (a) in the figure is pulled down (not set completely), and lock (b) is set completely.
SAFETY, BASIC INFORMATION
00 INDEX AND FOREWORD
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR
Method for disconnecting slide lock type connector (FRAMATOME-3, FRAMATOME- 2)
1.Slide lock (L1) to the right.
2.While pressing lock (L2), pull out connector (1) toward you.
REMARK
If portion A does not float when lock (L2) is pressed, and if connector (1) does not come out when it is pulled toward you, push up portion A with a small flat-head screwdriver while pressing lock (L2), and then pull out connector (1) toward you.
Method for connecting slide lock type connector (FRAMATOME-3, FRAMATOME- 2)
Insert it straight until it clicks.
Method for disconnecting slide lock type connector (FRAMATOME-24)
1.Slide down lock (red) (L1).
HD325-8E0, HD405-8E0 00-67
2.While pressing lock (L2), pull out connector (1). REMARK Lock (L2) is located behind connector (1) in the figure.
Method for connecting slide lock type connector (FRAMATOME-24)
Insert it straight until it clicks.
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL
Method for disconnecting connector with lock to pull
Disconnect the connector (2) by pulling lock (B) (on the wiring harness side) of connector (2) outward.
Method for connecting connector with lock to pull
Insert the connector securely until it "clicks".
00 INDEX AND FOREWORD
FOREWORD, SAFETY, BASIC INFORMATION
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH
Method for disconnecting connector with lock to push (BOSCH-3) While pressing lock (C), pull out connector (3) in the direction of the arrow. q 114 series q 107 series
REMARK
If the lock is located on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pushing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.
Method for connecting connector with lock to push (BOSCH-3) Insert it straight until it clicks.
HD325-8E0, HD405-8E0
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FOREWORD, SAFETY, BASIC INFORMATION00 INDEX AND FOREWORD
Method for disconnecting connector with lock to push (AMP-3)
While pressing lock (E), pull out connector (5) in the direction of the arrow.
Method for connecting connector with lock to push (AMP-3)
Insert it straight until it clicks.
Method for disconnecting connector with lock to push (SUMITOMO-3)
While pressing lock (E), pull out connector (5) in the direction of the arrow.
REMARK
Pull up the connector straight.
Method for connecting connector with lock to push (SUMITOMO-3)
Insert it straight until it clicks.
Method for disconnecting connector with lock to push (SUMITOMO-4)
While pressing lock (D), pull out connector (4) in the direction of the arrow.
Method for connecting connector with lock to push (SUMITOMO-4)
Insert it straight until it clicks.
00 INDEX AND FOREWORD
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE
Method for disconnecting connector with housing to rotate Turn housing (H1) to the left, and pull it out.
REMARK
Housing (H1) is left on the wiring harness side.
Method for connecting connector with housing to rotate
1.Insert the connector to the end while aligning its groove to the other.
2.Turn housing (H1) clockwise until it clicks.
FOREWORD, SAFETY, BASIC INFORMATION00 INDEX AND FOREWORD
HOW TO READ ELECTRICAL WIRE CODE
In the electrical circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electrical wire code is helpful in understanding the electrical circuit diagram. Example) AEX 0.85 L: Indicates heat-resistant, low-voltage blue wire for automobile, having nominal No. of 0.85
AEX
Indicates type of wire by symbol. Type, symbol, and material of wire are shown in (Table 1). (Since the use of AV and AVS wires depends on size (nominal No.), the symbols are not indicated on the diagram.)
0.85 Indicates size of wire by nominal No. Sizes (Nominal Nos.) are shown in (Table 2).
Type, symbol, and material
AV and AVS are different in only thickness and outside diameter of the coating. CAVS has a circular compressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of the coating. AEX is similar to AV in thickness and outside diameter of the coating but different from AV and AVS in material of the coating. (Table 1)
L Indicates color of wire by color code. Color codes are shown in (Table 3). TypeSymbol Conductor material Insulator
Thin-cover low-voltage wire for automobile (Type 1) AVS
Low-voltage wire for automobile AV Annealed copper for electric appliance Soft polyvinyl chloride-30 to +60
Thin-cover low-voltage wire for automobile (Type 2) CAVS
Heat-resistant low-voltage wire for automobile AEX
Dimensions
For large current wiring (nominal No. 5 and above)
General wiring (nominal No. 3 and lower)
For mid- to small-size excavators (nominal No. 1.25 and lower)
Heat-resistant crosslinked polyethylene -50 to +110
General wiring for extremely cold weather specification Wiring at high-temperature place
HD325-8E0, HD405-8E0
00-72
SAFETY, BASIC INFORMATION
00 INDEX AND FOREWORD
(Table 2)
Nominal No.0.5f(0.5)0.75f(0.85)1.25f(1.25)2f23f35
Nominal No. 815203040506085100
Number of strands 5084417085108127169217
Conductor
d (approx.)3.74.86.08.08.69.810.412.013.6
Coating D AVSStandard--------AVStandard5.57.08.210.811.413.013.616.017.6 AEXStandard5.37.08.210.811.413.013.616.017.6
Diameter of strand -round compression- round compression- round compression
Cross-sectional area (mm2) -0.56-0.88-1.29
d (approx.)-0.9-1.1-1.4
Coating D CAVSStandard-1.6-1.8-2.1
REMARK “f” of nominal No. denotes "flexible".
Color codes table (Table 3)
BBlack
BrBrown
BrBBrown and Black
BrRBrown and Red
BrWBrown and White
BrYBrown and Yellow
ChCharcoal
DgDark green
GGreen
GBGreen and Black
GLGreen and Blue
GrGray
GRGreen and Red
GWGreen and White
GYGreen and Yellow
LBlue
LBBlue and Black
LgLight green
LgBLight green and Black
LgRLight green and Red
REMARK
In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking. Example) GW indicates that the background is "Green" and marking is "White". Color
LgWLight green and White
LgYLight green and Yellow
LRBlue and Red
LWBlue and White
LYBlue and Yellow
OOrange
PPink
RRed
RBRed and Black
RGRed and Green
RLRed and Blue
RWRed and White
RYRed and Yellow
SbSky Blue
YYellow
YBYellow and Black
YGYellow and Green
YLYellow and Blue
YRYellow and Red
YWYellow and White
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
The maintenance standard section shows the judgment criteria whether the equipment or parts should be replaced or can be reused when the machine is disassembled for the maintenance. The following terms are the descriptions of the judgment criteria.
Standard dimension and tolerance
q The finished dimension of a part is slightly different from one to another actually.
q A standard dimension of a finished part is set, and an allowable difference from that dimension is set for the part.
q The dimension set as the standard is called the standard dimension and the allowable range of difference from this standard dimension is called "tolerance".
q An indication example of a standard dimension and tolerance is shown in the following table.
(The standard dimension is entered on the left side and the tolerance is entered with a positive or negative symbol on the right side)
Example:
q The tolerance may be indicated in the text and a table as "standard dimension (upper limit of tolerance/ lower limit of tolerance)." Example) 120 (-0.022/-0.126)
q Usually, the dimension of a hole and the dimension of the shaft to be inserted into that hole are indicated by the same standard dimension and different tolerances of the hole and shaft. The tightness of fit is determined by the tolerance.
q A dimension indication example of a shaft and hole is shown in the following table.
(The standard dimension is entered on the left side and the tolerance of the shaft is entered with a positive or negative symbol at the center and that of the hole on the right side)
00 INDEX AND FOREWORD FOREWORD, SAFETY, BASIC INFORMATION
Standard clearance and standard value
q The clearance made when new parts are assembled is called the standard clearance, which is indicated by the range from the minimum clearance to the maximum clearance.
q When some parts are repaired, the clearance is generally adjusted to the standard clearance.
q The values indicating performance and function of new products or equivalent are called "standard value", which is indicated by a range or a target value.
q When some parts are repaired, the value of performance/ function is set to the standard value.
Standard interference
q When the diameter of a hole of a part shown in the given standard dimension and tolerance table is smaller than that of the shaft to be inserted, the difference between those diameters is called "interference".
q Subtract the maximum dimension of the hole from the minimum dimension of the shaft and call it (A). Subtract the minimum dimension of the hole from the maximum dimension of the shaft and call it (B). The range between (A) and (B) is "standard interference".
q After repairing or replacing some parts, measure the dimension of their hole and shaft and check that the interference is in the standard range.
Repair limit and allowable value or allowable dimension
q The dimension of parts changes due to the wear or deformation while they are used. When the dimension changes exceeding certain value, parts cannot be used any longer. This value is called "repair limit".
q If a part is worn to the repair limit, it must be replaced or repaired.
q The performance and function of products lower while they are used. A value with which the product can be used without causing a problem is called "allowable value" or "allowable dimension".
q A product whose dimension is out of the allowable value, must be repaired. However, since the allowable values are generally estimated through various tests or experiences in most cases, the judgment must be made in consideration of the operating condition and customer's requirement.
Allowable clearance
q Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called "allowable clearance".
q If the clearance between the parts exceeds the allowable clearance, they must be replaced or repaired.
Allowable interference
q The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called "allowable interference".
q The allowable interference shows the repair limit of the part of smaller tolerance.
q The parts whose interferences are out of the allowable interference must be replaced or repaired.
STANDARD TIGHTENING TORQUE TABLE
Table of tightening torque for bolts and nuts
REMARK
Tighten the metric
SAFETY, BASIC INFORMATION
00 INDEX AND FOREWORD
REMARK
Tighten the unified coarse threaded bolts and nuts to the torque shown in the table below unless otherwise specified.
1/4-20UNC
3/8-16UNC 44.1 to 58.8 {4.5 to 6}52.0 {5.3}9.8 to 14.7 {1 to 1.5}11.8 {1.2}
7/16-14UNC 73.5 to 98.1 {7.5 to 10}86.3 {8.8}19.6 to 24.5 {2 to 2.5}21.6 {2.2}
1/2-13UNC 108 to 147 {11 to 15}127 {13}29.4 to 39.2 {3 to 4}34.3 {3.5}
9/16-12UNC 157 to 216 {16 to 22}186 {19}44.1 to 58.8 {4.5 to 6}51.0 {5.2}
5/8-11UNC 226 to 294 {23 to 30}265 {27}63.7 to 83.4 {6.5 to 8.5}68.6 {7}
3/4-10UNC 392 to 530 {40 to 54}461 {47}108 to 147 {11 to 15}127 {13}
7/8-9UNC 637 to 853 {65 to 87}745 {76}177 to 235 {18 to 24}206 {21} 1-8UNC883 to 1196 {90 to 122}1040 {106}245 to 333 {25 to 34}284 {29}
FOREWORD, SAFETY, BASIC INFORMATION00 INDEX AND FOREWORD
11/8-7UNC 1187 to 1608 {121 to 164}1393 {142}333 to 451 {34 to 46}392 {40}
11/4-7UNC 1598 to 2157 {163 to 220}1873 {191}451 to 608 {46 to 62}530 {54}
11/2-6UNC 2354 to 3177 {240 to 324}2765 {282}657 to 892 {67 to 91}775 {79}
REMARK
Tighten the unified fine threaded bolts and nuts to the torque shown in the table below unless otherwise specified.
00-80
1/4-28UNF
to
{5.5 to 7}61.8 {6.3}14.7 to 19.6 {1.5 to 2}16.7 {1.7}
7/16-20UNF 83.4 to 108 {8.5 to 11}96.1 {9.8}24.5 to 29.4 {2.5 to 3}26.5 {2.7}
1/2-20UNF 127 to 167 {13 to 17}147 {15}34.3 to 49.0 {3.5 to 5}41.2 {4.2}
9/16-18UNF 186 to 245 {19 to 25}216 {22}49.0 to 68.6 {5 to 7}58.8 {6}
5/8-18UNF 255 to 343 {26 to 35}294 {30}73.5 to 98.1 {7.5 to 10}83.4 {8.5}
3/4-16UNF 441 to 598 {45 to 61}520 {53}127 to 167 {13 to 17}147 {15}
7/8-14UNF 716 to 961 {73 to 98}843 {86}196 to 265 {20 to 27}226 {23}
1-14UNF1020 to 1373 {104 to 140}1196 {122}284 to 382 {29 to 39}333 {34}
11/8-12UNF 1353 to 1844 {138 to 188}1598 {163}382 to 520 {39 to 53}451 {46}
11/4-12UNF 1804 to 2432 {184 to 248}2118 {216}510 to 686 {52 to 70}598 {61}
11/2-12UNF 2707 to 3658 {276 to 373}3177 {324}765 to 1030 {78 to 105}892 {91}
00 INDEX AND FOREWORD
Table of tightening torque for O-ring boss piping joints
REMARK
Tighten the pipe joint for O-ring boss to the torque shown in the table below unless otherwise specified.
Table of tightening torque for O-ring boss plugs
REMARK
Tighten the plug for O-ring boss to the torque shown in the table
FOREWORD, SAFETY, BASIC INFORMATION00 INDEX AND FOREWORD
20203044.1 to 53.9 {4.5 to 5.5}49.0 {5.0} 24243258.8 to 78.4 {6.0 to 8.0}68.6 {7.0} 30303293.1 to 122.5 {9.5 to 12.5}107.8 {11.0} 3333-107.8 to 147.0 {11.0 to 15.0}127.4 {13.0} 363636127.4 to 176.4 {13.0 to 18.0}151.9 {15.5} 4242-181.3 to 240.1 {18.5 to 24.5}210.7 {21.5} 5252-274.4 to 367.5 {28.0 to 37.5}323.4 {33.0}
Table of tightening torque for hose (taper seal type and face seal type)
REMARK
q Tighten the hose fittings (taper seal type and face seal type) to the torque shown in the following table unless otherwise specified.
q The table is applied to the threaded portion coated with engine oil (wet threaded portion).
0219 34 to 54 {3.5 to 5.5}44 {4.5}-
34 to 63 {3.5 to 6.5}44 {4.5}14-03 2254 to 93 {5.5 to 9.5}74 {7.5}- 11/16-16UN 17.5 2459 to 98 {6.0 to 10.0}78 {8.0} 18
042784 to 132 {8.5 to 13.5}103 {10.5}22 13/16-16UN
0532128 to 186 {13.0 to 19.0}157 {16.0}241-14UNS25.4
0636177 to 245 {18.0 to 25.0}216 {22.0}30 13/16-12UN 30.2 (10)41177 to 245 {18.0 to 25.0}216 {22.0}33
(12)46197 to 294 {20.0 to 30.0}245 {25.0}36
(14)55246 to 343 {25.0 to 35.0}294 {30.0}42
00-82
FOREWORD, SAFETY, BASIC INFORMATION
00 INDEX AND FOREWORD
Table of tightening torque for face seal joints
REMARK
q The tightening torque table below applies to the seal joint (sleeve nut type) made with steel pipe for plated low pressure piping which is used for engine.
q The table is applied to the threaded portion coated with engine oil (wet threaded portion).
q Reference: The face seal joint of the dimension in ( ) is also used depending on the specification.
Tightening torque table for bolts and nuts on 102,107 and 114 series engines
REMARK
Tighten the metric threads bolts and nuts used on the 102, 107 and 114 series engines to the torques shown in the following table unless otherwise specified.
FOREWORD, SAFETY, BASIC INFORMATION00 INDEX AND FOREWORD
Tightening torque table for 102, 107, and 114 series engines (joint bolts)
REMARK
Tighten the metric joint bolts used on the 102, 107, and 114 series engines to the torque shown in the following table unless otherwise specified.
Tightening torque table for tapered screws on 102,107, and 114 series engines (National taper pipe thread (NPT))
REMARK
Tighten the National taper pipe threaded (NPT) screws used on the 102, 107, and 114 series engines to the torques shown in the following table unless otherwise specified.
SAFETY, BASIC INFORMATION
00 INDEX AND FOREWORD
CONVERSION TABLE
Method of using the conversion table
The conversion table is provided to enable simple conversion of the numerical numbers between the different units. For further details of the method of using the conversion table, see the examples given below.
Examples of using the conversion table to convert a unit from mm to in.
When converting 55 mm to in
1.Locate the number 50 in the leftmost column, take this as (A), and then draw a horizontal line from (A).
2.Locate the number 5 in the top row, take this as (B), then draw a vertical line down from (B).
3.Take the crossover point of the two lines as (C). This point (C) gives the value when converting the unit from mm to in. Accordingly, 55 mm = 2.165 in.
When converting 550 mm to in
1.The number 550 does not appear in the table. Divide it by 10 (move the decimal point one place to the left) to get 55 mm.
2.Convert 55 mm to 2.165 in according to the preceding procedure.
3.The original value (550 mm) has been divided by 10, so multiply 2.165 in by 10 (move the decimal point one place to the right) to restore the target value. This gives 550 mm = 21.65 in. mm to in
1 mm = 0.03937 in 0123456789 000.0390.0790.1180.1570.1970.2360.2760.3150.354 100.3940.4330.4720.5120.5510.5910.6300.6690.7090.748 200.7870.8270.8660.9060.9450.9841.0241.0631.1021.142 301.1811.2201.2601.2991.3391.3781.4171.4571.4961.536 401.5751.6141.6541.6931.7321.7721.8111.8501.8901.929 (C) (A) 501.9692.0082.0172.0872.1262.1652.2052.2442.2832.323 602.3622.4022.4412.4802.5202.5592.5982.6382.6772.717 702.7562.7952.8352.8472.9132.9532.9923.0323.0713.110 803.1503.1893.2283.2683.3073.3463.3863.4253.4653.504 903.5433.5833.6223.6613.701 3.7803.8193.8583.898
mm to in (B)
1 mm = 0.03937 in 0123456789
000.0390.0790.1180.1570.1970.2360.2760.3150.354 100.3940.4330.4720.5120.5510.5910.6300.6690.7090.748 200.7870.8270.8660.9060.9450.9841.0241.0631.1021.142 301.1811.2201.2601.2991.3391.3781.4171.4571.4961.536 401.5751.6141.6541.6931.7321.7721.8111.8501.8901.929 501.9692.0082.0472.0872.1262.1652.2052.2442.2832.323 602.3622.4022.4412.4802.5202.5592.5982.6382.6772.717
HD325-8E0, HD405-8E0 00-85
1 mm = 0.03937 in 0123456789
702.7562.7952.8352.8472.9132.9532.9923.0323.0713.110 803.1503.1893.2283.2683.3073.3463.3863.4253.4653.504 903.5433.5833.6223.6613.7013.7403.7803.8193.8583.898
FOREWORD, SAFETY, BASIC INFORMATION00 INDEX AND FOREWORD kg to lb
1 kg = 2.2046 lb 0123456789 002.204.416.618.8211.0213.2315.4317.6419.84 1022.0524.2526.4628.6630.8633.0735.2737.4839.6841.89 2044.0946.3048.5050.7151.9155.1257.3259.5361.7363.93 3066.1468.3470.5572.7574.9677.1679.3781.5783.7885.98 4088.1890.3992.5994.8097.0099.21101.41103.62105.82108.03 50110.23112.44114.64116.85119.05121.25123.46125.66127.87130.07 60132.28134.48136.69138.89141.10143.30145.51147.71149.91152.12 70154.32156.53158.73160.94163.14165.35167.55169.76171.96174.17 80176.37178.57180.78182.98185.19187.39189.60191.80194.01196.21 90198.42200.62202.83205.03207.24209.44211.64213.85216.05218.26
l to U.S.Gal
1l = 0.2642 U.S.Gal 0123456789 000.2640.5280.7931.0571.3211.5851.8492.1132.378 102.6422.9063.1703.4343.6983.9634.2274.4914.7555.019 205.2835.5485.8126.0766.3406.6046.8697.1337.3977.661 307.9258.1898.4548.7188.9829.2469.5109.77410.03910.303 4010.56710.83111.09511.35911.624 11.88812.15212.41612.68012.944 5013.20913.47313.73714.00114.265 14.52914.79515.05815.32215.586 6015.85016.11516.37916.64316.907 17.17117.43517.70017.96418.228 7018.49218.75619.02019.28519.549 19.81320.07720.34120.60520.870 8021.13421.39821.66221.92622.190 22.45522.71922.98323.24723.511 9023.77524.04024.30424.56824.832 25.09625.36125.62525.88926.153
l to U.K.Gal
1l = 0.21997 U.K.Gal 0123456789 000.2200.4400.6600.8801.1001.3201.5401.7601.980 102.2002.4202.6402.8603.0803.3003.5203.7403.9504.179 204.3994.6194.8395.0595.2795.4995.7195.9396.1596.379 306.5996.8197.0397.2597.4797.6997.9198.1398.3598.579
HD325-8E0, HD405-8E0
00-86
00 INDEX AND FOREWORD
SAFETY, BASIC INFORMATION
1l = 0.21997 U.K.Gal 0123456789
408.7999.0199.2399.4599.6799.89910.11910.33910.55910.778 5010.99811.28111.43811.65811.87812.09812.31812.52812.75812.978 6013.19813.41813.63813.85814.07814.29814.51814.73814.95815.178 7015.39815.61815.83816.05816.27816.49816.71816.93817.15817.378 8017.59817.81818.03718.25718.47718.69718.91719.13719.35719.577 9019.79720.01720.23720.45720.67720.89721.11721.33721.55721.777
kgm to lbft
1 kgm = 7.233 lbft 0123456789 007.214.521.728.936.243.450.657.965.1 1072.379.686.894.0101.3108.5115.7123.0130.2137.4 20144.7151.9159.1166.4173.6180.8188.1195.3202.5209.8 30217.0224.2231.5238.7245.9253.2260.4267.6274.9282.1 40289.3296.6303.8311.0318.3325.5332.7340.0347.2354.4 50361.7368.9376.1383.4390.6397.8405.1412.3419.5426.8 60434.0441.2448.5455.7462.9470.2477.4484.6491.8499.1 70506.3513.5520.8528.0535.2542.5549.7556.9564.2571.4 80578.6585.9593.1600.3607.6614.8622.0629.3636.5643.7 90651.0658.2665.4672.7679.9687.1694.4701.6708.8716.1 100723.3730.5737.8745.0752.2759.5766.7773.9781.2788.4 110795.6802.9810.1817.3824.6831.8839.0846.3853.5860.7 120868.0875.2882.4889.7896.9904.1911.4918.6925.8933.1 130940.3947.5954.8962.0969.2976.5983.7990.9998.21005.4 1401012.61019.91027.11034.31041.51048.81056.01063.21070.51077.7 1501084.91092.21099.41106.61113.91121.11128.31135.61142.81150.0 1601157.31164.51171.71179.01186.21193.41200.71207.91215.11222.4 1701129.61236.81244.11251.31258.51265.81273.01280.11287.51294.7 1801301.91309.21316.41323.61330.91338.11345.31352.61359.81367.0 1901374.31381.51388.71396.01403.21410.41417.71424.91432.11439.4
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2 0123456789 0014.228.442.756.971.185.399.6113.8128.0 10142.2156.5170.7184.9199.1213.4227.6241.8256.0270.2 20284.5298.7312.9327.1341.4355.6369.8384.0398.3412.5 30426.7440.9455.1469.4483.6497.8512.0526.3540.5554.7
HD325-8E0, HD405-8E0 00-87
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FOREWORD, SAFETY, BASIC INFORMATION00 INDEX AND FOREWORD
1 kg/cm2
0123456789
40568.9583.2597.4611.6625.8640.1654.3668.5682.7696.9 50711.2725.4739.6753.8768.1782.3796.5810.7825.0839.2 60853.4867.6881.8896.1910.3924.5938.7953.0967.2981.4 70995.6101010241038105310671081109511091124 801138115211661181119512091223123712521266 901280129413091323133713511365138013941408 1001422143714511465147914931508152215361550 1101565157915931607162116361650166416781693 1201707172117351749176417781792180618211835 1301849186318771892190619201934194919631977 1401991200520202034204820622077209121052119 1502134214821622176219022052219223322472262 1602276229023042318233323472361237523892404 1702418243224462460247524892503251825322546 1802560257425892603261726312646266026742688 1902702271727312745275927732788280228162830 2002845285928732887290129162930294429582973 2102987300130153030304430583072308631013115 2203129314331583172318632003214322932433257 2303271328633003314332833433357337133853399 2403414342834423456347034853499351335273542
Temperature
Conversion of Fahrenheit to Celsius
q A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice versa is to see the number in the center column of the following table. The figures in the center of the following table show the temperatures in both Fahrenheit and Celsius.
q When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Celsius temperature in the column at the left.
q When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius values, and read the corresponding Fahrenheit temperature on the right.
-40.4-40-40.0-11.71151.87.846114.827.281177.8 -37.2-35-31.0-11.11253.68.347116.627.882179.6 -34.4-30-22.0-10.61355.48.948118.428.383181.4 -31.7-25-13.0-10.01457.29.449120.228.984183.2 -28.9-20-4.0-9.41559.010.050122.029.485185.0 -28.3-19-2.2-8.91660.810.651123.830.086186.8 -27.8-18-0.4-8.31762.611.152125.630.687188.6
00-88
00 INDEX AND FOREWORD
SAFETY, BASIC INFORMATION
-27.2-171.4-7.81864.411.753127.431.188190.4 -26.7-163.2-7.21966.212.254129.231.789192.2 -26.1-155.0-6.72068.012.855131.032.290194.0 -25.6-146.8-6.12169.813.356132.832.891195.8 -25.0-138.6-5.62271.613.957134.633.392197.6 -24.4-1210.4-5.02373.414.458136.433.993199.4 -23.9-1112.2-4.42475.215.059138.234.494201.2 -23.3-1014.0-3.92577.015.660140.035.095203.0 -22.8-915.8-3.32678.816.161141.835.696204.8 -22.2-817.6-2.82780.616.762143.636.197206.6 -21.7-719.4-2.22882.417.263145.436.798208.4 -21.1-621.2-1.72984.217.864147.237.299210.2 -20.6-523.0-1.13086.0 18.365149.037.8100212.0 -20.0-424.8-0.63187.8 18.966150.840.6105221.0 -19.4-326.603289.619.467152.643.3110230.0 -18.9-228.40.63391.420.068154.446.1115239.0 -18.3-130.21.13493.220.669156.248.9120248.0 -17.8032.01.73595.021.170158.051.7125257.0 -17.2133.82.23696.821.771159.854.4130266.0 -16.7235.62.83798.622.272161.657.2135275.0 -16.1337.43.338100.422.873163.460.0140284.0 -15.6439.23.939102.223.374165.262.7145293.0 -15.0541.04.440104.023.975167.065.6150302.0 -14.4642.85.041105.824.476168.868.3155311.0 -13.9744.65.642107.625.077170.671.1160320.0 -13.3846.46.143109.425.678172.473.9165329.0 -12.8948.26.744111.226.179174.276.7170338.0 -12.21050.07.245113.026.780176.079.4175347.0
HD325-8E0, HD405-8E0 00-89
