Complete service repair manual with Electrical Wiring Diagrams for Komatsu Dump Trucks HD325, HD405, HD465, HD605, HD785, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Dump Trucks HD325, HD405, HD465, HD605, HD785 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

SEN06618-04 - Dump Truck HD325-8, HD405-8 Shop Manual.pdf
SEN00486-14 - Dump Truck HD325-7, HD405-7 Shop Manual.pdf
SEN00486-13 - Dump Truck HD325-7, HD405-7 Shop Manual.pdf
SEBMW00401 - Dump Truck HD325-6, HD405-6, HD465-5, HD605-5, HD785-5 Shop Manual.pdf
SEBM05660510 - Dump Truck HD325-5 Shop Manual.pdf
SEBM015115 - Dump Truck HD325-6, HD405-6 Shop Manual.pdf
SEBM000704 - Dump Truck HD325-6, HD405-6 Shop Manual.pdf
TEN00425-07 - Dump Truck HD325-7, HD405-7 Operation & Maintenance Manual.pdf
TEN00348-02 - Dump Truck HD325-7, HD405-7 Operation & Maintenance Manual.pdf
TEN00331-00 - Dump Truck HD325-7, HD405-7 Operation & Maintenance Manual.pdf
TEN00137-09 - Dump Truck HD325-7, HD405-7 Operation & Maintenance Manual.pdf
TEN00041-05 - Dump Truck HD325-6, HD405-6 Operation & Maintenance Manual.pdf
SEAMW00500 - Dump Truck HD325-6 Operation & Maintenance Manual.pdf
SEAM05660505 - Dump Truck HD325-5 Operation & Maintenance Manual.pdf
SEAM05660501 - Dump Truck HD325-5 Operation & Maintenance Manual.pdf
SEAM000819T - Dump Truck HD325-6, HD405-6 Operation & Maintenance Manual.pdf
SEAM000817T - Dump Truck HD325-6, HD405-6 Operation & Maintenance Manual.pdf
SEAM000808 - Dump Truck HD325-6 Operation & Maintenance Manual.pdf
SEAM000807 - Dump Truck HD325-6 Operation & Maintenance Manual.pdf
SEAM000806 - Dump Truck HD325-6 Operation & Maintenance Manual.pdf
SEAM000805 - Dump Truck HD325-6 Operation & Maintenance Manual.pdf
SEAM000803 - Dump Truck HD325-6 Operation & Maintenance Manual.pdf
SEAM000802 - Dump Truck HD325-6 Operation & Maintenance Manual.pdf
SEAM566D01 - Dump Truck HD320-3, HD325-3 Operation & Maintenance Manual.pdf
GEN00045-05 - Dump Truck HD325-7, HD405-7 Field Assembly Manual.pdf
GEN00020-00 - Dump Truck HD325-6, HD405-6 Field Assembly Manual.pdf
EPAM025104 - Camião Basculante HD325-7, HD405-7 Manual de Operação e Manutenção (PT).pdf
EEAM029201 - Dump Truck HD325-7, HD405-7 Operation & Maintenance Manual.pdf

PRODUCT DETAILS:
Total Pages: 15,124 pages
File Format: PDF
Language: English

TABLE OF CONTENTS

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

Komatsu Dump Trucks HD325, HD405, HD465, HD605, HD785 Workshop Service Repair Manuals