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KOMATSU HD325-5 SHOP MANUAL SEBM05660510 – PDF DOWNLOAD
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Description
KOMATSU HD325-5 SHOP MANUAL SEBM05660510 – PDF DOWNLOAD
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KOMATSU HD325-5 SHOP MANUAL SEBM05660510 – PDF DOWNLOAD
Language : English
Pages : 718
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU HD325-5 SHOP MANUAL SEBM05660510 – PDF DOWNLOAD
COVER.............................................................................................................................................................................................................................. 1 CONTENTS........................................................................................................................................................................................................................... 2 10 ENGINE.......................................................................................................................................................................................................................... 23 12 TESTING AND ADJUSTING....................................................................................................................................................................................................... 23 STANDARD VALUE TABLE....................................................................................................................................................................................................... 24 TOO LIST FOR TESTING AND ADJUSTING......................................................................................................................................................................................... 25 ADJUSTING VALVE CLEARANCE.................................................................................................................................................................................................. 26 MEASURING COMPRESSION PRESSURE............................................................................................................................................................................................. 27 MEASURING BLOW-BY PRESSURE................................................................................................................................................................................................. 28 ADJUSTING FUEL INJECTION TIMING............................................................................................................................................................................................ 29 AIR BLEEDING FROM FUEL SYSTEM.............................................................................................................................................................................................. 30 ADJUSTING CABLE FOR ENGINE STOP MOTOR...................................................................................................................................................................................... 30 MEASURING EXHAUST GAS COLOR................................................................................................................................................................................................ 31 ADJUSTING TENSION OF ALTERNATOR DRIVE BELT................................................................................................................................................................................. 33 MEASURING ENGINE OIL TEMPERATURE AND PRESSURE.............................................................................................................................................................................. 34 13 DISASSEMBLY AND ASSEMBLY.................................................................................................................................................................................................... 35 STARTING MOTOR............................................................................................................................................................................................................. 36 REMOVAL................................................................................................................................................................................................................ 36 INSTALLATION........................................................................................................................................................................................................... 36 ALTERNATOR................................................................................................................................................................................................................. 37 REMOVAL................................................................................................................................................................................................................ 37 INSTALLATION........................................................................................................................................................................................................... 37 OIL COOLER................................................................................................................................................................................................................. 38 REMOVAL................................................................................................................................................................................................................ 38 INSTALLATION........................................................................................................................................................................................................... 38 FUEL INJECTION PUMP........................................................................................................................................................................................................ 39 REMOVAL................................................................................................................................................................................................................ 39 INSTALLATION........................................................................................................................................................................................................... 39 AIR COMPRESSOR............................................................................................................................................................................................................. 40 REMOVAL................................................................................................................................................................................................................ 40 INSTALLATION........................................................................................................................................................................................................... 40 AIR CONDITIONER COMPRESSOR................................................................................................................................................................................................. 41 REMOVAL................................................................................................................................................................................................................ 41 INSTALLATION........................................................................................................................................................................................................... 41 WATER PUMP................................................................................................................................................................................................................. 42 REMOVAL................................................................................................................................................................................................................ 42 INSTALLATION........................................................................................................................................................................................................... 42 TURBOCHARGER............................................................................................................................................................................................................... 43 REMOVAL................................................................................................................................................................................................................ 43 INSTALLATION........................................................................................................................................................................................................... 43 NOZZLE HOLDER.............................................................................................................................................................................................................. 44 REMOVAL................................................................................................................................................................................................................ 44 INSTALLATION........................................................................................................................................................................................................... 44 AFTERCOOLER................................................................................................................................................................................................................ 45 REMOVAL................................................................................................................................................................................................................ 45 INSTALLATION........................................................................................................................................................................................................... 47 CYLINDER HEAD.............................................................................................................................................................................................................. 49 REMOVAL................................................................................................................................................................................................................ 49 INSTALLATION........................................................................................................................................................................................................... 53 RADIATOR................................................................................................................................................................................................................... 58 REMOVAL................................................................................................................................................................................................................ 58 INSTALLATION........................................................................................................................................................................................................... 61 ENGINE..................................................................................................................................................................................................................... 64 REMOVAL................................................................................................................................................................................................................ 64 INSTALLATION........................................................................................................................................................................................................... 68 20 POWER TRAIN..................................................................................................................................................................................................................... 73 21 STRUCTURE AND FUNCTION...................................................................................................................................................................................................... 73 GENERAL.................................................................................................................................................................................................................... 74 OUTPUT SHAFT............................................................................................................................................................................................................... 75 POWER TRAIN HYDRAULIC PIPING............................................................................................................................................................................................... 76 POWER TRAIN HYDRAULIC SYSTEM............................................................................................................................................................................................... 78 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM...................................................................................................................................................................................... 79 TORQUE CONVERTER........................................................................................................................................................................................................... 82 TORQUE CONVERTER VALVE..................................................................................................................................................................................................... 84 TRANSMISSION MOUNT......................................................................................................................................................................................................... 90 TRANSMISSION............................................................................................................................................................................................................... 91 TRANSMISSION CONTROL VALVE................................................................................................................................................................................................. 95 TRANSMISSION OIL TANK......................................................................................................................................................................................................107 TORQUE CONVERTER AND TRANSMISSION PUMP.....................................................................................................................................................................................108 RETARDER COOLING PUMP......................................................................................................................................................................................................109 REAR AXLE..................................................................................................................................................................................................................110 DIFFERENTIAL...............................................................................................................................................................................................................111 FRONT AXLE.................................................................................................................................................................................................................114 FINAL DRIVE SYSTEM.........................................................................................................................................................................................................116 DRIVE SHAFT................................................................................................................................................................................................................117 FRONT BRAKE................................................................................................................................................................................................................118 REAR BRAKE.................................................................................................................................................................................................................120 REAR BRAKE COMPONENT PARTS.................................................................................................................................................................................................121 PARKING BRAKE..............................................................................................................................................................................................................122 FRONT WHEEL................................................................................................................................................................................................................123 REAR WHEEL.................................................................................................................................................................................................................124 22 TESTING AND ADJUSTING.......................................................................................................................................................................................................125 TABLE OF JUDGEMENT STANDARD................................................................................................................................................................................................126 TOOL LIST FOR TESTING AND ADJUSTING........................................................................................................................................................................................128 TESTING AND ADJUSTING OF ACCELERATOR PEDAL (AUTOMATIC TRANSMISSION).......................................................................................................................................................129 PROCEDURE FOR ADJUSTING MANUAL SHIFT CONSOLE...............................................................................................................................................................................131 MEASURING OF TRANSMISSION SHIFT LEVER OPERATING FORCE (AUTOMATIC TRANSMISSION).............................................................................................................................................134 MEASURING OF TRANSMISSION OIL TEMPERATURE..................................................................................................................................................................................134 MEASURING OF TORQUE CONVERTER OIL PRESSURE.................................................................................................................................................................................135 MEASURING OF TRANSMISSION OIL PRESSURE.....................................................................................................................................................................................136 ADJUSTING OF TRANSMISSION MODULATION OIL PRESSURE (CLUTCH CIRCUIT OIL PRESSURE)............................................................................................................................................138 MEASURING OF TORQUE CONVERTER STALL........................................................................................................................................................................................139 TESTING OF SERVICE BRAKE PERFORMANCE.......................................................................................................................................................................................140 TESTING OF BRAKING DISTANCE................................................................................................................................................................................................140 ADJUSTING OF FRONT BRAKE...................................................................................................................................................................................................141 BLEEDING AIR FROM REAR BRAKE...............................................................................................................................................................................................141 BLEEDING AIR FROM FRONT BRAKE..............................................................................................................................................................................................142 MEASURING OF REAR BRAKE OIL PRESSURE.......................................................................................................................................................................................143 MEASURING OF WEAR OF BRAKE DISC............................................................................................................................................................................................143 TESTING FRONT WHEEL BEARING ...............................................................................................................................................................................................144 TESTING AND ADJUSTING OF PARKING BRAKE.....................................................................................................................................................................................146 23 DISASSEMBLY AND ASSEMBLY....................................................................................................................................................................................................147 OUTPUT SHAFT...............................................................................................................................................................................................................148 REMOVAL................................................................................................................................................................................................................148 INSTALLATION...........................................................................................................................................................................................................149 DISASSEMBLY............................................................................................................................................................................................................150 ASSEMBLY...............................................................................................................................................................................................................150 TORQUE CONVERTER AND TRANSMISSION..........................................................................................................................................................................................151 REMOVAL................................................................................................................................................................................................................151 INSTALLATION...........................................................................................................................................................................................................154 DISASSEMBLY............................................................................................................................................................................................................157 CONNECTION.............................................................................................................................................................................................................158 TRANSMISSION PUMP..........................................................................................................................................................................................................159 REMOVAL................................................................................................................................................................................................................159 INSTALLATION...........................................................................................................................................................................................................159 TORQUE CONVERTER...........................................................................................................................................................................................................160 DISASSEMBLY............................................................................................................................................................................................................160 ASSEMBLY...............................................................................................................................................................................................................165 PTO........................................................................................................................................................................................................................170 DISASSEMBLY............................................................................................................................................................................................................170 ASSEMBLY...............................................................................................................................................................................................................171 TORQUE CONVERTER CONTROL VALVE.............................................................................................................................................................................................172 REMOVAL................................................................................................................................................................................................................172 INSTALLATION...........................................................................................................................................................................................................172 DISASSEMBLY............................................................................................................................................................................................................173 ASSEMBLY...............................................................................................................................................................................................................173 TRANSMISSION...............................................................................................................................................................................................................174 DISASSEMBLY............................................................................................................................................................................................................174 ASSEMBLY...............................................................................................................................................................................................................187 TRANSMISSION CONTROL VALVE.................................................................................................................................................................................................204 REMOVAL................................................................................................................................................................................................................204 INSTALLATION...........................................................................................................................................................................................................204 DISASSEMBLY AND ASSEMBLY...............................................................................................................................................................................................206 ACCUMULATOR VALVE..........................................................................................................................................................................................................205 REMOVAL................................................................................................................................................................................................................205 INSTALLATION...........................................................................................................................................................................................................205 PARKING BRAKE SHOE.........................................................................................................................................................................................................211 REMOVAL................................................................................................................................................................................................................211 INSTALLATION...........................................................................................................................................................................................................212 DIFFERENTIAL GEAR..........................................................................................................................................................................................................213 REMOVAL................................................................................................................................................................................................................213 INSTALLATION...........................................................................................................................................................................................................216 DISASSEMBLY............................................................................................................................................................................................................218 ASSEMBLY...............................................................................................................................................................................................................229 PLANETARY CARRIER (FINAL DRIVE)............................................................................................................................................................................................256 REMOVAL................................................................................................................................................................................................................256 INSTALLATION...........................................................................................................................................................................................................257 FINAL DRIVE................................................................................................................................................................................................................258 DISASSEMBLY............................................................................................................................................................................................................258 ASSEMBLY...............................................................................................................................................................................................................261 REAR WHEEL BRAKE...........................................................................................................................................................................................................265 REMOVAL................................................................................................................................................................................................................265 INSTALLATION...........................................................................................................................................................................................................267 DISASSEMBLY............................................................................................................................................................................................................269 ASSEMBLY...............................................................................................................................................................................................................271 FRONT WHEEL................................................................................................................................................................................................................273 REMOVAL................................................................................................................................................................................................................273 INSTALLATION...........................................................................................................................................................................................................274 REAR WHEEL.................................................................................................................................................................................................................275 REMOVAL................................................................................................................................................................................................................275 INSTALLATION...........................................................................................................................................................................................................276 FRONT BRAKE SHOE...........................................................................................................................................................................................................278 REMOVAL................................................................................................................................................................................................................278 INSTALLATION...........................................................................................................................................................................................................279 FRONT CALIPER..............................................................................................................................................................................................................281 REMOVAL................................................................................................................................................................................................................281 INSTALLATION...........................................................................................................................................................................................................281 CALIPER....................................................................................................................................................................................................................282 DISASSEMBLY............................................................................................................................................................................................................282 ASSEMBLY...............................................................................................................................................................................................................282 FRONT WHEEL HUB............................................................................................................................................................................................................283 DISASSEMBLY............................................................................................................................................................................................................283 ASSEMBLY...............................................................................................................................................................................................................285 24 MAINTENANCE STANDARD........................................................................................................................................................................................................288 OUTPUT SHAFT...............................................................................................................................................................................................................289 TORQUE CONVERTER VALVE.....................................................................................................................................................................................................290 TORQUE CONVERTER...........................................................................................................................................................................................................291 TRANSMISSION CONTROL VALVE.................................................................................................................................................................................................293 TRANSMISSION...............................................................................................................................................................................................................295 TORQUE CONVERTER AND TRANSMISSION PUMP.....................................................................................................................................................................................298 RETARDER COOLING PUMP......................................................................................................................................................................................................299 DIFFERENTIAL...............................................................................................................................................................................................................300 FRONT BRAKE................................................................................................................................................................................................................303 FINAL DRIVE................................................................................................................................................................................................................305 REAR BRAKE.................................................................................................................................................................................................................306 PARKING BRAKE..............................................................................................................................................................................................................307 WHEEL......................................................................................................................................................................................................................308 40 STEERING AND SUSPENSION SYSTEM..................................................................................................................................................................................................309 41 STRUCTURE AND FUNCTION......................................................................................................................................................................................................309 STEERING SYSTEM............................................................................................................................................................................................................310 STEERING WHEEL.............................................................................................................................................................................................................311 STEERING LINKAGE...........................................................................................................................................................................................................312 CHASSIS SUSPENSION SYSTEM..................................................................................................................................................................................................313 FUNCTIONS OF CHASSIS SUSPENSION SYSTEM.....................................................................................................................................................................................314 REAR AXLE SUPPORT..........................................................................................................................................................................................................316 FRONT SUSPENSION CYLINDER..................................................................................................................................................................................................317 REAR SUSPENSION CYLINDER...................................................................................................................................................................................................318 42 TESTING AND ADJUSTING.......................................................................................................................................................................................................319 TABLE OF JUDGEMENT STANDARD................................................................................................................................................................................................320 MEASURING OF STEERING WHEEL................................................................................................................................................................................................321 TESTING AND ADJUSTING OF SUSPENSION CYLINDER...............................................................................................................................................................................322 43 DISASSEMBLY AND ASSEMBLY....................................................................................................................................................................................................327 STEERING VALVE.............................................................................................................................................................................................................328 REMOVAL................................................................................................................................................................................................................328 INSTALLATION...........................................................................................................................................................................................................328 DISASSEMBLY............................................................................................................................................................................................................330 ASSEMBLY...............................................................................................................................................................................................................334 FRONT SUSPENSION CYLINDER..................................................................................................................................................................................................340 REMOVAL................................................................................................................................................................................................................340 INSTALLATION...........................................................................................................................................................................................................342 REAR SUSPENSION CYLINDER...................................................................................................................................................................................................344 REMOVAL................................................................................................................................................................................................................344 INSTALLATION...........................................................................................................................................................................................................345 SUSPENSION CYLINDER........................................................................................................................................................................................................346 DISASSEMBLY............................................................................................................................................................................................................346 ASSEMBLY...............................................................................................................................................................................................................347 44 MAINTENANCE STANDARD........................................................................................................................................................................................................348 SUSPENSION CYLINDER........................................................................................................................................................................................................349 STEERING LINKAGE...........................................................................................................................................................................................................350 50 AIR SYSTEM......................................................................................................................................................................................................................351 51 STRUCTURE AND FUNCTION......................................................................................................................................................................................................351 AIR PIPING.................................................................................................................................................................................................................352 AIR CIRCUIT DIAGRAM........................................................................................................................................................................................................354 AIR CIRCUIT SCHEMATICS.....................................................................................................................................................................................................358 RELAY VALVE (ACTS ALSO AS EMERGENCY RELAY).................................................................................................................................................................................359 PROTECTION VALVE...........................................................................................................................................................................................................363 FRONT BRAKE CONTROL........................................................................................................................................................................................................364 FRONT BRAKE CHAMBER........................................................................................................................................................................................................365 REAR BRAKE CHAMBER.........................................................................................................................................................................................................367 SLACK ADJUSTER.............................................................................................................................................................................................................370 PARKING BRAKE VALVE........................................................................................................................................................................................................373 PARKING BRAKE REALY VALVE..................................................................................................................................................................................................375 PARKING BRAKE CONTROL......................................................................................................................................................................................................377 SPRING CYLINDER............................................................................................................................................................................................................378 RETARDER BRAKE VALVE.......................................................................................................................................................................................................379 AUTO-RETARDER VALVE........................................................................................................................................................................................................382 STOP LAMP SWITCH...........................................................................................................................................................................................................383 HORN VALVE.................................................................................................................................................................................................................383 LOW-PRESSURE BUZZER SWITCH.................................................................................................................................................................................................384 SAFETY VALVE...............................................................................................................................................................................................................385 AIR GOVERNOR...............................................................................................................................................................................................................386 CHECK VALVE................................................................................................................................................................................................................388 DOUBLE-CHECK VALVE.........................................................................................................................................................................................................389 BRAKE VALVES...............................................................................................................................................................................................................390 BRAKE CIRCUIT..............................................................................................................................................................................................................395 52 TESTING AND ADJUSTING.......................................................................................................................................................................................................398 TABLE OF JUDGEMENT STANDARD................................................................................................................................................................................................399 MEASURING OF BRAKE PEDAL...................................................................................................................................................................................................400 MEASURING OF RETARDER CONTROL LEVER........................................................................................................................................................................................400 TESTING AND ADJUSTING OF AIR PRESSURE......................................................................................................................................................................................401 53 DISASSEMBLY AND ASSEMBLY....................................................................................................................................................................................................402 SLACK ADJUSTER ASSEMBLY....................................................................................................................................................................................................403 REMOVAL................................................................................................................................................................................................................403 INSTALLATION...........................................................................................................................................................................................................403 DISASSEMBLY............................................................................................................................................................................................................404 ASSEMBLY...............................................................................................................................................................................................................404 PARKING BRAKE SPRING CYLINDER..............................................................................................................................................................................................405 REMOVAL................................................................................................................................................................................................................405 INSTALLATION...........................................................................................................................................................................................................405 DISASSEMBLY............................................................................................................................................................................................................406 ASSEMBLY...............................................................................................................................................................................................................407 BRAKE VALVE................................................................................................................................................................................................................408 REMOVAL................................................................................................................................................................................................................408 INSTALLATION...........................................................................................................................................................................................................408 DISASSEMBLY............................................................................................................................................................................................................409 ASSEMBLY...............................................................................................................................................................................................................411 FRONT BRAKE CHAMBER .......................................................................................................................................................................................................413 REMOVAL................................................................................................................................................................................................................413 INSTALLATION...........................................................................................................................................................................................................413 DISASSEMBLY............................................................................................................................................................................................................414 ASSEMBLY...............................................................................................................................................................................................................414 REAR BRAKE CHAMBER ........................................................................................................................................................................................................419 REMOVAL................................................................................................................................................................................................................419 INSTALLATION...........................................................................................................................................................................................................419 DISASSEMBLY............................................................................................................................................................................................................420 ASSEMBLY...............................................................................................................................................................................................................421 AIR GOVERNOR ..............................................................................................................................................................................................................426 REMOVAL................................................................................................................................................................................................................426 INSTALLATION...........................................................................................................................................................................................................426 DISASSEMBLY............................................................................................................................................................................................................427 ASSEMBLY...............................................................................................................................................................................................................427 54 MAINTENANCE STANDARD........................................................................................................................................................................................................428 AIR GOVERNOR...............................................................................................................................................................................................................429 SLACK ADJUSTER.............................................................................................................................................................................................................430 60 HYDRAULIC SYSTEM................................................................................................................................................................................................................431 61 STRUCTURE AND FUNCTION......................................................................................................................................................................................................431 HYDRAULIC PIPING...........................................................................................................................................................................................................432 HYDRAULIC SYSTEM...........................................................................................................................................................................................................434 HYDRAULIC CIRCUIT DIAGRAM..................................................................................................................................................................................................435 HYDRAULIC TANK WITH FILTER.................................................................................................................................................................................................436 HYDRAULIC TANK STEERING PUMP...............................................................................................................................................................................................437 DEMAND VALVE...............................................................................................................................................................................................................438 HOIST CONTROL VALVE........................................................................................................................................................................................................442 HOIST CONTROL SYSTEM.......................................................................................................................................................................................................446 STEERING CONTROL VALVE.....................................................................................................................................................................................................447 CROSSOVER RELIEF VALVE.....................................................................................................................................................................................................451 STEERING CYLINDER..........................................................................................................................................................................................................452 HOIST CYLINDER.............................................................................................................................................................................................................453 SLOW RETURN VALVE..........................................................................................................................................................................................................454 62 TESTING AND ADJUSTING.......................................................................................................................................................................................................456 TABLE OF JUDGEMENT STANDARD................................................................................................................................................................................................457 TESTING AND ADJUSTING OF HOIST LEVER.......................................................................................................................................................................................458 MEASURING OF HYDRAULIC OIL TEMPERATURE.....................................................................................................................................................................................459 TESTING AND ADJUSTING OF OIL PRESSURE IN STEERING AND HOIST CIRCUIT........................................................................................................................................................460 MEASURING OF RAISING SPEED OF DUMP BODY....................................................................................................................................................................................462 MEASURING OF HYDRAULIC DRIFT OF HOIST CYLINDER.............................................................................................................................................................................462 MEASURING OF HYDRAULIC PUMP PERFORMANCE....................................................................................................................................................................................463 BLEEDING AIR FROM STEERING CYLINDER........................................................................................................................................................................................465 63 DISASSEMBLY AND ASSEMBLY....................................................................................................................................................................................................466 TANDEM PUMP (BRAKE COOLING)................................................................................................................................................................................................467 REMOVAL................................................................................................................................................................................................................467 INSTALLATION...........................................................................................................................................................................................................467 TANDEM PUMP (HOIST, STEERING)..............................................................................................................................................................................................468 REMOVAL................................................................................................................................................................................................................468 INSTALLATION...........................................................................................................................................................................................................468 EMERGENCY STEERING MOTORใปPUMP..............................................................................................................................................................................................469 REMOVAL................................................................................................................................................................................................................469 INSTALLATION...........................................................................................................................................................................................................469 HOIST VALVE................................................................................................................................................................................................................470 REMOVAL................................................................................................................................................................................................................470 INSTALLATION...........................................................................................................................................................................................................470 DISASSEMBLY............................................................................................................................................................................................................471 ASSEMBLY...............................................................................................................................................................................................................472 DEMAND VALVE...............................................................................................................................................................................................................473 REMOVAL................................................................................................................................................................................................................473 INSTALLATION...........................................................................................................................................................................................................473 STEERING CYLINDER..........................................................................................................................................................................................................474 REMOVAL................................................................................................................................................................................................................474 INSTALLATION...........................................................................................................................................................................................................474 DISASSEMBLY............................................................................................................................................................................................................475 ASSEMBLY...............................................................................................................................................................................................................477 HOIST CYLINDER.............................................................................................................................................................................................................479 REMOVAL................................................................................................................................................................................................................479 INSTALLATION...........................................................................................................................................................................................................480 DISASSEMBLY............................................................................................................................................................................................................481 ASSEMBLY...............................................................................................................................................................................................................482 64 MAINTENANCE STANDARD........................................................................................................................................................................................................483 HYDRAULIC AND STEERING PUMP................................................................................................................................................................................................484 DEMAND VALVE...............................................................................................................................................................................................................485 HOIST VALVE................................................................................................................................................................................................................486 CROSSOVER RELIEF VALVE.....................................................................................................................................................................................................487 STEERING CYLINDER..........................................................................................................................................................................................................488 HOIST CYLINDER.............................................................................................................................................................................................................489 HOIST CONTROL SYSTEM.......................................................................................................................................................................................................490 70 WORK EQUIPMENT..................................................................................................................................................................................................................491 71 STRUCTURE AND FUNCTION......................................................................................................................................................................................................491 MAIN FRAME, DUMP BODY......................................................................................................................................................................................................492 73 DISASSEMBLY AND ASSEMBLY....................................................................................................................................................................................................493 DUMP BODY .................................................................................................................................................................................................................494 REMOVAL................................................................................................................................................................................................................494 INSTALLATION...........................................................................................................................................................................................................494 74 MAINTENANCE STANDARD........................................................................................................................................................................................................495 MAIN FRAME.................................................................................................................................................................................................................496 REPAIR OF DUMP BODY BY WELDING.............................................................................................................................................................................................498 80 ELECTRICAL AND ELECTRONIC SYSTEM................................................................................................................................................................................................499 81 STRUCTURE AND FUNCTION......................................................................................................................................................................................................499 ELECTRICAL CIRCUIT DIAGRAM.................................................................................................................................................................................................500 FILTER CLOGGING CAUTION SENSOR.............................................................................................................................................................................................505 RADIATOR WATER LEVEL SENSOR................................................................................................................................................................................................506 CENTER WARNING LAMP (RED)..................................................................................................................................................................................................508 ELECTRONIC VEHICLE MONITORING SYSTEM (E.V.M.S.) (IF EQUIPPED)..............................................................................................................................................................509 TRANSMISSION SHIFT CONTROL SYSTEM (MANUAL SHIFT)...........................................................................................................................................................................512 TRANSMISSION SELECTOR SWITCH...............................................................................................................................................................................................515 DIODE MATRIX...............................................................................................................................................................................................................515 AUTO-LOCK-UP CONTROL CIRCUIT...............................................................................................................................................................................................516 AUTO-LOCK-UP CONTROLLER....................................................................................................................................................................................................516 AUTOMATIC SHIFT CONTROL SYSTEM (IF EQUIPPED)...............................................................................................................................................................................517 SHIFT INDICATOR............................................................................................................................................................................................................528 82 TESTING AND ADJUSTING.......................................................................................................................................................................................................531 LOCATION DIAGRAM FOR CONNECTOR PINS........................................................................................................................................................................................532 CONNECTION TABLE FOR CONNECTOR PINS........................................................................................................................................................................................533 MS CONNECTORS..............................................................................................................................................................................................................535 TESTING OF SENSORS.........................................................................................................................................................................................................538 CHECKING PROCEDURE FOR AUTOMATIC SHIFT CONTROLLER (A.E.S.C.) WITH A-TYPE CHECKER...........................................................................................................................................542 CHECKING PROCEDURE FOR AUTOMATIC SHIFT CONTROLLER (A.E.S.C.) WITH B-TYPE CHECKER...........................................................................................................................................547 TROUBLESHOOTING............................................................................................................................................................................................................552 TROUBLESHOOTING PROCEDURE..............................................................................................................................................................................................552 CHECK BEFORE TROUBLESHOOTING...........................................................................................................................................................................................553 TROUBLESHOOTING........................................................................................................................................................................................................555 JUDGEMENT TABLE........................................................................................................................................................................................................559 TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM FOR AUTOMATIC SHIFT TRANSMISSION (E-1.TO E-11.)..................................................................................................................................562 E-1. ENGINE DOES NOT START.............................................................................................................................................................................................563 E-2. ENGINE DOES NOT START.............................................................................................................................................................................................572 E-3. MACHINE DOES NOT START............................................................................................................................................................................................574 E-4. ABNORMALITY IN OPERATION OF MACHINE WHEN STARTING.................................................................................................................................................................586 E-5. GEAR SHIFT ABNORMALLY.............................................................................................................................................................................................586 E-6. ABNORMALITY IN OPERATION OF MACHINE DURING TRAVEL.................................................................................................................................................................587 E-7. TRANSMISSION SUDDENLY SHIFTS TO NEUTRAL WHEN TRAVELING............................................................................................................................................................595 E-8. LONG TIME TAKEN TO SHIFT UP.......................................................................................................................................................................................605 E-9. SKIP SHIFT OPERATES ABNORMALLY....................................................................................................................................................................................612 E-10. KICK-DOWN OPERATES ABNORMALLY....................................................................................................................................................................................618 E-11. ABNORMALITY IN MACHINE OPERATION WHEN RETARDER IS OPERATED.......................................................................................................................................................622 TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM FOR MANUAL SHIFT TRANSMISSION (E-1.TO E-7.)......................................................................................................................................623 MANUAL SHIFT RELATED WIRING DIAGRAM....................................................................................................................................................................................624 CONNECTOR AND CONNECTOR POSITION.......................................................................................................................................................................................625 E-1. ENGINE DOES NOT START.............................................................................................................................................................................................629 E-2. ENGINE DOES NOT START.............................................................................................................................................................................................630 E-3. MACHINE DOES NOT MOVE OR TRANSMISSION SUDDENLY RETURNS TO NEUTRAL.................................................................................................................................................632 E-4. ABNORMALITY GEAR SHIFTING WHEN MACHINE START......................................................................................................................................................................633 E-5. GEAR SHIFTING IS ABNORMAL.........................................................................................................................................................................................634 E-6. ACTION OF MACHINE ABNORMAL WHEN TRAVELING.........................................................................................................................................................................634 E-7. ACTION OF MACHINE ABNORMAL WHEN TRAVELING.........................................................................................................................................................................635 TROUBLESHOOTING TABLE (H-1. TO H-18.)......................................................................................................................................................................................636 H-1. MACHINE DOES NOT MOVE.............................................................................................................................................................................................637 H-2. MACHINE DOES NOT TRAVEL SMOOTHLY..................................................................................................................................................................................639 H-3. CAN NOT DISENGAGE LOCK-UP CLUTCH (ENGINE STALL)...................................................................................................................................................................639 H-4. LARGE SHOCK WHEN STARTING OR SHIFTING.............................................................................................................................................................................640 H-5. DOES NOT SHIFT UP OR SHIFT UP SPEED IS HIGH.......................................................................................................................................................................640 H-6. MACHINE TRAVELS SLOWLY OR LACKS POWER.............................................................................................................................................................................641 H-7. LARGE TIME LAG WHEN STARTING AND GEARSHIFTING.....................................................................................................................................................................646 H-8. TORQUE CONVERTER OIL TEMPERATURE IS HIGH..........................................................................................................................................................................647 H-9. TORQUE CONVERTER OIL PRESSURE IS LOW..............................................................................................................................................................................648 H-10. FRONT BRAKE IS INEFFECTIVE OR EFFECTIVE ONLY ONE SIDE............................................................................................................................................................649 H-11. REAR BRAKE IS INEFFECTIVE OR EFFECTIVE ONLY ONE SIDE.............................................................................................................................................................650 H-12. STEERING WHEEL DRAGS.............................................................................................................................................................................................651 H-13. STEERING WHEEL DOES NOT FUNCTION.................................................................................................................................................................................652 H-14. STEERING WHEEL VIBRATES..........................................................................................................................................................................................652 H-15. HOIST CYLINDER LACKS LIFTING FORCE (LIFTING SPEED)...............................................................................................................................................................653 H-16. HOIST CYLINDER DOES NOT WORK.....................................................................................................................................................................................654 H-17. EXCESSIVE HYDRAULIC DRIFT OF THE DUMP BODY.......................................................................................................................................................................655 H-18. AIR PRESSURE DOES NOT RISE.......................................................................................................................................................................................656 TROUBLESHOOTING CHART FOR STANDARD PANEL (M-1. TO M-5.)....................................................................................................................................................................657 ELECTRICAL CIRCUIT DIAGRAM FOR STANDARD PANEL..........................................................................................................................................................................658 M-1. ENGINE WATER TEMPERATURE GAUGE DOES NOT DISPLAY OR DISPLAY ABNORMALLY.............................................................................................................................................659 M-2. TORQUE CONVERTER OIL TEMPERATURE GAUGE DOES NOT DISPLAY OR DISPLAYS ABNORMALLY....................................................................................................................................660 M-3. RETARDER OIL TEMPERATURE DOES NOT DISPLAY OR DISPLAYS ABNORMALLY..................................................................................................................................................661 M-4. ENGINE OIL PRESSURE DOES NOT DISPLAY OR DISPLAYS ABNORMALLY.......................................................................................................................................................662 M-5. SERVICE METER DOES NOT OPERATE....................................................................................................................................................................................663 TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM (OPTION) (M-6. TO M-32.)....................................................................................................................................664 HOW TO CONNECT CHECKER FOR EVMS........................................................................................................................................................................................664 TROUBLESHOOTING TABLE (EVMS)...........................................................................................................................................................................................666 ELECTRICAL CIRCUIT DIAGRAM FOR EVMS....................................................................................................................................................................................668 M-6. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR..........................................................................................................................................669 M-7. ENGINE SPEED DISPLAY DOES NOT APPEAR..............................................................................................................................................................................671 M-8. MACHINE SPEED DISPLAY DOES NOT APPEAR.............................................................................................................................................................................673 M-9. RETARDER OIL TEMPERATURE GAUGE DOES NOT OPERATE...................................................................................................................................................................675 M-10. SERVICE METER DOES NOT OPERATE...................................................................................................................................................................................677 M-11. ODOMETER DOES NOT OPERATE........................................................................................................................................................................................678 M-12. ENGINE OIL LEVEL IS CORRECT, BUT CHECK BEFORE STARTING ITEM LAMP FLASHES.........................................................................................................................................679 M-13. COOLANT LEVEL IS CORRECT, BUT CHECK BEFORE STARTING ITEM LAMP FLASHES............................................................................................................................................681 M-14. FUEL LEVEL IS CORRECT, BUT WARNING ITEM LAMP FLASHES.............................................................................................................................................................682 M-15. BATTERY CHARGING IS NORMAL, BUT WARNING ITEM LAMP FLASHES........................................................................................................................................................683 M-16. DUMP BODY IS NORMAL, BUT WARNING ITEM LAMP FLASHES...............................................................................................................................................................684 M-17. RETARDER OIL TEMPERATURE IS NORMAL, BUT DANGER ITEM LAMP FLASHES.................................................................................................................................................685 M-18. ENGINE OIL PRESSURE IS NORMAL, BUT DANGER ITEM LAMP FLASHES......................................................................................................................................................685 M-19. COOLANT LEVEL IS CORRECT, BUT DANGER ITEM LAMP FLASHES...........................................................................................................................................................687 M-20. AIR PRESSURE IS NORMAL, BUT DANGER ITEM LAMP FLASHES.............................................................................................................................................................689 M-21. TORQUE CONVERTER OIL TEMPERATURE IS NORMAL, BUT DANGER ITEM LAMP FLASHES.........................................................................................................................................690 M-22. PARKING BRAKE IS NORMAL, BUT DANGER ITEM LAMP FLASHES............................................................................................................................................................691 M-23. ENGINE WATER TEMPERATURE IS NORMAL, BUT DANGER ITEM LAMP FLASHES.................................................................................................................................................692 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....693 M-25. WHEN DANGER ITEM LAMP LIGHTS UP, THE BUZZER DOES NOT SOUND OR THE CENTRAL WARNING LAMP DOES NOT LIGHT UP.........................................................................................................694 M-26 NIGHT LIGHTING DOES NOT LIGHT UP..................................................................................................................................................................................696 M-27. PILOT LAMP FOR RETARDER DOES NOT LIGHT UP........................................................................................................................................................................698 M-28. PILOT LAMP FOR TURN SIGNAL LAMP (LEFT) DOES NOT LIGHT UP.........................................................................................................................................................700 M-29. PILOT LAMP FOR TURN SIGNAL LAMP (RIGHT) DOES NOT LIGHT UP........................................................................................................................................................702 M-30. PILOT LAMP FOR HIGH BEAM DOES NOT LIGHT UP.......................................................................................................................................................................704 M-31. PILOT LAMP FOR KICK-DOWN DOES NOT LIGHT UP.......................................................................................................................................................................706 M-32. PILOT LAMP FOR PARKING BRAKE DOES NOT LIGHT UP...................................................................................................................................................................708 TROUBLESHOOTING OF SHIFT INDICATOR (S-1. TO S-7.)..........................................................................................................................................................................710 SHIFT INDICATOR RELATED CIRCUIT DIAGRAM................................................................................................................................................................................711 SHIFT INDICATOR RELATED CONNECTORS.....................................................................................................................................................................................712 S-1 NO DISPLAY IS GIVEN FOR ANY GEAR SPEED.............................................................................................................................................................................713 S-2 N IS DISPLAYED FOR EVERY GEAR SPEED................................................................................................................................................................................714 S-3 E IS DISPLAYED FOR SOME GEAR SPEEDS ONLY...........................................................................................................................................................................715 S-4 SPEED SENSOR SIGNAL DISPLAY LED DOES NOT LIGHT UP..................................................................................................................................................................716 S-5 LOCK-UP OPERATION DISPLAY LED DOES NOT LIGHT UP....................................................................................................................................................................716 S-6 DISPLAY IS GIVEN BUT IT IS NOT CORRECT.............................................................................................................................................................................717 S-7 PART OF GEAR SPEED DISPLAY LED DOES NOT LIGHT UP, SO INCOMPLETE NUMBER OR LETTER IS DISPLAYED......................................................................................................................718
DESCRIPTION:
KOMATSU HD325-5 SHOP MANUAL SEBM05660510 – PDF DOWNLOAD
This shop manual has been prepared as an aid to improve the quality oi repairs by giving the serviceman an accurate understanding oi the product and by showing him the correct way to perform repairs and make judgments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop.
For ease oi understanding. the manual is divided into chapters for each main group of components; these chapters are further divided into the following sections.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component It serves not only to give an understanding of the structure. but also serves as reference material for troubleshooting
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs. as well as adjustments to be made at completion of the checks and repairs. โ Troubleshooting charts correlating “Problems” to “Causes” are also included in this section
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing. installing. disassembling or assembling each component. as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
S.S 29/12/24
