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KOMATSU HD325-7 HD405-7 DUMP TRUCK SERVICE REPAIR MANUAL (SEN00486-14) – PDF DOWNLOAD
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- KOMATSU HD325-7 HD405-7 DUMP TRUCK SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:SEN00486-14
- SERIAL NUMBERS:
HD325- 7001-7025
HD325-7101 and up
HD405- 3001-3035
HD405-7101 and up
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Description
KOMATSU HD325-7 HD405-7 DUMP TRUCK SERVICE REPAIR MANUAL(SEN00486-14)
KOMATSU HD325-7 HD405-7 DUMP TRUCK SERVICE REPAIR MANUAL (SEN00486-14) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU HD325-7 HD405-7 DUMP TRUCK SERVICE REPAIR MANUAL (SEN00486-14)
- This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
- 00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information. - 01. Specification
This section explains the specifications of the machine. - 10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. - 20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. - 30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting. - 40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. - 50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. - 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Engine volume
This section explains the method of reproducing, repairing, and replacing parts
TABLE OF CONTENTS:
KOMATSU HD325-7 HD405-7 DUMP TRUCK SERVICE REPAIR MANUAL (SEN00486-14)
COVER ............................................................................................................................................. 0 00 Index and foreword.............................................................................................................................. 0 Index.......................................................................................................................................... 3 Composition of shop manual................................................................................................................. 4 Table of contents.......................................................................................................................... 6 Foreword and general information............................................................................................................... 19 Safety notice.............................................................................................................................. 20 How to read the shop manual................................................................................................................ 25 Explanation of terms for maintenance standard.............................................................................................. 27 Handling of electric equipment and hydraulic component..................................................................................... 29 How to read electric wire code............................................................................................................. 41 Precautions when carrying out operation.................................................................................................... 44 Method of disassembling and connecting push-pull type coupler.............................................................................. 47 Standard tightening torque table........................................................................................................... 50 Conversion table........................................................................................................................... 54 01 Specification................................................................................................................................... 0 Specification and technical data............................................................................................................... 61 Specification drawing...................................................................................................................... 62 Specifications............................................................................................................................. 65 Weight table............................................................................................................................... 77 Fuel, coolant and lubricants............................................................................................................... 78 10 Structure, function and maintenance standard.................................................................................................... 0 Engine and cooling system...................................................................................................................... 81 Radiator, oil cooler, aftercooler.......................................................................................................... 82 Output shaft............................................................................................................................... 84 Power train, Part 1............................................................................................................................ 87 Power train skeleton....................................................................................................................... 88 Drive shaft................................................................................................................................ 90 Torque converter and transmission hydraulic piping......................................................................................... 91 Power train charge pump.................................................................................................................... 92 Retarder cooling pump...................................................................................................................... 93 Torque converter........................................................................................................................... 94 Torque converter valve..................................................................................................................... 100 Transmission............................................................................................................................... 101 Transmission control valve................................................................................................................. 117 ECMV....................................................................................................................................... 118 Power train, Part 2............................................................................................................................ 127 Axle....................................................................................................................................... 128 Differential............................................................................................................................... 130 Final drive................................................................................................................................ 132 Wheel...................................................................................................................................... 134 Steering system................................................................................................................................ 137 Steering column............................................................................................................................ 138 Steering linkage........................................................................................................................... 139 Brake system................................................................................................................................... 143 Brake piping............................................................................................................................... 144 Brake valve................................................................................................................................ 146 Secondary brake valve...................................................................................................................... 149 Relay valve................................................................................................................................ 150 Front brake cut valve...................................................................................................................... 151 Accumulator charge valve................................................................................................................... 152 Accumulator................................................................................................................................ 158 Slack adjuster............................................................................................................................. 160 Brake...................................................................................................................................... 162 Proportional reducing valve................................................................................................................ 167 Parking brake.............................................................................................................................. 168 Parking brake solenoid..................................................................................................................... 170 Hand brake (retarder)...................................................................................................................... 171 Undercarriage and frame........................................................................................................................ 173 Suspension................................................................................................................................. 174 Suspension cylinder........................................................................................................................ 176 Rear axle support.......................................................................................................................... 184 Hydraulic system............................................................................................................................... 187 Steering, hoist oil pressure piping diagram................................................................................................ 188 Dump body control.......................................................................................................................... 190 Hydraulic tank............................................................................................................................. 192 Steering valve............................................................................................................................. 194 Cross-over relief valve.................................................................................................................... 198 Steering control valve..................................................................................................................... 199 Hoist valve................................................................................................................................ 208 Dump control valve (EPC valve)............................................................................................................. 214 Steering cylinder.......................................................................................................................... 218 Hoist cylinder............................................................................................................................. 219 Work equipment and steering pump........................................................................................................... 220 Cab and its attachments........................................................................................................................ 223 ROPS cab................................................................................................................................... 224 Air conditioner............................................................................................................................ 225 Rear view monitor.......................................................................................................................... 231 Electrical system, Part 1...................................................................................................................... 235 Machine monitor system..................................................................................................................... 236 Electrical system, Part 2...................................................................................................................... 265 Automatic shift control system............................................................................................................. 266 Transmission controller.................................................................................................................... 270 External power supply heater............................................................................................................... 284 Auto emergency steering system............................................................................................................. 286 Retarder control system.................................................................................................................... 290 Battery disconnector switch................................................................................................................ 302 Dump control lever......................................................................................................................... 304 Auto suspension system..................................................................................................................... 306 Electrical system, Part 3...................................................................................................................... 313 Payload meter II (card type)............................................................................................................... 314 Electrical system, Part 4...................................................................................................................... 345 Sensors, switches.......................................................................................................................... 346 KOMTRAX terminal system (If equipped)...................................................................................................... 360 20 Standard value table............................................................................................................................ 0 Standard service value table................................................................................................................... 365 Standard value table for engine............................................................................................................ 366 Standard value table for machine........................................................................................................... 368 30 Testing and adjusting........................................................................................................................... 0 Testing and adjusting, Part 1.................................................................................................................. 375 Tools for testing, adjusting, and troubleshooting.......................................................................................... 377 Testing engine speed....................................................................................................................... 383 Testing intake air pressure (boost pressure)............................................................................................... 384 Testing exhaust temperature................................................................................................................ 385 Testing exhaust gas color.................................................................................................................. 387 Adjusting valve clearance.................................................................................................................. 388 Testing compression pressure............................................................................................................... 390 Testing blow-by pressure................................................................................................................... 392 Testing engine oil pressure................................................................................................................ 393 Testing EGR valve and bypass valve drive oil pressure...................................................................................... 394 Handling of fuel system devices............................................................................................................ 395 Releasing residual pressure from fuel system............................................................................................... 395 Testing fuel pressure...................................................................................................................... 396 Testing fuel return rate and leakage....................................................................................................... 397 Bleeding air from fuel circuit............................................................................................................. 400 Testing the fuel circuit for leakage....................................................................................................... 402 Testing and adjusting alternator belt tension.............................................................................................. 403 Testing and adjusting fan belt tension..................................................................................................... 404 Testing and adjusting air conditioner compressor belt tension.............................................................................. 405 Testing and adjusting, Part 2.................................................................................................................. 407 Testing torque converter stall speed....................................................................................................... 409 Testing power train oil pressure........................................................................................................... 410 Adjusting transmission speed sensor........................................................................................................ 417 Testing brake oil pressure................................................................................................................. 418 Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas...................................... 420 Testing brake performance.................................................................................................................. 425 Adjusting parking brake.................................................................................................................... 427 Bleeding air from brake circuit............................................................................................................ 428 Testing wear of rear brake disc............................................................................................................ 429 Testing wear of front brake pad............................................................................................................ 430 Method for emergency release of parking brake.............................................................................................. 431 Testing and adjusting front suspension cylinder............................................................................................ 432 Testing and adjusting inverted type rear suspension cylinder............................................................................... 437 Testing and adjusting front suspension cylinder (mode selector hydraulic cylnder).......................................................... 441 Testing and adjusting hydraulic pressure in steering, hoist circuit........................................................................ 442 Testing and adjusting dump EPC circuit oil pressure........................................................................................ 445 Air bleeding from steering cylinder........................................................................................................ 446 Procedure for raising body in emergency.................................................................................................... 447 Adjusting body positioner sensor........................................................................................................... 448 Handling of high voltage circuit of engine controller...................................................................................... 449 Adjusting transmission controller.......................................................................................................... 449 Method for emergency escape at electrical system failure................................................................................... 450 Testing and adjusting, Part 3.................................................................................................................. 455 Setting and adjusting of devices........................................................................................................... 456 Special functions of machine monitor (EMMS)................................................................................................ 468 Testing and adjusting, Part 4.................................................................................................................. 527 How to start operation of KOMTRAX terminal................................................................................................. 528 Lamp display of KOMTRAX terminal........................................................................................................... 533 Pm Clinic check sheet...................................................................................................................... 536 Setting of card-type payload meter (PLM-II ) after installation or replacement............................................................. 538 40 Troubleshooting................................................................................................................................. 0 General information on troubleshooting......................................................................................................... 545 Points to remember when troubleshooting.................................................................................................... 546 Sequence of events in troubleshooting...................................................................................................... 547 Checks before troubleshooting.............................................................................................................. 548 Classification and procedures of troubleshooting........................................................................................... 549 Connection table for connector pin numbers................................................................................................. 550 T- branch box and T- branch adapter table.................................................................................................. 586 Troubleshooting by failure code, General....................................................................................................... 591 Failure codes table........................................................................................................................ 592 Before troubleshooting by failure codes.................................................................................................... 601 Contents of troubleshooting table.......................................................................................................... 606 Troubleshooting by failure code, Part 1........................................................................................................ 609 Failure code [1500L0] (Dual engagement).................................................................................................... 611 Failure code [15B0NX] (Transmission oil filter: Clogging).................................................................................. 612 Failure code [15F0KM] (R → F shifting abuse 1: Mistake in operation)....................................................................... 614 Failure code [15F0MB] (R → F shifting abuse 2: Mistake in operation)....................................................................... 614 Failure code [15F7KM] (Forward clutch disk abuse: Mistake in operation or setting)......................................................... 615 Failure code [15G0MW] (R clutch: Slipping)................................................................................................. 616 Failure code [15G7KM] (Reverse clutch disk abuse: Mistake in operation or setting)......................................................... 618 Failure code [15H0MW] (Hi clutch: Slipping)................................................................................................ 620 Failure code [15J0MW] ( Lo clutch: Slipping)............................................................................................... 622 Failure code [15K0MW] (1st clutch: Slipping)............................................................................................... 624 Failure code [15L0MW] (2nd clutch: Slipping)............................................................................................... 626 Failure code [15M0MW] (3rd clutch: Slipping)............................................................................................... 628 Failure code [15N0MW] (4th clutch: Slipping)............................................................................................... 630 Failure code [15SBL1] (R clutch solenoid: Fill signal is ON when command current is OFF)................................................... 632 Failure code [15SBMA] (R clutch solenoid: Malfunction)..................................................................................... 636 Failure code [15SCL1] (Hi clutch solenoid: Fill signal is ON when command current is OFF).................................................. 638 Failure code [15SCMA] (Hi clutch solenoid: Malfunction).................................................................................... 642 Failure code [15SDL1] (Lo clutch solenoid: Fill signal is ON when command current is OFF).................................................. 644 Failure code [15SDMA] (Lo clutch solenoid: Malfunction).................................................................................... 648 Failure code [15SEL1] (1st clutch solenoid: Fill signal is ON when command current is OFF)................................................. 650 Failure code [15SEMA] (1st clutch solenoid: Malfunction)................................................................................... 654 Failure code [15SFL1] (2nd clutch solenoid: Fill signal is ON when command current is OFF)................................................. 656 Failure code [15SFMA] (2nd clutch solenoid: Malfunction)................................................................................... 660 Failure code [15SGL1] (3rd clutch solenoid: Fill signal is ON when command current is OFF)................................................. 662 Failure code [15SGMA] (3rd clutch solenoid: Malfunction)................................................................................... 666 Failure code [15SHL1] (4th clutch solenoid: Command current is OFF and fill signal is ON).................................................. 668 Failure code [15SHMA] (4th clutch solenoid: Malfunction)................................................................................... 672 Failure code [15SJMA] (Lockup clutch solenoid: Malfunction)................................................................................ 674 Failure code [989A00] (Engine over run prevention command signal: Operating)............................................................... 676 Failure code [989D00] (Rear section tipping over alarm: Alarm is activated)................................................................ 676 Failure code [2F00KM] (Parking brake: Mistake in operation or setting)..................................................................... 678 Failure code [2G42ZG] (Front accumulator: Lowering of oil pressure)........................................................................ 680 Failure code [2G43ZG] (Rear accumulator: Lowering of oil pressure)......................................................................... 680 Failure code [A570NX] (Engine oil filter: Clogging)........................................................................................ 681 Failure code [AA10NX] (Air cleaner element: Clogging)...................................................................................... 682 Failure code [AB00MA] (Alternator: Malfunction)............................................................................................ 684 Failure code [B@BAZG] (Abnormal lowering of engine oil pressure: Lowering of oil pressure)................................................. 686 Failure code [B@BAZK] (Engine oil: Level too low).......................................................................................... 688 Failure code [B@BCZK] (Lowering of radiator coolant: Lowering of level).................................................................... 690 Failure code [B@BCNS] (Engine: Overheat)................................................................................................... 692 Failure code [B@C7NS] (Rear brake oil: Overheat)........................................................................................... 693 Failure code [B@CENS] (Torque converter oil: Overheat)..................................................................................... 693 Failure code [B@GAZK] (Battery electrolyte level: Lowering of level)....................................................................... 694 Failure code [B@JANS] (Steering oil: Overheat)............................................................................................. 695 Troubleshooting by failure code, Part 2........................................................................................................ 697 Failure code [CA111] (Abnormality in engine controller).................................................................................... 699 Failure code [CA115] (Abnormal engine Ne and Bkup sensors)................................................................................. 700 Failure code [CA122] (Charge pressure sensor too high)..................................................................................... 702 Failure code [CA123] (Charge pressure sensor too low)...................................................................................... 704 Failure code [CA131] (Throttle sensor too high)............................................................................................ 706 Failure code [CA132] (Throttle sensor too low)............................................................................................. 708 Failure code [CA135] (Oil pressure sensor too high)........................................................................................ 710 Failure code [CA141] (Oil pressure sensor too low)......................................................................................... 712 Failure code [CA144] (Coolant temperature sensor too high)................................................................................. 714 Failure code [CA145] (Coolant temperature sensor too low).................................................................................. 716 Failure code [CA153] (Charge temperature sensor too high).................................................................................. 718 Failure code [CA154] (Charge temperature sensor too low)................................................................................... 720 Failure code [CA187] (Sensor power source 2 too low)....................................................................................... 720 Failure code [CA221] (Atmospheric pressure sensor too high)................................................................................ 722 Failure code [CA222] (Atmospheric pressure sensor too low)................................................................................. 724 Failure code [CA227] (Sensor power source 2 too high)...................................................................................... 726 Failure code [CA234] (Engine over speed)................................................................................................... 728 Failure code [CA238] (Abnormal power source for engine Ne speed sensor).................................................................... 730 Failure code [CA263] (Fuel temperature sensor too high).................................................................................... 732 Failure code [CA265] (Fuel temperature sensor too low)..................................................................................... 734 Failure code [CA271] (PCV1 short circuit).................................................................................................. 735 Failure code [CA272] (PCV1 disconnection).................................................................................................. 736 Failure code [CA273] (PCV2 short circuit).................................................................................................. 737 Failure code [CA274] (PCV2 disconnection).................................................................................................. 738 Failure code [CA322] (Injector No. 1 system disconnection or short circuit)................................................................ 740 Failure code [CA323] (Injector No. 5 system disconnection or short circuit)................................................................ 742 Failure code [CA324] (Injector No. 3 system disconnection or short circuit)................................................................ 744 Failure code [CA325] (Injector No. 6 system disconnection or short circuit)................................................................ 746 Failure code [CA331] (Injector No. 2 system disconnection or short circuit)................................................................ 748 Failure code [CA332] (Injector No. 4 system disconnection or short circuit)................................................................ 750 Failure code [CA342] (Abnormal engine controller data consistency)......................................................................... 752 Failure code [CA351] (Abnormal injector drive circuit)..................................................................................... 753 Failure code [CA352] (Sensor power source 1 too low)....................................................................................... 754 Failure code [CA386] (Sensor power source 1 too high)...................................................................................... 756 Failure code [CA431] (Abnormal idle validation switch)..................................................................................... 758 Failure code [CA432] (Abnormal process with idle validation switch)........................................................................ 761 Failure code [CA441] (Power source voltage too low)........................................................................................ 762 Failure code [CA442] (Power source voltage too high)....................................................................................... 762 Failure code [CA449] (Common rail pressure too high 2)..................................................................................... 763 Failure code [CA451] (Common rail pressure sensor too high)................................................................................ 764 Failure code [CA452] (Common rail pressure sensor too low)................................................................................. 766 Failure code [CA553] (Common rail pressure too high 1)..................................................................................... 766 Failure code [CA554] (In-range error of common rail pressure sensor)....................................................................... 767 Failure code [CA559] (Loss of pressure feed from supply pump abnormal 1)................................................................... 768 Failure code [CA689] (Abnormal engine Ne speed sensor)..................................................................................... 772 Failure code [CA731] (Abnormal engine Bkup speed sensor phase)............................................................................. 774 Failure code [CA757] (Loss of all engine controller data).................................................................................. 774 Failure code [CA778] (Abnormal engine Bkup speed sensor)................................................................................... 776 Failure code [CA1228] (Abnormal EGR valve servo 1)......................................................................................... 778 Failure code [CA1625] (Abnormal EGR valve servo 2)......................................................................................... 779 Failure code [CA1626] (Short circuit of bypass valve solenoid drive)....................................................................... 780 Failure code [CA1627] (Disconnection in bypass valve solenoid drive)....................................................................... 782 Failure code [CA1628] (Abnormal bypass valve servo 1)...................................................................................... 783 Failure code [CA1629] (Abnormal bypass valve servo 2)...................................................................................... 784 Troubleshooting by failure code, Part 3........................................................................................................ 787 Failure code [CA1631] (Bypass valve lift sensor too high).................................................................................. 790 Failure code [CA1632] (Bypass valve lift sensor too low)................................................................................... 792 Failure code [CA1633] (Abnormal KOMNET).................................................................................................... 794 Failure code [CA1642] (EGR inlet pressure sensor too low).................................................................................. 796 Failure code [CA1653] (EGR inlet pressure sensor too high)................................................................................. 798 Failure code [CA2185] (Throttle sensor power source too high).............................................................................. 800 Failure code [CA2186] (Throttle sensor power source too low)............................................................................... 802 Failure code [CA2249] (Loss of pressure feed from supply pump abnormal 2).................................................................. 802 Failure code [CA2271] (EGR valve lift sensor too high)..................................................................................... 804 Failure code [CA2272] (EGR valve lift sensor too low)...................................................................................... 806 Failure code [CA2351] (EGR valve solenoid drive short circuit)............................................................................. 808 Failure code [CA2352] (EGR valve solenoid drive disconnection)............................................................................. 810 Failure code [CA2555] (Intake air heater relay disconnection).............................................................................. 810 Failure code [CA2556] (Intake air heater relay short circuit).............................................................................. 812 Failure code [D19HKB] (Stop lamp relay output system: Short circuit)....................................................................... 814 Failure code [D5ZKKZ] (Front brake cut-off solenoid valve: Disconnection or short circuit)................................................. 816 Failure code [DAF9KM] Wrong connection of connector........................................................................................ 818 Failure code [DAFRKR] (Abnormal CAN communication (machine monitor): Abnormal communication)............................................... 820 Failure code [DAQ0KK] (Transmission controller direct power supply: Lowering of source voltage)............................................ 822 Failure code [DAQ0KT] (Transmission controller nonvolatile memory: Abnormality in controller).............................................. 824 Failure code [DAQ2KK] (Transmission controller solenoid power source: Power source voltage too low)........................................ 825 Failure code [DAQ9KQ] (Transmission controller: Disagreement of model selection)........................................................... 826 Failure code [DAQRKR] (Communication lost: Defect communication)........................................................................... 828 Failure code [DAQRMA] (Transmission controller option setting: Malfunction)................................................................ 830 Failure code [DB10KT] (Retarder controller nonvolatile memory: Abnormality in controller).................................................. 830 Failure code [DB12KK] (Retarder controller solenoid power source: Power source voltage too low)............................................ 832 Failure code [DB13KK] (Retarder controller direct power source: Power source voltage too low).............................................. 834 Failure code [DB19KQ] Disagreement of model selection (Retarder controller)................................................................ 836 Failure code [DB1RKR] (CAN communication (retarder controller): Communication disabled).................................................... 838 Failure code [DB1RMA] Disagreement of option setting (Retarder controller)................................................................. 840 Failure code [DB1SKQ] (Model selection: Wrong information)................................................................................. 841 Failure code [DB2RKR] (CAN communication (engine controller): Communication disabled)...................................................... 842 Failure code [DBC9KQ] Disagreement of model selection (ABS controller)..................................................................... 844 Failure code [DBCRMA] Disagreement of option setting (ABS controller)...................................................................... 845 Failure code [DDD7KX] (Trouble in travel speed setting switch system: Out of input signal range) (If equipped)............................. 846 Failure code [DDD8KA] (ARSC system switch system: Disconnection)........................................................................... 848 Failure code [DDD8KB] (ARSC system switch system: Short circuit)........................................................................... 850 Failure code [DDDAKA] (ASR system switch: Disconnection) (If equipped)..................................................................... 852 Failure code [DDDAKB] (ASR system switch: Short circuit)................................................................................... 854 Failure code [DDTHKA] (Hi clutch fill switch: Disconnection)............................................................................... 856 Failure code [DDTJKA] (Lo clutch fill switch: Disconnection)............................................................................... 858 Failure code [DDTKKA] (1st clutch fill switch: Disconnection).............................................................................. 860 Failure code [DDTLKA] (2nd clutch fill switch: Disconnection).............................................................................. 862 Failure code [DDTMKA] (3rd clutch fill switch: Disconnection).............................................................................. 864 Failure code [DDTNKA] (R clutch fill switch: Disconnection)................................................................................ 866 Failure code [DDTPKA] (4th clutch fill switch : Disconnection)............................................................................. 868 Failure code [DF10KA] (Gear shift lever: Disconnection).................................................................................... 870 Failure code [DF10KB] (Gear shift lever: Short circuit).................................................................................... 873 Failure code [DGF1KX] (Transmission oil temperature sensor: Out of input signal range)..................................................... 876 Failure code [DGR2KZ] (Retarder oil temperature sensor : Disconnection or short circuit)................................................... 878 Failure code [DGR6KX] (Steering oil temperature sensor: Input signal out of range)......................................................... 880 Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)................................................. 882 Troubleshooting by failure code, Part 4........................................................................................................ 885 Failure code [DHP6KA] (Suspension pressure sensor system (Rear right): Disconnection)...................................................... 888 Failure code [DHP6KX] (Failure in suspension pressure sensor system trouble (Rear right): Out of input signal range)....................... 890 Failure code [DHP7KA] (Suspension pressure sensor system (Rear left): Disconnection)....................................................... 892 Failure code [DHP7KX] (Failure in suspension pressure sensor system trouble (Rear left): Out of input signal range)........................ 894 Failure code [DHT5KX] (Torque converter oil pressure sensor: Out of input signal range).................................................... 896 Failure code [DHT5L6] (Torque converter oil pressure sensor: Disagreement of run and stop condition with signal)........................... 898 Failure code [DHU2KX] (Front accumulator oil pressure sensor: Out of input signal range)................................................... 900 Failure code [DHU3KX] (Rear accumulator oil pressure sensor: Out of input signal range).................................................... 902 Failure code [DJF1KA] (Fuel level sensor: Disconnection)................................................................................... 904 Failure code [DK30KX] Trouble in steering angle potentiometer.............................................................................. 905 Failure code [DK51L5] (Retarder lever potentiometer: Potentiometer signal is inconsistent with switch signal).............................. 907 Failure code [DK52KX] (Failure in hoist lever potentiometer 1: Out of input signal range).................................................. 910 Failure code [DK53L8] (Failure in hoist lever potentiometer 2: Disagreement of analog signal).............................................. 912 Failure code [DK54KX] (Body positioner sensor: Out of input signal range).................................................................. 914 Failure code [DKD0L6] (Failure in steering speed sensor: Disagreement of run and stop condition with signal) (If equipped)................. 916 Failure code [DKH0KX] (Pitch angle sensor: Out of input signal range) (If equipped)........................................................ 918 Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection)............................................................... 920 Failure code [DLF1LC] (Transmission input shaft speed sensor: Disagreement of revolution speed signal)..................................... 922 Failure code [DLF2KA] (Transmission intermediate shaft speed sensor: Disconnection)........................................................ 924 Failure code [DLF2LC] (Transmission intermediate shaft speed sensor: Disagreement of revolution speed signal).............................. 926 Failure code [DLF8KA] Disconnection in wheel speed sensor (Right rear)..................................................................... 928 Failure code [DLF8LC] Trouble in wheel speed sensor system (Right rear).................................................................... 929 Failure code [DLF9KA] Disconnection in wheel speed sensor (Left rear)...................................................................... 930 Failure code [DLF9LC] Trouble in wheel speed sensor system (Left rear)..................................................................... 931 Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection).............................................................. 932 Failure code [DLT3LC] (Transmission output shaft speed sensor: Disagreement of revolution speed signal) (If equipped)...................... 934 Failure code [DLT4KA] (Transmission output shaft speed sensor: Disconnection) (If equipped)................................................ 936 Failure code [DLT4LC] (Transmission output shaft speed sensor: Disagreement of revolution speed signal) (If equipped)...................... 938 Failure code [DLT4MA] Disconnection in transmission output shaft speed sensor: Defective function (If equipped)............................ 940 Failure code [DV00KB] Short circuit in buzzer output....................................................................................... 942 Failure code [DW35KZ] (Failure in output system of auto suspension solenoid 1: Disconnection or short circuit) (If equipped)............... 944 Failure code [DW36KZ] (Failure in output system of auto suspension solenoid 2: Disconnection or short circuit) (If equipped)............... 946 Failure code [DW72KZ] (Failure in kick-out solenoid output system: Disconnection or short circuit)......................................... 948 Failure code [DW73KZ] (Failure in hoist select valve output system: Disconnection or short circuit)........................................ 950 Failure code [DW78KZ] (Failure in rear brake BCV command output system: Disconnection or short circuit).................................... 952 Failure code [DWNBK4] Trouble in ASR shut-off valve (Valve keeps operating)................................................................ 954 Failure code [DWNBKA] Disconnection in ASR shut-off valve output circuit................................................................... 956 Failure code [DWNBKB] Ground fault in ASR shut-off valve output circuit.................................................................... 958 Failure code [DWNBKY] Short circuit in ASR shut-off valve output circuit................................................................... 960 Failure code [DWNBMA] Trouble in ASR shut-off valve (Valve does not operate)............................................................... 961 Failure code [DX11K4] (Rear brake proportional pressure reducing solenoid valve: Out of control)........................................... 962 Failure code [DX11KA] (Rear brake proportional pressure reducing solenoid valve output circuit: Disconnection)............................. 964 Failure code [DX11KB] (Rear brake proportional pressure reducing solenoid valve: Short circuit)............................................ 965 Failure code [DX11KY] (Rear brake proportional pressure reducing solenoid valve: Short circuit to power source line)....................... 966 Failure code [DX11MA] (Rear brake proportional pressure reducing solenoid valve: Malfunction).............................................. 968 Failure code [DX13KA] (Output circuit of hoist EPC valve: Disconnection)................................................................... 970 Failure code [DX13KB] (Output circuit of hoist EPC valve: Short circuit)................................................................... 972 Failure code [DX13KY] (Output circuit of hoist EPC valve: Short circuit with power source line)............................................ 974 Troubleshooting by failure code, Part 5........................................................................................................ 977 Failure code [DX17K4] Trouble in ASR proportional pressure reducing solenoid valve (right) (Valve keeps operating)......................... 980 Failure code [DX17KA] Disconnection in ASR proportional pressure reducing solenoid valve (right) output circuit............................ 982 Failure code [DX17KB] Ground fault in ASR proportional pressure reducing solenoid valve (right) output circuit............................. 984 Failure code [DX17KY] Short circuit in ASR proportional pressure reducing solenoid valve (right) output circuit............................ 986 Failure code [DX17MA] Trouble in ASR proportional pressure reducing solenoid valve (right) (Valve does not operate)........................ 986 Failure code [DX18K4] Trouble in ASR proportional pressure reducing solenoid valve (left) (Valve keeps operating).......................... 988 Failure code [DX18KA] Disconnection in ASR proportional pressure reducing solenoid valve (left) output circuit............................. 990 Failure code [DX18KB] Ground fault in ASR proportional pressure reducing solenoid valve (left) output circuit.............................. 992 Failure code [DX18KY] Short circuit in ASR proportional pressure reducing solenoid valve (left) output circuit............................. 994 Failure code [DX18MA] Trouble in ASR proportional pressure reducing solenoid valve (left) (Valve does not operate)......................... 994 Failure code [DXH1KA] (Lockup clutch solenoid output circuit: Disconnection)............................................................... 996 Failure code [DXH1KB] (Lock-up clutch solenoid output circuit: Short circuit).............................................................. 998 Failure code [DXH1KY] (Lockup clutch solenoid output circuit: Short circuit to power source line)..........................................1000 Failure code [DXH2KA] (Hi clutch solenoid output circuit: Disconnection)...................................................................1002 Failure code [DXH2KB] (Hi clutch solenoid output circuit: Short circuit)...................................................................1004 Failure code [DXH2KY] (Hi clutch solenoid output circuit: Short circuit to power source line)..............................................1006 Failure code [DXH3KA] (Lo clutch solenoid output circuit: Disconnection)...................................................................1010 Failure code [DXH3KB] (Lo clutch solenoid output circuit: Short circuit)...................................................................1012 Failure code [DXH3KY] (Lo clutch solenoid output circuit: Short circuit in power source line)..............................................1014 Failure code [DXH4KA] (1st clutch solenoid output circuit: Disconnection)..................................................................1018 Failure code [DXH4KB] (1st clutch solenoid output circuit: Short circuit)..................................................................1020 Failure code [DXH4KY] (1st clutch solenoid output circuit: Short circuit to power source line).............................................1022 Failure code [DXH5KA] (2nd clutch solenoid output circuit: Disconnection)..................................................................1026 Failure code [DXH5KB] (2nd clutch solenoid output circuit: Short circuit)..................................................................1028 Failure code [DXH5KY] (2nd clutch solenoid output circuit: Short circuit in power source line).............................................1030 Failure code [DXH6KA] (3rd clutch solenoid output circuit: Disconnection)..................................................................1034 Failure code [DXH6KB] (3rd clutch solenoid output circuit: Short circuit)..................................................................1036 Failure code [DXH6KY] (3rd clutch solenoid output circuit: Short circuit to power source line).............................................1038 Failure code [DXH7KA] (R clutch solenoid output circuit: Disconnection)....................................................................1042 Failure code [DXH7KB] (R clutch solenoid output circuit: Short circuit)....................................................................1044 Failure code [DXH7KY] (R clutch solenoid output circuit: Short circuit to power source line)...............................................1046 Failure code [DXHHKA] (4th clutch solenoid output circuit: Disconnection)..................................................................1050 Failure code [DXHHKB] (4th clutch solenoid output circuit: Short circuit)..................................................................1052 Failure code [DXHHKY] (4th clutch solenoid output circuit: Short circuit to power source line).............................................1054 Troubleshooting of electrical system (E-mode)..................................................................................................1059 Before troubleshooting of electric system..................................................................................................1061 Contents of troubleshooting table..........................................................................................................1067 E-1 Engine does not start..................................................................................................................1069 E-2 Automatic preheating does not operate..................................................................................................1072 E-3 Machine monitor does not display all, when starting switch is turned ON................................................................1076 E-4 Machine monitor does not operate when starting switch is OFF...........................................................................1078 E-5 Alarm buzzer does not stop sounding....................................................................................................1080 E-6 Gauges of machine monitor, caution lamps or character display section do not display properly..........................................1081 E-7 A selection of the display in character display section cannot be changed..............................................................1082 E-8 Power mode selecting function does not operate properly................................................................................1085 E-9 AISS function does not operate properly................................................................................................1086 E-10 Seat belt caution lamp does not display properly......................................................................................1087 E-11 Turn signal lamp or turning lamp (hazard lamp) do not work properly...................................................................1088 E-12 Night illumination (lighting) does not work properly..................................................................................1091 E-13 Emergency steering does not operate...................................................................................................1100 Troubleshooting of hydraulic and mechanical system (H-mode)....................................................................................1105 Contents of troubleshooting table..........................................................................................................1107 H-1 Machine does not start.................................................................................................................1108 H-2 Machine does not travel smoothly (hunting).............................................................................................1110 H-3 Lockup cannot be cancelled.............................................................................................................1110 H-4 Excessive shock when starting or shifting..............................................................................................1111 H-5 Transmission does not shift up.........................................................................................................1112 H-6 Machine lacks power or speed when traveling............................................................................................1113 H-7 Time lag is excessive when starting or shifting gear...................................................................................1115 H-8 Torque converter oil temperature is high...............................................................................................1116 H-9 Torque converter oil pressure is low...................................................................................................1117 H-10 Front brake is ineffective............................................................................................................1118 H-11 Rear brake is ineffective.............................................................................................................1119 H-12 Steering wheel is heavy...............................................................................................................1120 H-13 Steering wheel does not work..........................................................................................................1121 H-14 Steering wheel vibrates...............................................................................................................1122 H-15 Dump body lifting speed is slow.......................................................................................................1123 H-16 Dump body does not work...............................................................................................................1124 H-17 Excessive hydraulic drift of dump body................................................................................................1125 Troubleshooting of mechanical system (S-mode)..................................................................................................1127 Method of using troubleshooting charts.....................................................................................................1130 S-1 Starting performance is poor...........................................................................................................1134 S-2 Engine does not start..................................................................................................................1136 S-3 Engine does not pick up smoothly.......................................................................................................1140 S-4 Engine stops during operations.........................................................................................................1141 S-5 Engine does not rotate smoothly........................................................................................................1142 S-6 Engine lacks output (or lacks power)...................................................................................................1143 S-7 Exhaust gas color is black (incomplete combustion).....................................................................................1144 S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................................................1146 S-9 Oil becomes contaminated quickly.......................................................................................................1147 S-10 Fuel consumption is excessive.........................................................................................................1148 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).................................................................1149 S-12 Oil pressure drops....................................................................................................................1150 S-13 Oil level rises (Entry of coolant/fuel)...............................................................................................1152 S-14 Coolant temperature becomes too high (overheating)....................................................................................1154 S-15 Abnormal noise is made................................................................................................................1155 S-16 Vibration is excessive................................................................................................................1156 50 Disassembly and assembly........................................................................................................................ 0 General information on disassembly and assembly................................................................................................1159 How to read this manual....................................................................................................................1160 Coating materials list.....................................................................................................................1162 Special tool list..........................................................................................................................1165 Sketches of special tools..................................................................................................................1168 Engine and cooling system......................................................................................................................1173 Removal and installation of engine assembly................................................................................................1174 Removal and installation of radiator assembly..............................................................................................1180 Removal and installation of output shaft assembly..........................................................................................1188 Disassembly and assembly of output shaft assembly..........................................................................................1190 Removal and installation of fuel supply pump assembly......................................................................................1193 Removal and installation of cylinder head assembly.........................................................................................1197 Removal and installation of fuel injector assembly.........................................................................................1208 Removal and installation of engine front seal..............................................................................................1213 Removal and installation of engine rear seal...............................................................................................1217 Power train, Part 1............................................................................................................................1223 Removal and installation of torque converter and transmission assembly.....................................................................1224 Disassembly and assembly of torque converter and control valve assembly....................................................................1231 Disassembly and assembly of torque converter assembly......................................................................................1232 Disassembly and assembly of PTO assembly...................................................................................................1240 Disassembly and assembly of transmission assembly..........................................................................................1243 Removal and installation of transmission control valve assembly (ECMV assembly)............................................................1268 Disassembly and assembly of transmission control valve assembly (ECMV assembly)............................................................1269 Power train, Part 2............................................................................................................................1275 Removal and installation of differential assembly..........................................................................................1276 Disassembly and assembly of differential assembly..........................................................................................1277 Removal and installation of rear final drive carrier assembly..............................................................................1290 Disassembly and assembly of rear final drive carrier assembly..............................................................................1292 Disassembly and assembly of rear final drive assembly......................................................................................1294 Disassembly and assembly of front wheel hub assembly.......................................................................................1298 Steering system................................................................................................................................1303 Disassembly and assembly of steering cylinder assembly.....................................................................................1304 Removal and installation of emergency steering motor pump assembly.........................................................................1307 Brake system...................................................................................................................................1309 Removal and installation of front brake caliper pad........................................................................................1310 Removal and installation of front brake caliper assembly...................................................................................1311 Disassembly and assembly of front brake caliper assembly...................................................................................1312 Removal and installation of rear brake assembly............................................................................................1314 Disassembly and assembly of rear brake assembly............................................................................................1315 Removal and installation of parking brake pad..............................................................................................1318 Removal and installation of parking brake caliper assembly.................................................................................1320 Disassembly and assembly of front brake caliper pad assembly...............................................................................1321 Removal and installation of parking brake spring cylinder assembly.........................................................................1322 Removal and installation of slack adjuster assembly........................................................................................1323 Disassembly and assembly of slack adjuster assembly........................................................................................1324 Undercarriage and frame........................................................................................................................1327 Removal and installation of front wheel assembly...........................................................................................1328 Removal and installation of rear wheel assembly............................................................................................1329 Removal and installation of front suspension cylinder assembly.............................................................................1331 Disassembly and assembly of front suspension cylinder assembly.............................................................................1332 Disassembly and assembly of variable damping selector valve assembly.......................................................................1334 Removal and installation of rear suspension cylinder assembly..............................................................................1336 Disassembly and assembly of rear suspension cylinder assembly..............................................................................1337 Hydraulic system...............................................................................................................................1341 Disassembly and assembly of hoist cylinder assembly........................................................................................1342 Body...........................................................................................................................................1349 Removal and installation of body assembly..................................................................................................1350 Cab and its attachments........................................................................................................................1355 Disassembly and assembly of operator’s seat assembly.......................................................................................1356 Removal and installation of air conditioner unit assembly..................................................................................1365 Electrical system..............................................................................................................................1369 Removal and installation of engine controller assembly.....................................................................................1370 Removal and installation of transmission controller assembly...............................................................................1371 Removal and installation of retarder controller assembly...................................................................................1372 90 Diagrams and drawings........................................................................................................................... 0 Hydraulic diagrams and drawings................................................................................................................1375 Power train hydraulic circuit diagram......................................................................................................1376 Steering and hoist hydraulic circuit diagram HD325-7 Serial No. 7001 - 7025, 7101 - 7523 HD405-7 Serial No. 3001 - 3035, 7101 - 7523.......1377 Steering and hoist hydraulic circuit diagram HD325-7 Serial No. 7524 and up HD405-7 Serial No. 7525 and up.................................1378 Brake hydraulic circuit diagram............................................................................................................1379 Electrical diagrams and drawings...............................................................................................................1382 Electrical circuit diagram for inside cab (1/5)............................................................................................1384 Electrical circuit diagram for inside cab (2/5) HD325-7 Serial No. 7001 - 7025, 7101 - 7161 HD405-7 Serial No. 3001 - 3035, 7101 - 7157....1385 Electrical circuit diagram for inside cab (2/5) HD325-7 Serial No. 7162 and up HD405-7 Serial No. 7158 and up..............................1386 Electrical circuit diagram for inside cab (3/5) HD325-7 Serial No. 7001 - 7025, 7101 - 7161 HD405-7 Serial No. 3001 - 3035, 7101 - 7157....1387 Electrical circuit diagram for inside cab (3/5) HD325-7 Serial No. 7162 and up HD405-7 Serial No. 7158 and up..............................1388 Electrical circuit diagram for inside cab (4/5)............................................................................................1389 Electrical circuit diagram for inside cab (5/5)............................................................................................1390 Electrical circuit diagram for outside cab (1/3)...........................................................................................1391 Electrical circuit diagram for outside cab (2/3)...........................................................................................1392 Electrical circuit diagram for outside cab (3/3)...........................................................................................1393 Air conditioner electrical circuit diagram.................................................................................................1394 Electrical circuit diagram of external power supply heater.................................................................................1395 Connectors table and arrangement drawing...................................................................................................1397
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