Repair Manual for Komatsu HD325-7 HD405-7 Dump Truck PDF Download

Description

Komatsu HD325-7 HD405-7 Dump Truck Shop Manual SEN00486-19 – PDF DOWNLOAD

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DESCRIPTION:

Komatsu HD325-7 HD405-7 Dump Truck Shop Manual SEN00486-19 – PDF DOWNLOAD

SERIAL NUMBERS
HD325- 7001-7025 and up
HD325- 7101 and up
HD405- 3001-3035 and up
HD405- 7101 and up

How to read the shop manual 
1. Composition of shop manual
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)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

TABLE OF CONTENTS:

Komatsu HD325-7 HD405-7 Dump Truck Shop Manual SEN00486-19 – PDF DOWNLOAD

Cover 1
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 1 241
Machine monitor system 242
Electrical system, Part 2 271
Automatic shift control system 272
Transmission controller 276
External power supply heater 290
Auto emergency steering system 292
Retarder control system 296
Dump control lever 310
Auto suspension system 314
Battery disconnector switch 308
Electrical system, Part 3 319
Payload meter II (card type) 320
Payload meter (PLM) controller related 350
Electrical system, Part 4 375
Sensors, switches 376
KOMTRAX terminal system (If equipped) 390
20 Standard value table 0
Standard service value table 395
Standard value table for engine 396
Standard value table for machine 398
30 Testing and adjusting 0
Testing and adjusting, Part 1 405
Tools for testing, adjusting, and troubleshooting 407
Testing engine speed 413
Testing intake air pressure (boost pressure) 414
Testing exhaust temperature 415
Testing exhaust gas color 417
Adjusting valve clearance 418
Testing compression pressure 420
Testing blow-by pressure 422
Testing engine oil pressure 423
Testing EGR valve and bypass valve drive oil pressure 424
Handling of fuel system devices 425
Releasing residual pressure from fuel system 425
Testing fuel pressure 426
Testing fuel return rate and leakage 427
Bleeding air from fuel circuit 430
Testing the fuel circuit for leakage 432
Testing and adjusting alternator belt tension 433
Testing and adjusting fan belt tension 434
Testing and adjusting air conditioner compressor belt tension 436
Testing and adjusting, Part 2 439
Testing torque converter stall speed 441
Testing power train oil pressure 442
Adjusting transmission speed sensor 449
Testing brake oil pressure 450
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas 452
Testing brake performance 460
Adjusting parking brake 462
Releasing remaining pressure in brake circuit 463
Bleeding air from brake circuit 464
Testing wear of rear brake disc 465
Testing wear of front brake pad 466
Method for emergency release of parking brake 467
Testing and adjusting front suspension cylinder 468
Testing and adjusting inverted type rear suspension cylinder 473
Testing and adjusting front suspension cylinder (mode selector hydraulic cylnder) 477
Testing and adjusting hydraulic pressure in steering, hoist circuit 478
Testing and adjusting dump EPC circuit oil pressure 481
Air bleeding from steering cylinder 482
Procedure for raising body in emergency 483
Adjusting body positioner sensor 484
Resetting method for dump body seating control 485
Adjustment of tilt lock lever of steering wheel 486
Handling of high voltage circuit of engine controller 487
Adjusting transmission controller 487
Method for emergency escape at electrical system failure 488
Testing and adjusting, Part 3 493
Setting and adjusting of devices 494
Special functions of machine monitor (EMMS) 506
Testing and adjusting, Part 4 565
How to start operation of KOMTRAX terminal 566
Lamp display of KOMTRAX terminal 571
Pm Clinic check sheet 574
Setting of card-type payload meter (PLM-II) after installation or replacement 576
Setting of payload meter 582
40 Troubleshooting 0
General information on troubleshooting 591
Points to remember when performing troubleshooting 592
How to proceed in troubleshooting 594
Checks before troubleshooting 596
Classification and procedures of troubleshooting 597
Information in troubleshooting table 601
Connection table for connector pin numbers 603
T- branch box and T- branch adapter table 639
Troubleshooting by failure code, General 643
Failure codes table 644
Before troubleshooting by failure codes 654
Contents of troubleshooting table 659
Troubleshooting by failure code, Part 1 663
Failure code [1500L0] Dual engagement 665
Failure code [15B0NX] Transmission oil filter: Clogging 666
Failure code [15F0KM] R → F shifting abuse 1: Mistake in operation 668
Failure code [15F0MB] R → F shifting abuse 2: Mistake in operation 668
Failure code [15F7KM] Forward clutch disk abuse: Mistake in operation or setting 669
Failure code [15G0MW] R clutch: Slipping 670
Failure code [15G7KM] Reverse clutch disk abuse: Mistake in operation or setting 672
Failure code [15H0MW] Hi clutch: Slipping 674
Failure code [15J0MW] Lo clutch: Slipping 676
Failure code [15K0MW] 1st clutch: Slipping 678
Failure code [15L0MW] 2nd clutch: Slipping 680
Failure code [15M0MW] 3rd clutch: Slipping 682
Failure code [15N0MW] 4th clutch: Slipping 684
Failure code [15SBL1] R clutch solenoid: Fill signal is ON when command current is OFF 686
Failure code [15SBMA] R clutch solenoid: Malfunction 688
Failure code [15SCL1] Hi clutch solenoid: Fill signal is ON when command current is OFF 689
Failure code [15SCMA] Hi clutch solenoid: Malfunction 692
Failure code [15SDL1] Lo clutch solenoid: Fill signal is ON when command current is OFF 693
Failure code [15SDMA] Lo clutch solenoid: Malfunction 696
Failure code [15SEL1] 1st clutch solenoid: Fill signal is ON when command current is OFF 697
Failure code [15SEMA] 1st clutch solenoid: Malfunction 700
Failure code [15SFL1] 2nd clutch solenoid: Fill signal is ON when command current is OFF 701
Failure code [15SFMA] 2nd clutch solenoid: Malfunction 704
Failure code [15SGL1] 3rd clutch solenoid: Fill signal is ON when command current is OFF 705
Failure code [15SGMA] 3rd clutch solenoid: Malfunction 708
Failure code [15SHL1] 4th clutch solenoid: Command current is OFF and fill signal is ON 709
Failure code [15SHMA] 4th clutch solenoid: Malfunction 712
Failure code [15SJMA] Lockup clutch solenoid: Malfunction 714
Failure code [989A00] Engine over run prevention command signal: Operating 716
Failure code [989D00] Rear section tipping over alarm: Alarm is activated 717
Failure code [2F00KM] Parking brake: Mistake in operation or setting 718
Failure code [2G42ZG] Front accumulator: Lowering of oil pressure 720
Failure code [2G43ZG] Rear accumulator: Lowering of oil pressure 720
Failure code [A570NX] Engine oil filter: Clogging 721
Failure code [AA10NX] Air cleaner element: Clogging 722
Failure code [AB00MA] Alternator: Malfunction 724
Failure code [B@BAZG] Abnormal lowering of engine oil pressure: Lowering of oil pressure 726
Failure code [B@BAZK] Engine oil: Level too low 727
Failure code [B@BCZK] Lowering of radiator coolant: Lowering of level 728
Failure code [B@BCNS] Engine: Overheat 730
Failure code [B@C7NS] Rear brake oil: Overheat 730
Failure code [B@CENS] Torque converter oil: Overheat 731
Failure code [B@GAZK] Battery electrolyte level: Lowering of level 732
Failure code [B@JANS] Steering oil: Overheat 733
Troubleshooting by failure code, Part 2 735
Failure code [CA111] Abnormality in engine controller 738
Failure code [CA115] Engine Ne or Bkup speed sensor error 740
Failure code [CA122] Charge (boost) pressure sensor high error 742
Failure code [CA123] Charge (boost) pressure sensor low error 744
Failure code [CA131] Throttle sensor high error 746
Failure code [CA132] Throttle sensor low error 749
Failure code [CA135] Engine oil pressure sensor high error 752
Failure code [CA141] Engine oil pressure sensor low error 754
Failure code [CA144] Coolant temperature sensor high error 756
Failure code [CA145] Coolant temperature sensor low error 758
Failure code [CA153] Charge (boost) temperature sensor high error 760
Failure code [CA154] Charge (boost) temperature sensor low error 762
Failure code [CA187] Sensor power supply 2 low error 764
Failure code [CA221] Atmospheric pressure sensor high error 768
Failure code [CA222] Atmospheric pressure sensor low error 770
Failure code [CA227] Sensor power supply 2 high error 772
Failure code [CA234] Engine overspeed 773
Failure code [CA238] Ne speed sensor power supply error 774
Failure code [CA263] Fuel Temperature Sensor High Error 776
Failure code [CA265] Fuel Temperature Sensor Low Error 778
Failure code [CA271] PCV1 Short circuit 780
Failure code [CA272] PCV1 Disconnection 781
Failure code [CA273] PCV2 Short circuit 782
Failure code [CA274] PCV2 Disconnection 783
Failure code [CA322] Injector #1 open/short error 784
Failure code [CA323] Injector #5 open/short error 786
Failure code [CA324] Injector #3 open/short error 788
Failure code [CA325] Injector #6 open/short error 790
Failure code [CA331] Injector #2 open/short error 792
Failure code [CA332] Injector #4 open/short error 794
Failure code [CA342] Calibration code inconsistency 796
Failure code [CA351] Injectors drive circuit error 797
Failure code [CA352] Sensor power supply 1 low error 798
Failure code [CA386] Sensor power supply 1 high error 800
Failure code [CA431] Idle validation switch error 802
Failure code [CA432] Idle validation action error 805
Failure code [CA441] Battery voltage low error 808
Failure code [CA442] Battery voltage high error 809
Failure code [CA449] Common rail pressure high error 2 810
Failure code [CA451] Common rail pressure sensor high error 812
Failure code [CA452] Common rail pressure sensor low error 814
Failure code [CA553] Common rail pressure high error 1 816
Failure code [CA554] Common rail pressure sensor in range error 817
Failure code [CA559] Supply pump pressure very low error 1 818
Failure code [CA689] Engine Ne speed sensor error 822
Failure code [CA731] Engine Bkup speed sensor phase error 824
Failure code [CA757] All continuous data lost error 825
Failure code [CA778] Engine Bkup speed sensor error 826
Failure code [CA1228] EGR valve servo error 1 828
Failure code [CA1625] EGR valve servo error 2 829
Failure code [CA1626] Bypass valve solenoid current high error 830
Failure code [CA1627] Bypass valve solenoid current low error 832
Failure code [CA1628] Bypass Valve Servo Error 1 834
Failure code [CA1629] Bypass Valve Servo Error 2 835
Troubleshooting by failure code, Part 3 837
Failure code [CA1631] Bypass valve lift sensor high error 840
Failure code [CA1632] Bypass valve lift sensor low error 842
Failure code [CA1633] KOMNET datalink timeout error 844
Failure code [CA1642] EGR inlet pressure sensor low error 846
Failure code [CA1653] EGR inlet pressure sensor high error 848
Failure code [CA2185] Throttle sensor power supply voltage high error 850
Failure code [CA2186] Throttle sensor power supply voltage low error 852
Failure code [CA2249] Supply pump pressure very low error 2 854
Failure code [CA2271] EGR valve lift sensor high error 856
Failure code [CA2272] EGR valve lift sensor low error 858
Failure code [CA2351] EGR valve solenoid operation short circuit 860
Failure code [CA2352] EGR valve solenoid operation disconnect 862
Failure code [CA2555] Intake air heater relay open circuit error 864
Failure code [CA2556] Intake air heater relay short circuit error 866
Failure code [D19HKB] Stop lamp relay output system: Short circuit 868
Failure code [D5ZKKZ] Front brake cut-off solenoid valve: Disconnection or short circuit 870
Failure code [DAF9KM] Wrong connection of connector 872
Failure code [DAFRKR] Abnormal CAN communication (machine monitor): Abnormal communication 874
Failure code [DAQ0KK] Transmission controller direct power supply: Lowering of source voltage 876
Failure code [DAQ0KT] Transmission controller nonvolatile memory: Abnormality in controller 878
Failure code [DAQ2KK] Transmission controller solenoid power source: Power source voltage too low 879
Failure code [DAQ9KQ] Transmission controller: Disagreement of model selection 880
Failure code [DAQRKR] Abnormal CAN communication (Transmission): Abnormal communication 881
Failure code [DAQRMA] Transmission controller option setting: Malfunction 886
Failure code [DB10KT] Retarder controller nonvolatile memory: Abnormality in controller 887
Failure code [DB12KK] Retarder controller solenoid power source: Power source voltage too low 888
Failure code [DB13KK] Retarder controller direct power source: Power source voltage too low 890
Failure code [DB19KQ] Disagreement of model selection (Retarder controller) 892
Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled 894
Failure code [DB1RMA] Disagreement of option setting (Retarder controller) 898
Failure code [DB1SKQ] Model selection: Wrong information 899
Failure code [DB2RKR] CAN communication (engine controller): Communication disabled 900
Failure code [DBB0KK] PLM controller: Low source voltage (input) or PLM controller_LED display: “n9” → “01” 906
Failure code [DBB0KQ] PLM controller: Disagreement of model selection signals or PLM controller_LED display: “nF” → “11” 908
Failure code [DBB3KK] PLM controller battery power supply: Low source voltage (input) or PLM controller_LED display: “n9” → “05” 910
Failure code [DBB6KP] PLM controller 24V power supply output: Low output voltage or PLM controller_LED display: “n9” → “02” 912
Failure code [DBBQKR] PLM controller CAN communication: Defective communication or PLM controller_LED display: “n8” → “02” 914
Failure code [DBBRKR] Abnormal CAN communication (PLM) : Defective communication 915
Failure code [DBC9KQ] Disagreement of model selection (ABS controller) 916
Failure code [DBCRMA] Disagreement of option setting (ABS controller) 917
Failure code [DDD7KX] Trouble in travel speed setting switch system: Out of input signal range (If equipped) 918
Failure code [DDD8KA] ARSC system switch system: Disconnection 920
Failure code [DDD8KB] ARSC system switch system: Short circuit 922
Failure code [DDDAKA] ASR system switch: Disconnection (If equipped) 924
Failure code [DDDAKB] ASR system switch: Short circuit 926
Failure code [DDTHKA] Hi clutch fill switch: Disconnection 928
Failure code [DDTJKA] Lo clutch fill switch: Disconnection 930
Failure code [DDTKKA] 1st clutch fill switch: Disconnection 931
Failure code [DDTLKA] 2nd clutch fill switch: Disconnection 932
Failure code [DDTMKA] 3rd clutch fill switch: Disconnection 933
Failure code [DDTNKA] R clutch fill switch: Disconnection 934
Failure code [DDTPKA] 4th clutch fill switch : Disconnection 935
Failure code [DF10KA] Gear shift lever: Disconnection 936
Failure code [DF10KB] Gear shift lever: Short circuit 939
Failure code [DGF1KX] Transmission oil temperature sensor: Out of input signal range 942
Failure code [DGR2KZ] Retarder oil temperature sensor : Disconnection or short circuit 944
Failure code [DGR6KX] Steering oil temperature sensor: Input signal out of range 946
Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range 948
Troubleshooting by failure code, Part 4 951
Failure code [DHP4KY] Short circuit in suspension pressure sensor system (Front right) or PLM controller_LED display: “n5” → “44” 954
Failure code [DHP4KZ] Disconnection or ground fault in suspension pressure sensor system (Front right) or PLM controller_LED display: “n5” → “43” 956
Failure code [DHP5KY] Short circuit in suspension pressure sensor system (Front left) or PLM controller_LED display: “n5” → “54” 958
Failure code [DHP5KZ] Disconnection or ground fault in suspension pressure sensor system (Front left) or PLM controller_LED display: “n5” → “53” 960
Failure code [DHP6KA] (Suspension pressure sensor system (Rear right): Disconnection) 962
Failure code [DHP6KX] (Failure in suspension pressure sensor system trouble (Rear right): Out of input signal range) 964
Failure code [DHP6KY] Suspension pressure sensor system: Short circuit (Right rear) or PLM controller_LED display: “n5” → “64” 966
Failure code [DHP6KZ] Suspension pressure sensor system: Disconnection or ground fault (Right rear) or PLM controller_LED display: “n5” → “63” 968
Failure code [DHP7KA] (Suspension pressure sensor system (Rear left): Disconnection) 970
Failure code [DHP7KX] (Failure in suspension pressure sensor system trouble (Rear left): Out of input signal range) 972
Failure code [DHP7KY] Suspension pressure sensor system: Short circuit (Left rear) or PLM controller_LED display: “n5” → “74” 974
Failure code [DHP7KZ] Suspension pressure sensor system: Disconnection or ground fault (Left rear) or PLM controller_LED display: “n5” → “73” 976
Failure code [DHT5KX] (Torque converter oil pressure sensor: Out of input signal range) 978
Failure code [DHT5L6] (Torque converter oil pressure sensor: Disagreement of run and stop condition with signal) 980
Failure code [DHU2KX] (Front accumulator oil pressure sensor: Out of input signal range) 982
Failure code [DHU3KX] (Rear accumulator oil pressure sensor: Out of input signal range) 984
Failure code [DJF1KA] (Fuel level sensor: Disconnection) 986
Failure code [DK30KX] Trouble in steering angle potentiometer 987
Failure code [DK51L5] (Retarder lever potentiometer: Potentiometer signal is inconsistent with switch signal) 989
Failure code [DK52KX] (Failure in hoist lever potentiometer 1: Out of input signal range) 992
Failure code [DK53L8] (Failure in hoist lever potentiometer 2: Disagreement of analog signal) 994
Failure code [DK54KX] (Body positioner sensor: Out of input signal range) 996
Failure code [DKD0L6] (Failure in steering speed sensor: Disagreement of run and stop condition with signal) (If equipped) 998
Failure code [DKH0KX] (Pitch angle sensor: Out of input signal range) (If equipped) 1000
Failure code [DKH1KX] Abnormality in clinometer sensor or PLM controller_LED display: “n4” → “33” 1002
Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection) 1004
Failure code [DLF1LC] (Transmission input shaft speed sensor: Disagreement of revolution speed signal) 1006
Failure code [DLF2KA] (Transmission intermediate shaft speed sensor: Disconnection) 1008
Failure code [DLF2LC] (Transmission intermediate shaft speed sensor: Disagreement of revolution speed signal) 1010
Failure code [DLF8KA] Disconnection in wheel speed sensor (Right rear) 1012
Failure code [DLF8LC] Trouble in wheel speed sensor system (Right rear) 1013
Failure code [DLF9KA] Disconnection in wheel speed sensor (Left rear) 1014
Failure code [DLF9LC] Trouble in wheel speed sensor system (Left rear) 1015
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection) 1016
Failure code [DLT3LC] (Transmission output shaft speed sensor: Disagreement of revolution speed signal) (If equipped) 1018
Failure code [DLT4KA] (Transmission output shaft speed sensor: Disconnection) (If equipped) 1020
Failure code [DLT4LC] (Transmission output shaft speed sensor: Disagreement of revolution speed signal) (If equipped) 1022
Failure code [DLT4MA] Disconnection in transmission output shaft speed sensor: Defective function (If equipped) 1024
Failure code [DV00KB] Short circuit in buzzer output 1026
Failure code [DW35KZ] (Failure in output system of auto suspension solenoid 1: Disconnection or short circuit) (If equipped) 1028
Failure code [DW36KZ] (Failure in output system of auto suspension solenoid 2: Disconnection or short circuit) (If equipped) 1030
Failure code [DW72KZ] (Failure in kick-out solenoid output system: Disconnection or short circuit) 1032
Failure code [DW73KZ] (Failure in hoist select valve output system: Disconnection or short circuit) 1034
Failure code [DW78KZ] (Failure in rear brake BCV command output system: Disconnection or short circuit) 1036
Failure code [DWNBK4] Trouble in ASR shut-off valve (Valve keeps operating) 1038
Failure code [DWNBKA] Disconnection in ASR shut-off valve output circuit 1040
Failure code [DWNBKB] Ground fault in ASR shut-off valve output circuit 1042
Failure code [DWNBKY] Short circuit in ASR shut-off valve output circuit 1044
Failure code [DWNBMA] Trouble in ASR shut-off valve (Valve does not operate) 1045
Failure code [DX11K4] (Rear brake proportional pressure reducing solenoid valve: Out of control) 1046
Failure code [DX11KA] (Rear brake proportional pressure reducing solenoid valve output circuit: Disconnection) 1048
Failure code [DX11KB] (Rear brake proportional pressure reducing solenoid valve: Short circuit) 1049
Failure code [DX11KY] (Rear brake proportional pressure reducing solenoid valve: Short circuit to power source line) 1050
Failure code [DX11MA] (Rear brake proportional pressure reducing solenoid valve: Malfunction) 1052
Failure code [DX13KA] (Output circuit of hoist EPC valve: Disconnection) 1054
Failure code [DX13KB] (Output circuit of hoist EPC valve: Short circuit) 1056
Failure code [DX13KY] (Output circuit of hoist EPC valve: Short circuit with power source line) 1058
Troubleshooting by failure code, Part 5 1061
Failure code [DX17K4] Trouble in ASR proportional pressure reducing solenoid valve (right) (Valve keeps operating) 1064
Failure code [DX17KA] Disconnection in ASR proportional pressure reducing solenoid valve (right) output circuit 1066
Failure code [DX17KB] Ground fault in ASR proportional pressure reducing solenoid valve (right) output circuit 1068
Failure code [DX17KY] Short circuit in ASR proportional pressure reducing solenoid valve (right) output circuit 1070
Failure code [DX17MA] Trouble in ASR proportional pressure reducing solenoid valve (right) (Valve does not operate) 1071
Failure code [DX18K4] Trouble in ASR proportional pressure reducing solenoid valve (left) (Valve keeps operating) 1072
Failure code [DX18KA] Disconnection in ASR proportional pressure reducing solenoid valve (left) output circuit 1074
Failure code [DX18KB] Ground fault in ASR proportional pressure reducing solenoid valve (left) output circuit 1076
Failure code [DX18KY] Short circuit in ASR proportional pressure reducing solenoid valve (left) output circuit 1078
Failure code [DX18MA] Trouble in ASR proportional pressure reducing solenoid valve (left) (Valve does not operate) 1079
Failure code [DXH1KA] Lockup clutch solenoid output circuit: Disconnection 1080
Failure code [DXH1KB] Lock-up clutch solenoid output circuit: Short circuit 1082
Failure code [DXH1KY] Lockup clutch solenoid output circuit: Short circuit to power source line 1083
Failure code [DXH2KA] Hi clutch solenoid output circuit: Disconnection 1084
Failure code [DXH2KB] Hi clutch solenoid output circuit: Short circuit 1086
Failure code [DXH2KY] Hi clutch solenoid output circuit: Short circuit to power source line 1088
Failure code [DXH3KA] Lo clutch solenoid output circuit: Disconnection 1090
Failure code [DXH3KB] Lo clutch solenoid output circuit: Short circuit 1092
Failure code [DXH3KY] Lo clutch solenoid output circuit: Short circuit in power source line 1094
Failure code [DXH4KA] 1st clutch solenoid output circuit: Disconnection 1096
Failure code [DXH4KB] 1st clutch solenoid output circuit: Short circuit 1098
Failure code [DXH4KY] 1st clutch solenoid output circuit: Short circuit to power source line 1100
Failure code [DXH5KA] 2nd clutch solenoid output circuit: Disconnection 1102
Failure code [DXH5KB] 2nd clutch solenoid output circuit: Short circuit 1104
Failure code [DXH5KY] 2nd clutch solenoid output circuit: Short circuit in power source line 1106
Failure code [DXH6KA] 3rd clutch solenoid output circuit: Disconnection 1108
Failure code [DXH6KB] 3rd clutch solenoid output circuit: Short circuit 1110
Failure code [DXH6KY] 3rd clutch solenoid output circuit: Short circuit to power source line 1112
Failure code [DXH7KA] R clutch solenoid output circuit: Disconnection 1114
Failure code [DXH7KB] R clutch solenoid output circuit: Short circuit 1116
Failure code [DXH7KY] R clutch solenoid output circuit: Short circuit to power source line 1117
Failure code [DXHHKA] 4th clutch solenoid output circuit: Disconnection 1118
Failure code [DXHHKB] 4th clutch solenoid output circuit: Short circuit 1120
Failure code [DXHHKY] 4th clutch solenoid output circuit: Short circuit to power source line 1122
Troubleshooting of electrical system (E-mode) 1125
Before troubleshooting of electric system 1127
Contents of troubleshooting table 1133
E-1 Engine does not start 1135
E-2 Automatic preheating does not operate 1138
E-3 Machine monitor does not display all, when starting switch is turned ON 1142
E-4 Machine monitor does not operate when starting switch is OFF 1144
E-5 Alarm buzzer does not stop sounding 1146
E-6 Gauges of machine monitor, caution lamps or character display section do not display properly 1147
E-7 A selection of the display in character display section cannot be changed 1148
E-8 Power mode selecting function does not operate properly 1151
E-9 AISS function does not operate properly 1152
E-10 Seat belt caution lamp does not display properly 1153
E-11 Turn signal lamp or turning lamp (hazard lamp) do not work properly 1154
E-12 Night illumination (lighting) does not work properly 1157
E-13 Emergency steering does not operate 1166
Troubleshooting of hydraulic and mechanical system (H-mode) 1171
Contents of troubleshooting table 1173
H-1 Machine does not start 1174
H-2 Machine does not travel smoothly (hunting) 1176
H-3 Lockup cannot be cancelled 1176
H-4 Excessive shock when starting or shifting 1177
H-5 Transmission does not shift up 1178
H-6 Machine lacks power or speed when traveling 1179
H-7 Time lag is excessive when starting or shifting gear 1181
H-8 Torque converter oil temperature is high 1182
H-9 Torque converter oil pressure is low 1183
H-10 Front brake is ineffective 1184
H-11 Rear brake is ineffective 1185
H-12 Steering wheel is heavy 1186
H-13 Steering wheel does not work 1187
H-14 Steering wheel vibrates 1188
H-15 Dump body lifting speed is slow 1189
H-16 Dump body does not work 1190
H-17 Excessive hydraulic drift of dump body 1191
Troubleshooting of mechanical system (S-mode) 1193
Method of using troubleshooting charts 1196
S-1 Starting performance is poor 1200
S-2 Engine does not start 1202
S-3 Engine does not pick up smoothly 1206
S-4 Engine stops during operations 1207
S-5 Engine does not rotate smoothly 1208
S-6 Engine lacks output (or lacks power) 1209
S-7 Exhaust gas color is black (incomplete combustion) 1210
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1212
S-9 Oil becomes contaminated quickly 1213
S-10 Fuel consumption is excessive 1214
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 1215
S-12 Oil pressure drops 1216
S-13 Oil level rises (Entry of coolant/fuel) 1218
S-14 Coolant temperature becomes too high (overheating) 1220
S-15 Abnormal noise is made 1221
S-16 Vibration is excessive 1222
50 Disassembly and assembly 0
General information on disassembly and assembly 1225
How to read this manual 1226
Coating materials list 1228
Special tool list 1231
Sketches of special tools 1239
Engine and cooling system 1243
Removal and installation of engine assembly 1244
Removal and installation of radiator assembly 1254
Removal and installation of output shaft assembly 1266
Disassembly and assembly of output shaft assembly 1270
Removal and installation of fuel supply pump assembly 1273
Removal and installation of cylinder head assembly 1279
Removal and installation of fuel injector assembly 1294
Removal and installation of engine front seal 1300
Removal and installation of engine rear seal 1304
Power train, Part 1 1311
Removal and installation of torque converter and transmission assembly 1312
Disassembly and assembly of torque converter and control valve assembly 1324
Disassembly and assembly of torque converter assembly 1326
Disassembly and assembly of PTO assembly 1337
Disassembly and assembly of transmission assembly 1341
Removal and installation of transmission control valve assembly (ECMV assembly) 1378
Disassembly and assembly of transmission control valve assembly (ECMV assembly) 1379
Power train, Part 2 1385
Removal and installation of differential assembly 1386
Disassembly and assembly of differential assembly 1389
Removal and installation of rear final drive carrier assembly 1406
Disassembly and assembly of rear final drive carrier assembly 1409
Disassembly and assembly of rear final drive assembly 1411
Disassembly and assembly of front wheel hub assembly 1419
Steering system 1425
Disassembly and assembly of steering cylinder assembly 1426
Removal and installation of emergency steering motor pump assembly 1430
Brake system 1433
Removal and installation of front brake caliper pad 1434
Removal and installation of front brake caliper assembly 1435
Disassembly and assembly of front brake caliper assembly 1437
Removal and installation of parking brake pad 1439
Removal and installation of parking brake caliper assembly 1442
Disassembly and assembly of front brake caliper pad assembly 1443
Removal and installation of parking brake spring cylinder assembly 1444
Removal and installation of slack adjuster assembly 1446
Disassembly and assembly of slack adjuster assembly 1447
Undercarriage and frame 1449
Removal and installation of front wheel assembly 1450
Removal and installation of rear wheel assembly 1452
Removal and installation of front suspension cylinder assembly 1454
Disassembly and assembly of front suspension cylinder assembly 1457
Disassembly and assembly of variable damping selector valve assembly 1460
Removal and installation of rear suspension cylinder assembly 1463
Disassembly and assembly of rear suspension cylinder assembly 1465
Hydraulic system 1469
Disassembly and assembly of hoist cylinder assembly 1470
Body 1479
Removal and installation of body assembly 1480
Cab and its attachments 1485
Disassembly and assembly of operator’s seat assembly 1486
Removal and installation of air conditioner unit assembly 1499
Electrical system 1503
Removal and installation of engine controller assembly 1504
Removal and installation of transmission controller assembly 1505
Removal and installation of retarder controller assembly 1506
90 Diagrams and drawings 0
Hydraulic diagrams and drawings 1509
Power train hydraulic circuit diagram 1510
Steering and hoist hydraulic circuit diagram HD325-7 Serial No 7001 – 7025, 7101 – 7523 HD405-7 Serial No 3001 – 3035, 7101 – 7523 1511
Steering and hoist hydraulic circuit diagram HD325-7 Serial No 7524 and up HD405-7 Serial No 7525 and up 1513
Brake hydraulic circuit diagram 1515
Electrical diagrams and drawings 1519
Electrical circuit diagram for inside cab (1/5) 1521
Electrical circuit diagram for inside cab (2/5) HD325-7 Serial No 7001 – 7025, 7101 – 7161 HD405-7 Serial No 3001 – 3035, 7101 – 7157 1523
Electrical circuit diagram for inside cab (2/5) HD325-7 Serial No 7162 and up HD405-7 Serial No 7158 and up 1525
Electrical circuit diagram for inside cab (3/5) HD325-7 Serial No 7001 – 7025, 7101 – 7161 HD405-7 Serial No 3001 – 3035, 7101 – 7157 1527
Electrical circuit diagram for inside cab (3/5) HD325-7 Serial No 7162 and up HD405-7 Serial No 7158 and up 1529
Electrical circuit diagram for inside cab (4/5) 1531
Electrical circuit diagram for inside cab (5/5) 1533
Electrical circuit diagram for outside cab (1/3) 1535
Electrical circuit diagram for outside cab (2/3) 1537
Electrical circuit diagram for outside cab (3/3) 1539
Air conditioner electrical circuit diagram 1541
Payload meter electrical circuit diagram 1543
Electrical circuit diagram of external power supply heater 1545
Connectors table and arrangement drawing 1547

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