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

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

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

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

Shop Manual, contents binder, binder label and tabs SEN00486-19
00 Index and foreword SEN00743-19
Index SEN00744-19 q
Foreword and general information SEN00745-04
01 Specification SEN00746-05
Specification and technical data SEN00747-05
10 Structure, function and maintenance standard SEN00748-11
Engine and cooling system SEN00749-02
Power train, Part 1 SEN00750-02
Power train, Part 2 SEN00853-02
Steering system SEN00751-02
Brake system SEN00752-04
Undercarriage and frame SEN00753-03
Hydraulic system SEN00754-04
Cab and its attachments SEN00755-03
Electrical system, Part 1 SEN00756-04
Electrical system, Part 2 SEN00757-06
Electrical system, Part 3 SEN00863-04
Electrical system, Part 4 SEN00873-03
20 Standard value table SEN00758-04
Standard service value table SEN01181-04
30 Testing and adjusting SEN00759-10
Testing and adjusting, Part 1 SEN01182-08
Testing and adjusting, Part 2 SEN01183-08
Testing and adjusting, Part 3 SEN01184-06
Testing and adjusting, Part 4 SEN02401-03
40 Troubleshooting SEN00760-05
General information on troubleshooting SEN01185-03
Troubleshooting by failure code, General SEN01186-03
Troubleshooting by failure code, Part 1 SEN01187-03
00 Index and foreword SEN00744-19
HD325-7, HD405-7 3
Troubleshooting by failure code, Part 2 SEN01188-04
Troubleshooting by failure code, Part 3 SEN01189-04
Troubleshooting by failure code, Part 4 SEN01190-03
Troubleshooting by failure code, Part 5 SEN01191-03
Troubleshooting of electrical system (E-mode) SEN01192-02
Troubleshooting of hydraulic and mechanical system (H-mode) SEN01193-01
Troubleshooting of mechanical system (S-mode) SEN01194-02
50 Disassembly and assembly SEN00761-06
General information on disassembly and assembly SEN01954-05 q
Engine and cooling system SEN01955-04 q
Power train, Part 1 SEN01956-04 q
Power train, Part 2 SEN01957-05 q
Steering system SEN01958-02 q
Brake system SEN01959-05 q
Undercarriage and frame SEN01960-04 q
Hydraulic system SEN01961-02 q
Body SEN01962-02 q
Cab and its attachments SEN01963-03 q
Electrical system SEN01964-02 q
90 Diagrams and drawings SEN00762-09
Hydraulic diagrams and drawings SEN00763-04
Electrical diagrams and drawings SEN00764-07
SEN00744-19 00 Index and foreword
4 HD325-7, HD405-7
Table of contents 1
00 Index and foreword
Index SEN00744-19
Composition of shop manual 2
Table of contents 4
Foreword and general information SEN00745-04
Safety notice 2
How to read the shop manual 7
Explanation of terms for maintenance standard 9
Handling electric equipment and hydraulic component 11
How to read electric wire code 23
Precautions when carrying out operation 26
Method of disassembling and connecting push-pull type coupler 29
Standard tightening torque table 32
Conversion table 36
01 Specification
Specification and technical data SEN00747-05
Specification drawing 2
Specifications 5
Weight table 17
Fuel, coolant and lubricants 18
10 Structure, function and maintenance standard
Engine and cooling system SEN00749-02
Radiator, oil cooler, aftercooler 2
Output shaft 4
Power train, Part 1 SEN00750-02
Power train skeleton 2
Drive shaft 4
Torque converter and transmission hydraulic piping 5
Power train charge pump 6
Retarder cooling pump 7
Torque converter 8
Torque converter valve 14
Transmission 15
Transmission control valve 31
ECMV 32
Power train, Part 2 SEN00853-02
Axle 2
Differential 4
Final drive 6
Wheel 8
Steering system SEN00751-02
Steering column 2
Steering linkage 3
Brake system SEN00752-04
Brake piping 2
Brake valve 4
Secondary brake valve 7
Relay valve 8
Front brake cut valve 9
Accumulator charge valve 10
00 Index and foreword SEN00744-19
HD325-7, HD405-7 5
Accumulator 16
Slack adjuster 18
Brake 20
Proportional reducing valve 25
Parking brake 26
Parking brake solenoid 28
Hand brake (retarder) 29
Undercarriage and frame SEN00753-03
Suspension 2
Suspension cylinder 4
Rear axle support 12
Hydraulic system SEN00754-04
Steering, hoist oil pressure piping diagram 2
Dump body control 4
Hydraulic tank 6
Steering valve 8
Cross-over relief valve 12
Steering control valve 13
Hoist valve 22
Dump control valve (EPC valve) 28
Steering cylinder 32
Hoist cylinder 33
Work equipment and steering pump 34
Cab and its attachments SEN00755-03
ROPS cab 2
Air conditioner 3
Rear view monitor 9
Electrical system, Part 1 SEN00756-04
Machine monitor system 2
Electrical system, Part 2 SEN00757-06
Automatic shift control system 2
Transmission controller 6
External power supply heater 20
Auto emergency steering system 22
Retarder control system 26
Battery disconnector switch 38
Dump control lever 40
Auto suspension system 44
Electrical system, Part 3 SEN00863-04
Payload meter (card type) 2
Payload meter (PLM) controller related 32
Electrical system, Part 4 SEN00873-03
Sensors, switches 2
KOMTRAX terminal system (If equipped) 16
20 Standard value table
Standard service value table SEN01181-04
Standard value table for engine 2
Standard value table for machine 4
30 Testing and adjusting
Testing and adjusting, Part 1 SEN01182-08
Tools for testing, adjusting, and troubleshooting 3
Testing engine speed 9
Testing intake air pressure (boost pressure) 10
SEN00744-19 00 Index and foreword
6 HD325-7, HD405-7
Testing exhaust temperature 11
Testing exhaust gas color 13
Adjusting valve clearance 14
Testing compression pressure 16
Testing blow-by pressure 18
Testing engine oil pressure 19
Testing EGR valve and bypass valve drive oil pressure 20
Handling of fuel system devices 21
Releasing residual pressure from fuel system 21
Testing fuel pressure 22
Testing fuel return rate and leakage 23
Bleeding air from fuel circuit 26
Testing the fuel circuit for leakage 28
Testing and adjusting alternator belt tension 29
Testing and adjusting fan belt tension 30
Testing and adjusting air conditioner compressor belt tension 32
Testing and adjusting, Part 2 SEN01183-08
Testing torque converter stall speed 3
Testing power train oil pressure 4
Adjusting transmission speed sensor 11
Testing brake oil pressure 12
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator
with nitrogen gas 14
Testing brake performance 22
Adjusting parking brake 24
Releasing remaining pressure in brake circuit 25
Bleeding air from brake circuit 26
Testing wear of rear brake disc 27
Testing wear of front brake pad 28
Method for emergency release of parking brake 29
Testing and adjusting front suspension cylinder 30
Testing and adjusting inverted type rear suspension cylinder 35
Testing and adjusting front suspension cylinder (mode selector hydraulic cylnder) 39
Testing and adjusting hydraulic pressure in steering, hoist circuit 40
Testing and adjusting dump EPC circuit oil pressure 43
Air bleeding from steering cylinder 44
Procedure for raising body in emergency 45
Adjusting body positioner sensor 46
Resetting method for dump body seating control 47
Adjustment of tilt lock lever of steering wheel 48
Handling of high voltage circuit of engine controller 49
Adjusting transmission controller 49
Method for emergency escape at electrical system failure 50
Testing and adjusting, Part 3 SEN01184-06
Setting and adjusting of devices 2
Special functions of machine monitor (EMMS) 14
Testing and adjusting, Part 4 SEN02401-03
How to start operation of KOMTRAX terminal 2
Lamp display of KOMTRAX terminal 7
Pm Clinic check sheet 10
Setting of card-type payload meter (PLM- ) after installation or replacement 12
Setting of payload meter 18
40 Troubleshooting
General information on troubleshooting SEN01185-03
Points to remember when performing troubleshooting 2
How to proceed in troubleshooting 4
00 Index and foreword SEN00744-19
HD325-7, HD405-7 7
Checks before troubleshooting 6
Classification and procedures of troubleshooting 7
Information in troubleshooting table 11
Connection table for connector pin numbers 13
T- branch box and T- branch adapter table 49
Troubleshooting by failure code, General SEN01186-03
Failure codes table 2
Before troubleshooting by failure codes 12
Contents of troubleshooting table 17
Troubleshooting by failure code, Part 1 SEN01187-03
Failure code [1500L0] Dual engagement 3
Failure code [15B0NX] Transmission oil filter: Clogging 4
Failure code [15F0KM] R o F shifting abuse 1: Mistake in operation 6
Failure code [15F0MB] R o F shifting abuse 2: Mistake in operation 6
Failure code [15F7KM] Forward clutch disk abuse: Mistake in operation or setting 7
Failure code [15G0MW] R clutch: Slipping 8
Failure code [15G7KM] Reverse clutch disk abuse: Mistake in operation or setting 10
Failure code [15H0MW] Hi clutch: Slipping 12
Failure code [15J0MW] Lo clutch: Slipping 14
Failure code [15K0MW] 1st clutch: Slipping 16
Failure code [15L0MW] 2nd clutch: Slipping 18
Failure code [15M0MW] 3rd clutch: Slipping 20
Failure code [15N0MW] 4th clutch: Slipping 22
Failure code [15SBL1] R clutch solenoid: Fill signal is ON when command current is OFF 24
Failure code [15SBMA] R clutch solenoid: Malfunction 26
Failure code [15SCL1] Hi clutch solenoid: Fill signal is ON when command current is OFF 27
Failure code [15SCMA] Hi clutch solenoid: Malfunction 30
Failure code [15SDL1] Lo clutch solenoid: Fill signal is ON when command current is OFF 31
Failure code [15SDMA] Lo clutch solenoid: Malfunction 34
Failure code [15SEL1] 1st clutch solenoid: Fill signal is ON when command current is OFF 35
Failure code [15SEMA] 1st clutch solenoid: Malfunction 38
Failure code [15SFL1] 2nd clutch solenoid: Fill signal is ON when command current is OFF 39
Failure code [15SFMA] 2nd clutch solenoid: Malfunction 42
Failure code [15SGL1] 3rd clutch solenoid: Fill signal is ON when command current is OFF 43
Failure code [15SGMA] 3rd clutch solenoid: Malfunction 46
Failure code [15SHL1] 4th clutch solenoid: Command current is OFF and fill signal is ON 47
Failure code [15SHMA] 4th clutch solenoid: Malfunction 50
Failure code [15SJMA] Lockup clutch solenoid: Malfunction 52
Failure code [989A00] Engine over run prevention command signal: Operating 54
Failure code [989D00] Rear section tipping over alarm: Alarm is activated 55
Failure code [2F00KM] Parking brake: Mistake in operation or setting 56
Failure code [2G42ZG] Front accumulator: Lowering of oil pressure 58
Failure code [2G43ZG] Rear accumulator: Lowering of oil pressure 58
Failure code [A570NX] Engine oil filter: Clogging 59
Failure code [AA10NX] Air cleaner element: Clogging 60
Failure code [AB00MA] Alternator: Malfunction 62
Failure code [B@BAZG] Abnormal lowering of engine oil pressure: Lowering of oil pressure 64
Failure code [B@BAZK] Engine oil: Level too low 65
Failure code [B@BCZK] Lowering of radiator coolant: Lowering of level 66
Failure code [B@BCNS] Engine: Overheat 68
Failure code [B@C7NS] Rear brake oil: Overheat 68
Failure code [B@CENS] Torque converter oil: Overheat 69
Failure code [B@GAZK] Battery electrolyte level: Lowering of level 70
Failure code [B@JANS] Steering oil: Overheat 71
Troubleshooting by failure code, Part 2 SEN01188-04
Failure code [CA111] Abnormality in engine controller 4
Failure code [CA115] Engine Ne or Bkup speed sensor error 6
SEN00744-19 00 Index and foreword
8 HD325-7, HD405-7
Failure code [CA122] Charge (boost) pressure sensor high error 8
Failure code [CA123] Charge (boost) pressure sensor low error 10
Failure code [CA131] Throttle sensor high error 12
Failure code [CA132] Throttle sensor low error 15
Failure code [CA135] Engine oil pressure sensor high error 18
Failure code [CA141] Engine oil pressure sensor low error 20
Failure code [CA144] Coolant temperature sensor high error 22
Failure code [CA145] Coolant temperature sensor low error 24
Failure code [CA153] Charge (boost) temperature sensor high error 26
Failure code [CA154] Charge (boost) temperature sensor low error 28
Failure code [CA187] Sensor power supply 2 low error 30
Failure code [CA221] Atmospheric pressure sensor high error 34
Failure code [CA222] Atmospheric pressure sensor low error 36
Failure code [CA227] Sensor power supply 2 high error 38
Failure code [CA234] Engine overspeed 39
Failure code [CA238] Ne speed sensor power supply error 40
Failure code [CA263] Fuel Temperature Sensor High Error 42
Failure code [CA265] Fuel Temperature Sensor Low Error 44
Failure code [CA271] PCV1 Short circuit 46
Failure code [CA272] PCV1 Disconnection 47
Failure code [CA273] PCV2 Short circuit 48
Failure code [CA274] PCV2 Disconnection 49
Failure code [CA322] Injector #1 open/short error 50
Failure code [CA323] Injector #5 open/short error 52
Failure code [CA324] Injector #3 open/short error 54
Failure code [CA325] Injector #6 open/short error 56
Failure code [CA331] Injector #2 open/short error 58
Failure code [CA332] Injector #4 open/short error 60
Failure code [CA342] Calibration code inconsistency 62
Failure code [CA351] Injectors drive circuit error 63
Failure code [CA352] Sensor power supply 1 low error 64
Failure code [CA386] Sensor power supply 1 high error 66
Failure code [CA431] Idle validation switch error 68
Failure code [CA432] Idle validation action error 71
Failure code [CA441] Battery voltage low error 74
Failure code [CA442] Battery voltage high error 75
Failure code [CA449] Common rail pressure high error 2 76
Failure code [CA451] Common rail pressure sensor high error 78
Failure code [CA452] Common rail pressure sensor low error 80
Failure code [CA553] Common rail pressure high error 1 82
Failure code [CA554] Common rail pressure sensor in range error 83
Failure code [CA559] Supply pump pressure very low error 1 84
Failure code [CA689] Engine Ne speed sensor error 88
Failure code [CA731] Engine Bkup speed sensor phase error 90
Failure code [CA757] All continuous data lost error 91
Failure code [CA778] Engine Bkup speed sensor error 92
Failure code [CA1228] EGR valve servo error 1 94
Failure code [CA1625] EGR valve servo error 2 95
Failure code [CA1626] Bypass valve solenoid current high error 96
Failure code [CA1627] Bypass valve solenoid current low error 98
Failure code [CA1628] Bypass Valve Servo Error 1 100
Failure code [CA1629] Bypass Valve Servo Error 2 101
Troubleshooting by failure code, Part 3 SEN01189-04
Failure code [CA1631] Bypass valve lift sensor high error 4
Failure code [CA1632] Bypass valve lift sensor low error 6
Failure code [CA1633] KOMNET datalink timeout error 8
Failure code [CA1642] EGR inlet pressure sensor low error 10
Failure code [CA1653] EGR inlet pressure sensor high error 12
00 Index and foreword SEN00744-19
HD325-7, HD405-7 9
Failure code [CA2185] Throttle sensor power supply voltage high error 14
Failure code [CA2186] Throttle sensor power supply voltage low error 16
Failure code [CA2249] Supply pump pressure very low error 2 18
Failure code [CA2271] EGR valve lift sensor high error 20
Failure code [CA2272] EGR valve lift sensor low error 22
Failure code [CA2351] EGR valve solenoid operation short circuit 24
Failure code [CA2352] EGR valve solenoid operation disconnect 26
Failure code [CA2555] Intake air heater relay open circuit error 28
Failure code [CA2556] Intake air heater relay short circuit error 30
Failure code [D19HKB] Stop lamp relay output system: Short circuit 32
Failure code [D5ZKKZ] Front brake cut-off solenoid valve: Disconnection or short circuit 34
Failure code [DAF9KM] Wrong connection of connector 36
Failure code [DAFRKR] Abnormal CAN communication (machine monitor):
Abnormal communication 38
Failure code [DAQ0KK] Transmission controller direct power supply:
Lowering of source voltage 40
Failure code [DAQ0KT] Transmission controller nonvolatile memory:
Abnormality in controller 42
Failure code [DAQ2KK] Transmission controller solenoid power source:
Power source voltage too low 43
Failure code [DAQ9KQ] Transmission controller: Disagreement of model selection 44
Failure code [DAQRKR] Abnormal CAN communication (Transmission):
Abnormal communication 45
Failure code [DAQRMA] Transmission controller option setting: Malfunction 50
Failure code [DB10KT] Retarder controller nonvolatile memory: Abnormality in controller 51
Failure code [DB12KK] Retarder controller solenoid power source:
Power source voltage too low 52
Failure code [DB13KK] Retarder controller direct power source:
Power source voltage too low 54
Failure code [DB19KQ] Disagreement of model selection (Retarder controller) 56
Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled 58
Failure code [DB1RMA] Disagreement of option setting (Retarder controller) 62
Failure code [DB1SKQ] Model selection: Wrong information 63
Failure code [DB2RKR] CAN communication (engine controller): Communication disabled 64
Failure code [DBB0KK] PLM controller:
Low source voltage (input) or PLM controller_LED display: “n9” o “01” 70
Failure code [DBB0KQ] PLM controller:
Disagreement of model selection signals or PLM controller_LED display: “nF” o “11” 72
Failure code [DBB3KK] PLM controller battery power supply:
Low source voltage (input) or PLM controller_LED display: “n9” o “05” 74
Failure code [DBB6KP] PLM controller 24V power supply output:
Low output voltage or PLM controller_LED display: “n9” o “02” 76
Failure code [DBBQKR] PLM controller CAN communication:
Defective communication or PLM controller_LED display: “n8” o “02” 78
Failure code [DBBRKR] Abnormal CAN communication (PLM) : Defective communication 79
Failure code [DBC9KQ] Disagreement of model selection (ABS controller) 80
Failure code [DBCRMA] Disagreement of option setting (ABS controller) 81
Failure code [DDD7KX] Trouble in travel speed setting switch system:
Out of input signal range (If equipped) 82
Failure code [DDD8KA] ARSC system switch system: Disconnection 84
Failure code [DDD8KB] ARSC system switch system: Short circuit 86
Failure code [DDDAKA] ASR system switch: Disconnection (If equipped) 88
Failure code [DDDAKB] ASR system switch: Short circuit 90
Failure code [DDTHKA] Hi clutch fill switch: Disconnection 92
Failure code [DDTJKA] Lo clutch fill switch: Disconnection 94
Failure code [DDTKKA] 1st clutch fill switch: Disconnection 95
Failure code [DDTLKA] 2nd clutch fill switch: Disconnection 96
Failure code [DDTMKA] 3rd clutch fill switch: Disconnection 97
SEN00744-19 00 Index and foreword
10 HD325-7, HD405-7
Failure code [DDTNKA] R clutch fill switch: Disconnection 98
Failure code [DDTPKA] 4th clutch fill switch : Disconnection 99
Failure code [DF10KA] Gear shift lever: Disconnection 100
Failure code [DF10KB] Gear shift lever: Short circuit 103
Failure code [DGF1KX] Transmission oil temperature sensor: Out of input signal range 106
Failure code [DGR2KZ] Retarder oil temperature sensor : Disconnection or short circuit 108
Failure code [DGR6KX] Steering oil temperature sensor: Input signal out of range 110
Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range 112
Troubleshooting by failure code, Part 4 SEN01190-03
Failure code [DHP4KY] Short circuit in suspension pressure sensor system (Front right) or
PLM controller_LED display: “n5” o “44” 4
Failure code [DHP4KZ] Disconnection or ground fault in suspension pressure sensor system
(Front right) or PLM controller_LED display: “n5” o “43” 6
Failure code [DHP5KY] Short circuit in suspension pressure sensor system (Front left) or
PLM controller_LED display: “n5” o “54” 8
Failure code [DHP5KZ] Disconnection or ground fault in suspension pressure sensor system
(Front left) or PLM controller_LED display: “n5” o “53” 10
Failure code [DHP6KA] (Suspension pressure sensor system (Rear right): Disconnection) 12
Failure code [DHP6KX] (Failure in suspension pressure sensor system trouble (Rear right):
Out of input signal range) 14
Failure code [DHP6KY] Suspension pressure sensor system: Short circuit (Right rear) or
PLM controller_LED display: “n5” o “64” 16
Failure code [DHP6KZ] Suspension pressure sensor system: Disconnection or ground fault
(Right rear) or PLM controller_LED display: “n5” o “63” 18
Failure code [DHP7KA] (Suspension pressure sensor system (Rear left): Disconnection) 20
Failure code [DHP7KX] (Failure in suspension pressure sensor system trouble (Rear left):
Out of input signal range) 22
Failure code [DHP7KY] Suspension pressure sensor system: Short circuit (Left rear) or
PLM controller_LED display: “n5” o “74” 24
Failure code [DHP7KZ] Disconnection or ground fault (Left rear) or PLM controller_LED display:
“n5” o “73” Suspension pressure sensor system: 26
Failure code [DHT5KX] (Torque converter oil pressure sensor: Out of input signal range) 28
Failure code [DHT5L6] (Torque converter oil pressure sensor:
Disagreement of run and stop condition with signal) 30
Failure code [DHU2KX] (Front accumulator oil pressure sensor: Out of input signal range) 32
Failure code [DHU3KX] (Rear accumulator oil pressure sensor: Out of input signal range) 34
Failure code [DJF1KA] (Fuel level sensor: Disconnection) 36
Failure code [DK30KX] Trouble in steering angle potentiometer 37
Failure code [DK51L5] (Retarder lever potentiometer:
Potentiometer signal is inconsistent with switch signal) 39
Failure code [DK52KX] (Failure in hoist lever potentiometer 1: Out of input signal range) 42
Failure code [DK53L8] (Failure in hoist lever potentiometer 2: Disagreement of analog signal) 44
Failure code [DK54KX] (Body positioner sensor: Out of input signal range) 46
Failure code [DKD0L6] (Failure in steering speed sensor: Disagreement of run and stop condition
with signal) (If equipped) 48
Failure code [DKH0KX] (Pitch angle sensor: Out of input signal range) (If equipped) 50
Failure code [DKH1KX] Abnormality in clinometer sensor or PLM controller_LED display:
“n4″o”33” 52
Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection) 54
Failure code [DLF1LC] (Transmission input shaft speed sensor:
Disagreement of revolution speed signal) 56
Failure code [DLF2KA] (Transmission intermediate shaft speed sensor: Disconnection) 58
Failure code [DLF2LC] (Transmission intermediate shaft speed sensor:
Disagreement of revolution speed signal) 60
Failure code [DLF8KA] Disconnection in wheel speed sensor (Right rear) 62
Failure code [DLF8LC] Trouble in wheel speed sensor system (Right rear) 63
Failure code [DLF9KA] Disconnection in wheel speed sensor (Left rear) 64
Failure code [DLF9LC] Trouble in wheel speed sensor system (Left rear) 65
00 Index and foreword SEN00744-19
HD325-7, HD405-7 11
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection) 66
Failure code [DLT3LC] (Transmission output shaft speed sensor:
Disagreement of revolution speed signal) (If equipped) 68
Failure code [DLT4KA] (Transmission output shaft speed sensor: Disconnection) (If equipped) 70
Failure code [DLT4LC] (Transmission output shaft speed sensor:
Disagreement of revolution speed signal) (If equipped) 72
Failure code [DLT4MA] Disconnection in transmission output shaft speed sensor:
Defective function (If equipped) 74
Failure code [DV00KB] Short circuit in buzzer output 76
Failure code [DW35KZ] (Failure in output system of auto suspension solenoid 1:
Disconnection or short circuit) (If equipped) 78
Failure code [DW36KZ] (Failure in output system of auto suspension solenoid 2:
Disconnection or short circuit) (If equipped) 80
Failure code [DW72KZ] (Failure in kick-out solenoid output system:
Disconnection or short circuit) 82
Failure code [DW73KZ] (Failure in hoist select valve output system:
Disconnection or short circuit) 84
Failure code [DW78KZ] (Failure in rear brake BCV command output system:
Disconnection or short circuit) 86
Failure code [DWNBK4] Trouble in ASR shut-off valve (Valve keeps operating) 88
Failure code [DWNBKA] Disconnection in ASR shut-off valve output circuit 90
Failure code [DWNBKB] Ground fault in ASR shut-off valve output circuit 92
Failure code [DWNBKY] Short circuit in ASR shut-off valve output circuit 94
Failure code [DWNBMA] Trouble in ASR shut-off valve (Valve does not operate) 95
Failure code [DX11K4] (Rear brake proportional pressure reducing solenoid valve:
Out of control) 96
Failure code [DX11KA] (Rear brake proportional pressure reducing solenoid valve output circuit:
Disconnection) 98
Failure code [DX11KB] (Rear brake proportional pressure reducing solenoid valve:
Short circuit) 99
Failure code [DX11KY] (Rear brake proportional pressure reducing solenoid valve:
Short circuit to power source line) 100
Failure code [DX11MA] (Rear brake proportional pressure reducing solenoid valve:
Malfunction) 102
Failure code [DX13KA] (Output circuit of hoist EPC valve: Disconnection) 104
Failure code [DX13KB] (Output circuit of hoist EPC valve: Short circuit) 106
Failure code [DX13KY] (Output circuit of hoist EPC valve: Short circuit
with power source line) 108
Troubleshooting by failure code, Part 5 SEN01191-03
Failure code [DX17K4] Trouble in ASR proportional pressure reducing solenoid valve
(right) (Valve keeps operating) 4
Failure code [DX17KA] Disconnection in ASR proportional pressure reducing solenoid valve
(right) output circuit 6
Failure code [DX17KB] Ground fault in ASR proportional pressure reducing solenoid valve
(right) output circuit 8
Failure code [DX17KY] Short circuit in ASR proportional pressure reducing solenoid valve
(right) output circuit 10
Failure code [DX17MA] Trouble in ASR proportional pressure reducing solenoid valve
(right) (Valve does not operate) 11
Failure code [DX18K4] Trouble in ASR proportional pressure reducing solenoid valve (left)
(Valve keeps operating) 12
Failure code [DX18KA] Disconnection in ASR proportional pressure reducing solenoid valve
(left) output circuit 14
Failure code [DX18KB] Ground fault in ASR proportional pressure reducing solenoid valve
(left) output circuit 16
Failure code [DX18KY] Short circuit in ASR proportional pressure reducing solenoid valve
(left) output circuit 18
SEN00744-19 00 Index and foreword
12 HD325-7, HD405-7
Failure code [DX18MA] Trouble in ASR proportional pressure reducing solenoid valve (left)
(Valve does not operate) 19
Failure code [DXH1KA] Lockup clutch solenoid output circuit: Disconnection 20
Failure code [DXH1KB] Lock-up clutch solenoid output circuit: Short circuit 22
Failure code [DXH1KY] Lockup clutch solenoid output circuit: Short circuit to power source line 23
Failure code [DXH2KA] Hi clutch solenoid output circuit: Disconnection 24
Failure code [DXH2KB] Hi clutch solenoid output circuit: Short circuit 26
Failure code [DXH2KY] Hi clutch solenoid output circuit: Short circuit to power source line 28
Failure code [DXH3KA] Lo clutch solenoid output circuit: Disconnection 30
Failure code [DXH3KB] Lo clutch solenoid output circuit: Short circuit 32
Failure code [DXH3KY] Lo clutch solenoid output circuit: Short circuit in power source line 34
Failure code [DXH4KA] 1st clutch solenoid output circuit: Disconnection 36
Failure code [DXH4KB] 1st clutch solenoid output circuit: Short circuit 38
Failure code [DXH4KY] 1st clutch solenoid output circuit: Short circuit to power source line 40
Failure code [DXH5KA] 2nd clutch solenoid output circuit: Disconnection 42
Failure code [DXH5KB] 2nd clutch solenoid output circuit: Short circuit 44
Failure code [DXH5KY] 2nd clutch solenoid output circuit: Short circuit in power source line 46
Failure code [DXH6KA] 3rd clutch solenoid output circuit: Disconnection 48
Failure code [DXH6KB] 3rd clutch solenoid output circuit: Short circuit 50
Failure code [DXH6KY] 3rd clutch solenoid output circuit: Short circuit to power source line 52
Failure code [DXH7KA] R clutch solenoid output circuit: Disconnection 54
Failure code [DXH7KB] R clutch solenoid output circuit: Short circuit 56
Failure code [DXH7KY] R clutch solenoid output circuit: Short circuit to power source line 57
Failure code [DXHHKA] 4th clutch solenoid output circuit: Disconnection 58
Failure code [DXHHKB] 4th clutch solenoid output circuit: Short circuit 60
Failure code [DXHHKY] 4th clutch solenoid output circuit: Short circuit to power source line 62
Troubleshooting of electrical system (E-mode) SEN01192-02
Before troubleshooting of electric system 3
Contents of troubleshooting table 9
E-1 Engine does not start 11
E-2 Automatic preheating does not operate 14
E-3 Machine monitor does not display all, when starting switch is turned ON 18
E-4 Machine monitor does not operate when starting switch is OFF 20
E-5 Alarm buzzer does not stop sounding 22
E-6 Gauges of machine monitor, caution lamps or character display
section do not display properly 23
E-7 A selection of the display in character display section cannot be changed 24
E-8 Power mode selecting function does not operate properly 27
E-9 AISS function does not operate properly 28
E-10 Seat belt caution lamp does not display properly 29
E-11 Turn signal lamp or turning lamp (hazard lamp) do not work properly 30
E-12 Night illumination (lighting) does not work properly 33
E-13 Emergency steering does not operate 42
Troubleshooting of hydraulic and mechanical system (H-mode) SEN01193-01
Contents of troubleshooting table 3
H-1 Machine does not start 4
H-2 Machine does not travel smoothly (hunting) 6
H-3 Lockup cannot be cancelled 6
H-4 Excessive shock when starting or shifting 7
H-5 Transmission does not shift up 8
H-6 Machine lacks power or speed when traveling 9
H-7 Time lag is excessive when starting or shifting gear 11
H-8 Torque converter oil temperature is high 12
H-9 Torque converter oil pressure is low 13
H-10 Front brake is ineffective 14
H-11 Rear brake is ineffective 15
H-12 Steering wheel is heavy 16
00 Index and foreword SEN00744-19
HD325-7, HD405-7 13
H-13 Steering wheel does not work 17
H-14 Steering wheel vibrates 18
H-15 Dump body lifting speed is slow 19
H-16 Dump body does not work 20
H-17 Excessive hydraulic drift of dump body 21
Troubleshooting of mechanical system (S-mode) SEN01194-02
Method of using troubleshooting charts 4
S-1 Starting performance is poor 8
S-2 Engine does not start 10
S-3 Engine does not pick up smoothly 14
S-4 Engine stops during operations 15
S-5 Engine does not rotate smoothly 16
S-6 Engine lacks output (or lacks power) 17
S-7 Exhaust gas color is black (incomplete combustion) 18
S-8 Oil consumption is excessive (or exhaust smoke is blue) 20
S-9 Oil becomes contaminated quickly 21
S-10 Fuel consumption is excessive 22
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 23
S-12 Oil pressure drops 24
S-13 Oil level rises (Entry of coolant/fuel) 26
S-14 Coolant temperature becomes too high (overheating) 28
S-15 Abnormal noise is made 29
S-16 Vibration is excessive 30
50 Disassembly and assembly
General information on disassembly and assembly SEN01954-05
How to read this manual 2
Coating materials list 4
Special tool list 7
Sketches of special tools 15
Engine and cooling system SEN01955-04
Removal and installation of engine assembly 2
Removal and installation of radiator assembly 12
Removal and installation of output shaft assembly 24
Disassembly and assembly of output shaft assembly 28
Removal and installation of fuel supply pump assembly 31
Removal and installation of cylinder head assembly 37
Removal and installation of fuel injector assembly 52
Removal and installation of engine front seal 58
Removal and installation of engine rear seal 62
Power train, Part 1 SEN01956-04
Removal and installation of torque converter and transmission assembly 2
Disassembly and assembly of torque converter and control valve assembly 14
Disassembly and assembly of torque converter assembly 16
Disassembly and assembly of PTO assembly 27
Disassembly and assembly of transmission assembly 31
Removal and installation of transmission control valve assembly (ECMV assembly) 68
Disassembly and assembly of transmission control valve assembly (ECMV assembly) 69
Power train, Part 2 SEN01957-05
Removal and installation of differential assembly 2
Disassembly and assembly of differential assembly 5
Removal and installation of rear final drive carrier assembly 22
Disassembly and assembly of rear final drive carrier assembly 26
SEN00744-19 00 Index and foreword
14 HD325-7, HD405-7
Disassembly and assembly of rear final drive assembly 28
Disassembly and assembly of front wheel hub assembly 36
Steering system SEN01958-02
Disassembly and assembly of steering cylinder assembly 2
Removal and installation of emergency steering motor pump assembly 6
Brake system SEN01959-05
Removal and installation of front brake caliper pad 2
Removal and installation of front brake caliper assembly 3
Disassembly and assembly of front brake caliper assembly 5
Removal and installation of parking brake pad 7
Removal and installation of parking brake caliper assembly 10
Disassembly and assembly of front brake caliper pad assembly 11
Removal and installation of parking brake spring cylinder assembly 12
Removal and installation of slack adjuster assembly 14
Disassembly and assembly of slack adjuster assembly 15
Undercarriage and frame SEN01960-04
Removal and installation of front wheel assembly 2
Removal and installation of rear wheel assembly 4
Removal and installation of front suspension cylinder assembly 6
Disassembly and assembly of front suspension cylinder assembly 9
Disassembly and assembly of variable damping selector valve assembly 12
Removal and installation of rear suspension cylinder assembly 15
Disassembly and assembly of rear suspension cylinder assembly 17
Hydraulic system SEN01961-02
Disassembly and assembly of hoist cylinder assembly 2
Body SEN01962-02
Removal and installation of body assembly 2
Cab and its attachments SEN01963-03
Disassembly and assembly of operator’s seat assembly 2
Removal and installation of air conditioner unit assembly 11
Electrical system SEN01964-02
Removal and installation of engine controller assembly 2
Removal and installation of transmission controller assembly 3
Removal and installation of retarder controller assembly 4
90 Diagrams and drawings
Hydraulic diagrams and drawings SEN00763-04
Power train hydraulic circuit diagram 2
Steering and hoist hydraulic circuit diagram
HD325-7 Serial No 7001 – 7025, 7101 – 7523
HD405-7 Serial No 3001 – 3035, 7101 – 7523 3
Steering and hoist hydraulic circuit diagram
HD325-7 Serial No 7524 and up
HD405-7 Serial No 7525 and up 5
Brake hydraulic circuit diagram 7
Electrical diagrams and drawings SEN00764-07
Electrical circuit diagram for inside cab (1/5) 3
Electrical circuit diagram for inside cab (2/5)
HD325-7 Serial No 7001 – 7025, 7101 – 7161
HD405-7 Serial No 3001 – 3035, 7101 – 7157 5
Electrical circuit diagram for inside cab (2/5)
HD325-7 Serial No 7162 and up
00 Index and foreword SEN00744-19
HD325-7, HD405-7 15
HD405-7 Serial No 7158 and up 7
Electrical circuit diagram for inside cab (3/5)
HD325-7 Serial No 7001 – 7025, 7101 – 7161
HD405-7 Serial No 3001 – 3035, 7101 – 7157 9
Electrical circuit diagram for inside cab (3/5)
HD325-7 Serial No 7162 and up
HD405-7 Serial No 7158 and up 11
Electrical circuit diagram for inside cab (4/5) 13
Electrical circuit diagram for inside cab (5/5) 15
Electrical circuit diagram for outside cab (1/3) 17
Electrical circuit diagram for outside cab (2/3) 19
Electrical circuit diagram for outside cab (3/3) 21
Air conditioner electrical circuit diagram 23
Payload meter electrical circuit diagram 25
Electrical circuit diagram of external power supply heater 27
Connectors table and arrangement drawing 29

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DESCRIPTION:

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

Composition of shop manual :
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accordingly.

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

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