Komatsu HD325-7R HD405-7R Dump Truck Service Manual (SEN02373-12) PDF

Description

Komatsu HD325-7R HD405-7R Dump Truck Shop Manual SEN02373-12 – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu HD325-7R HD405-7R Dump Truck Shop Manual SEN02373-12 – PDF DOWNLOAD

SERIAL NUMBERS

HD325-11001 and up
HD405-11001 and up

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.

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.

TABLE OF CONTENTS:

Komatsu HD325-7R HD405-7R Dump Truck Shop Manual SEN02373-12 – 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
Handling of connectors newly used for engines 38
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 63
Weight table 69
Fuel, coolant and lubricants 70
10 Structure, function and maintenance standard 0
Engine and cooling system 73
Radiator, oil cooler, aftercooler 74
Output shaft 76
Power train, Part 1 79
Power train skeleton 80
Drive shaft 82
Torque converter and transmission hydraulic piping 83
Power train charge pump 84
Retarder cooling pump 85
Torque converter 86
Torque converter valve 92
Transmission 93
Transmission control valve 109
ECMV 110
Power train, Part 2 119
Axle 120
Differential 122
Final drive 124
Wheel 126
Steering system 129
Steering column 130
Steering linkage 131
Brake system 135
Brake piping 136
Brake valve 138
Secondary brake valve 141
Relay valve 142
Front brake cut valve 143
Accumulator charge valve 144
Accumulator 148
Slack adjuster 150
Brake 152
Proportional reducing valve 157
Parking brake 158
Parking brake solenoid 160
Hand brake (retarder) 161
Undercarriage and frame 163
Suspension 164
Suspension cylinder 166
Rear axle support 174
Hydraulic system 177
Steering, hoist oil pressure piping diagram 178
Dump body control 180
Hydraulic tank 181
Steering valve 182
Cross-over relief valve 186
Steering control valve 187
Hoist valve 196
EPC valve 202
Steering cylinder 206
Hoist cylinder 207
Work equipment and steering pump 208
Cab and its attachments 211
ROPS cab 212
Air conditioner 213
Rear view monitor 219
Electrical system, Part 1 229
Machine monitor system 230
Electrical system, Part 2 283
Automatic shift control system 284
Transmission controller 288
Auto emergency steering system 302
Retarder control system 304
Dump control lever 316
Auto suspension system 320
Electrical system, Part 3 325
Payload meter II (card type) 326
Payload meter (PLM) controller related 356
Electrical system, Part 4 381
Sensors, switches 382
KOMTRAX terminal system (If equipped) 395
20 Standard value table 0
Standard service value table 399
Standard value table for engine 400
Standard value table for machine 401
30 Testing and adjusting 0
Testing and adjusting, Part 1 407
Tools for testing, adjusting, and troubleshooting 409
Sketches of special tools 415
Testing engine speed 416
Testing intake air pressure (boost pressure) 417
Testing exhaust temperature 418
Testing exhaust gas color 420
Adjusting valve clearance 422
Testing compression pressure 423
Testing blow-by pressure 425
Testing engine oil pressure 426
Handling of fuel system devices 427
Releasing residual pressure from fuel system 427
Testing fuel pressure 428
Reduced cylinder mode operation 429
No-injection cranking 429
Testing fuel return rate and leakage 430
Bleeding air from fuel circuit 433
Testing the fuel circuit for leakage 435
Testing and adjusting alternator belt tension 436
Testing and adjusting fan belt tension 437
Testing and adjusting air conditioner compressor belt tension 439
Testing and adjusting, Part 2 441
Testing torque converter stall speed 443
Testing power train oil pressure 444
Adjusting transmission speed sensor 451
Testing brake oil pressure 452
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas 454
Testing brake performance 462
Testing and adjusting parking brake performance 464
Releasing remaining pressure in brake circuit 465
Bleeding air from brake circuit 466
Testing wear of rear brake disc 467
Testing wear of front brake pad 468
Method for emergency release of parking brake 469
Testing and adjusting front suspension cylinder 470
Testing and adjusting inverted type rear suspension cylinder 475
Testing and adjusting front suspension cylinder (mode selector hydraulic cylnder) 479
Testing and adjusting hydraulic pressure in steering, hoist circuit 480
Testing and adjusting dump EPC circuit oil pressure 483
Air bleeding from steering cylinder 484
Procedure for raising body in emergency 485
Adjusting body positioner sensor 486
Resetting method for dump body seating control 487
Adjustment of tilt lock lever of steering wheel 488
Handling of high voltage circuit of engine controller 489
Adjusting transmission controller 489
Method for emergency escape at electrical system failure 490
Testing and adjusting, Part 3 495
Setting and adjusting of devices 496
Special functions of machine monitor (EMMS) 508
Testing and adjusting, Part 4 567
How to start operation of KOMTRAX terminal 568
Lamp display of KOMTRAX terminal 573
Pm Clinic check sheet 576
Setting of card-type payload meter (PLM-) after installation or replacement 578
Setting of payload meter 584
40 Troubleshooting 0
Failure code table and fuse locations 593
Failure codes table 594
Fuse locations 604
General information on troubleshooting 609
Points to remember when performing troubleshooting 610
How to proceed in troubleshooting 612
Checks before troubleshooting 614
Classification and procedures of troubleshooting 615
Information in troubleshooting table 619
Troubleshooting method for disconnecting wiring harness of pressure sensor system 621
Contents of troubleshooting table 624
Connection table for connector pin numbers 626
T-branch box and T-branch adapter table 662
Troubleshooting by failure code, Part 1 667
Failure code [1500L0] Dual engagement 669
Failure code [15B0NX] Transmission oil filter: Clogging 670
Failure code [15F0KM] R → F shifting abuse 1: Mistake in operation 672
Failure code [15F0MB] R → F shifting abuse 2: Mistake in operation 672
Failure code [15F7KM] Forward clutch disk abuse: Mistake in operation or setting 673
Failure code [15G0MW] R clutch: Slipping 674
Failure code [15G7KM] Reverse clutch disk abuse: Mistake in operation or setting 676
Failure code [15H0MW] Hi clutch: Slipping 678
Failure code [15J0MW] Lo clutch: Slipping 680
Failure code [15K0MW] 1st clutch: Slipping 682
Failure code [15L0MW] 2nd clutch: Slipping 684
Failure code [15M0MW] 3rd clutch: Slipping 686
Failure code [15N0MW] 4th clutch: Slipping 688
Failure code [15SBL1] R clutch solenoid: Fill signal is ON when command current is OFF 690
Failure code [15SBMA] R clutch solenoid: Malfunction 692
Failure code [15SCL1] Hi clutch solenoid: Fill signal is ON when command current is OFF 693
Failure code [15SCMA] Hi clutch solenoid: Malfunction 696
Failure code [15SDL1] Lo clutch solenoid: Fill signal is ON when command current is OFF 697
Failure code [15SDMA] Lo clutch solenoid: Malfunction 700
Failure code [15SEL1] 1st clutch solenoid: Fill signal is ON when command current is OFF 701
Failure code [15SEMA] 1st clutch solenoid: Malfunction 704
Failure code [15SFL1] 2nd clutch solenoid: Fill signal is ON when command current is OFF 705
Failure code [15SFMA] 2nd clutch solenoid: Malfunction 708
Failure code [15SGL1] 3rd clutch solenoid: Fill signal is ON when command current is OFF 709
Failure code [15SGMA] 3rd clutch solenoid: Malfunction 712
Failure code [15SHL1] 4th clutch solenoid: Command current is OFF and fill signal is ON 713
Failure code [15SHMA] 4th clutch solenoid: Malfunction 716
Failure code [15SJMA] Lockup clutch solenoid: Malfunction 718
Failure code [989A00] Engine over run prevention command signal: Operating 720
Failure code [989D00] Rear section tipping over alarm: Alarm is activated 721
Failure code [2F00KM] Parking brake: Mistake in operation or setting 722
Failure code [2G42ZG] Front accumulator: Lowering of oil pressure 724
Failure code [2G43ZG] Rear accumulator: Lowering of oil pressure 724
Failure code [A570NX] Engine oil filter: Clogging 725
Failure code [AA10NX] Air cleaner element: Clogging 726
Failure code [AB00MA] Alternator: Malfunction 728
Failure code [B@BAZG] Abnormal lowering of engine oil pressure: Lowering of oil pressure 730
Failure code [B@BAZK] Engine oil: Level too low 731
Failure code [B@BCZK] Lowering of radiator coolant: Lowering of level 732
Failure code [B@BCNS] Engine: Overheat 734
Failure code [B@C7NS] Rear brake oil: Overheat 734
Failure code [B@CENS] Torque converter oil: Overheat 735
Failure code [B@GAZK] Battery electrolyte level: Lowering of level 736
Failure code [B@JANS] Steering oil: Overheat 737
Troubleshooting by failure code, Part 2 739
Failure code [CA111] Abnormality in engine controller 742
Failure code [CA115] Engine Ne or Bkup speed sensor error 744
Failure code [CA122] Charge (boost) pressure sensor high error 746
Failure code [CA123] Charge (boost) pressure sensor low error 748
Failure code [CA131] Throttle sensor high error 750
Failure code [CA132] Throttle sensor low error 752
Failure code [CA135] Engine oil pressure sensor high error 754
Failure code [CA141] Engine oil pressure sensor low error 756
Failure code [CA144] Coolant temperature sensor high error 758
Failure code [CA145] Coolant temperature sensor low error 760
Failure code [CA153] Charge (boost) temperature sensor high error 762
Failure code [CA154] Charge (boost) temperature sensor low error 764
Failure code [CA187] Sensor power supply 2 low error 766
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 801
Failure code [CA432] Idle validation action error 804
Failure code [CA441] Battery voltage low error 807
Failure code [CA442] Battery voltage high error 808
Failure code [CA449] Common rail pressure high error 2 809
Failure code [CA451] Common rail pressure sensor high error 810
Failure code [CA452] Common rail pressure sensor low error 812
Failure code [CA553] Common rail pressure high error 1 814
Failure code [CA554] Common rail pressure sensor in range error 815
Failure code [CA559] Supply pump pressure very low error 1 816
Failure code [CA689] Engine Ne speed sensor error 820
Failure code [CA731] Engine Bkup speed sensor phase error 822
Failure code [CA757] All continuous data lost error 823
Failure code [CA778] Engine Bkup speed sensor error 824
Troubleshooting by failure code, Part 3 827
Failure code [CA1633] KOMNET datalink timeout error 829
Failure code [CA2185] Throttle sensor power supply voltage high error 830
Failure code [CA2186] Throttle sensor power supply voltage low error 832
Failure code [CA2249] Supply pump pressure very low error 2 834
Failure code [CA2555] Intake air heater relay open circuit error 836
Failure code [CA2556] Intake air heater relay short circuit error 838
Failure code [D19HKB] Stop lamp relay output system: Short circuit 840
Failure code [D5ZKKZ] Front brake cut-off solenoid valve: Disconnection or short circuit 842
Failure code [DAF9KM] Machine monitor: Wrong operation or wrong setting 844
Failure code [DAFRKR] Abnormal CAN communication (machine monitor): Abnormal communication 845
Failure code [DAQ0KK] Transmission controller direct power supply: Lowering of source voltage 846
Failure code [DAQ0KT] Transmission controller nonvolatile memory: Abnormality in controller 848
Failure code [DAQ2KK] Transmission controller solenoid power source: Power source voltage too low 849
Failure code [DAQ9KQ] Transmission controller: Disagreement of model selection 850
Failure code [DAQRKR] Abnormal CAN communication (Transmission): Abnormal communication 851
Failure code [DAQRMA] Transmission controller option setting: Malfunction 856
Failure code [DB10KT] Retarder controller nonvolatile memory: Abnormality in controller 857
Failure code [DB12KK] Retarder controller solenoid power source: Power source voltage too low 858
Failure code [DB13KK] Retarder controller direct power source: Power source voltage too low 860
Failure code [DB19KQ] Retarder controller model selection signal: Disagreement of model selection signals 862
Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled 864
Failure code [DB1RMA] Retarder controller option setting: Defective function 868
Failure code [DB1SKQ] Model selection: Wrong information 869
Failure code [DB2RKR] CAN communication (engine controller): Communication disabled 870
Failure code [DBB0KK] PLM controller: Low source voltage (input) or PLM controller_LED display: “n9” → “01” 876
Failure code [DBB0KQ] PLM controller: Disagreement of model selection signals or PLM controller_LED display: “nF” → “11” 878
Failure code [DBB3KK] PLM controller battery power supply: Low source voltage (input) or PLM controller_LED display: “n9” → “05” 880
Failure code [DBB6KP] PLM controller 24V power supply output: Low output voltage or PLM controller_LED display: “n9” → “02” 882
Failure code [DBBQKR] PLM controller CAN communication: Defective communication or PLM controller_LED display: “n8” → “02” 884
Failure code [DBBRKR] Abnormal CAN communication (PLM) : Defective communication 885
Failure code [DBC9KQ] Disagreement of model selection (ABS controller) 886
Failure code [DBCRMA] Disagreement of option setting (ABS controller) 887
Failure code [DDD7KX] Trouble in travel speed setting switch system: Out of input signal range (If equipped) 888
Failure code [DDD8KA] ARSC system switch system: Disconnection 890
Failure code [DDD8KB] ARSC system switch system: Short circuit 892
Failure code [DDDAKA] ASR system switch: Disconnection (If equipped) 894
Failure code [DDDAKB] ASR system switch: Short circuit 896
Failure code [DDTHKA] Hi clutch fill switch: Disconnection 898
Failure code [DDTJKA] Lo clutch fill switch: Disconnection 900
Failure code [DDTKKA] 1st clutch fill switch: Disconnection 901
Failure code [DDTLKA] 2nd clutch fill switch: Disconnection 902
Failure code [DDTMKA] 3rd clutch fill switch: Disconnection 903
Failure code [DDTNKA] R clutch fill switch: Disconnection 904
Failure code [DDTPKA] 4th clutch fill switch : Disconnection 905
Failure code [DF10KA] Gear shift lever: Disconnection 906
Failure code [DF10KB] Gear shift lever: Short circuit 909
Failure code [DGF1KX] Transmission oil temperature sensor: Out of input signal range 912
Failure code [DGR2KZ] Retarder oil temperature sensor : Disconnection or short circuit 914
Failure code [DGR6KX] Steering oil temperature sensor: Input signal out of range 916
Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range 918
Troubleshooting by failure code, Part 4 921
Failure code [DHP4KY] Short circuit in suspension pressure sensor system (Front right) or PLM controller_LED display: “n5” → “44” 924
Failure code [DHP4KZ] Disconnection or ground fault in suspension pressure sensor system (Front right) or PLM controller_LED display: “n5” → “43” 926
Failure code [DHP5KY] Short circuit in suspension pressure sensor system (Front left) or PLM controller_LED display: “n5” → “54” 928
Failure code [DHP5KZ] Disconnection or ground fault in suspension pressure sensor system (Front left) or PLM controller_LED display: “n5” → “53” 930
Failure code [DHP6KA] (Suspension pressure sensor system (Rear right): Disconnection) 932
Failure code [DHP6KX] (Failure in suspension pressure sensor system trouble (Rear right): Out of input signal range) 934
Failure code [DHP6KY] Suspension pressure sensor system: Short circuit (Right rear) or PLM controller_LED display: “n5” → “64” 936
Failure code [DHP6KZ] Suspension pressure sensor system: Disconnection or ground fault (Right rear) or PLM controller_LED display: “n5” → “63” 938
Failure code [DHP7KA] (Suspension pressure sensor system (Rear left): Disconnection) 940
Failure code [DHP7KX] (Failure in suspension pressure sensor system trouble (Rear left): Out of input signal range) 942
Failure code [DHP7KY] Suspension pressure sensor system: Short circuit (Left rear) or PLM controller_LED display: “n5” → “74” 944
Failure code [DHP7KZ] Suspension pressure sensor system: Disconnection or ground fault (Left rear) or PLM controller_LED display: “n5” → “73” 946
Failure code [DHT5KX] (Torque converter oil pressure sensor: Out of input signal range) 948
Failure code [DHT5L6] (Torque converter oil pressure sensor: Disagreement of run and stop condition with signal) 950
Failure code [DHU2KX] (Front accumulator oil pressure sensor: Out of input signal range) 952
Failure code [DHU3KX] (Rear accumulator oil pressure sensor: Out of input signal range) 954
Failure code [DJF1KA] (Fuel level sensor: Disconnection) 956
Failure code [DK30KX] Trouble in steering angle potentiometer 957
Failure code [DK51L5] (Retarder lever potentiometer: Potentiometer signal is inconsistent with switch signal) 958
Failure code [DK52KX] (Failure in hoist lever potentiometer 1: Out of input signal range) 962
Failure code [DK53L8] (Failure in hoist lever potentiometer 2: Disagreement of analog signal) 964
Failure code [DK54KX] (Body positioner sensor: Out of input signal range) 966
Failure code [DKD0L6] (Failure in steering speed sensor: Disagreement of run and stop condition with signal) (If equipped) 968
Failure code [DKH0KX] (Pitch angle sensor: Out of input signal range) (If equipped) 970
Failure code [DKH1KX] Abnormality in clinometer sensor or PLM controller_LED display: “n4” → “33” 972
Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection) 974
Failure code [DLF1LC] (Transmission input shaft speed sensor: Disagreement of revolution speed signal) 976
Failure code [DLF2KA] (Transmission intermediate shaft speed sensor: Disconnection) 978
Failure code [DLF2LC] (Transmission intermediate shaft speed sensor: Disagreement of revolution speed signal) 980
Failure code [DLF8KA] Disconnection in wheel speed sensor (Right rear) 982
Failure code [DLF8LC] Trouble in wheel speed sensor system (Right rear) 983
Failure code [DLF9KA] Disconnection in wheel speed sensor (Left rear) 984
Failure code [DLF9LC] Trouble in wheel speed sensor system (Left rear) 985
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection) 986
Failure code [DLT3LC] (Transmission output shaft speed sensor: Disagreement of revolution speed signal) (If equipped) 988
Failure code [DLT4KA] (Transmission output shaft speed sensor: Disconnection) (If equipped) 990
Failure code [DLT4MA] (Transmission output shaft speed sensor: Malfunction) 992
Failure code [DV00KB] (Warning buzzer output: Short circuit) 994
Failure code [DW35KZ] (Failure in output system of auto suspension solenoid 1: Disconnection or short circuit) (If equipped) 996
Failure code [DW36KZ] (Failure in output system of auto suspension solenoid 2: Disconnection or short circuit) (If equipped) 998
Failure code [DW72KZ] (Failure in kick-out solenoid output system: Disconnection or short circuit) 1000
Failure code [DW73KZ] (Failure in hoist select valve output system: Disconnection or short circuit) 1002
Failure code [DW78KZ] (Failure in rear brake BCV command output system: Disconnection or short circuit) 1004
Failure code [DWNBK4] Trouble in ASR shut-off valve (Valve keeps operating) 1006
Failure code [DWNBKA] Disconnection in ASR shut-off valve output circuit 1008
Failure code [DWNBKB] Ground fault in ASR shut-off valve output circuit 1010
Failure code [DWNBKY] Short circuit in ASR shut-off valve output circuit 1012
Failure code [DWNBMA] Trouble in ASR shut-off valve (Valve does not operate) 1013
Failure code [DX11K4] (Rear brake proportional pressure reducing solenoid valve: Out of control) 1014
Failure code [DX11KA] (Rear brake proportional pressure reducing solenoid valve output circuit: Disconnection) 1016
Failure code [DX11KB] (Rear brake proportional pressure reducing solenoid valve: Short circuit) 1017
Failure code [DX11KY] (Rear brake proportional pressure reducing solenoid valve: Short circuit to power source line) 1018
Failure code [DX11MA] (Rear brake proportional pressure reducing solenoid valve: Malfunction) 1020
Failure code [DX13KA] (Output circuit of hoist EPC valve: Disconnection) 1022
Failure code [DX13KB] (Output circuit of hoist EPC valve: Short circuit) 1024
Failure code [DX13KY] (Output circuit of hoist EPC valve: Short circuit with power source line) 1026
Troubleshooting by failure code, Part 5 1029
Failure code [DX17K4] Trouble in ASR proportional pressure reducing solenoid valve (right) (Valve keeps operating) 1032
Failure code [DX17KA] Disconnection in ASR proportional pressure reducing solenoid valve (right) output circuit 1034
Failure code [DX17KB] Ground fault in ASR proportional pressure reducing solenoid valve (right) output circuit 1036
Failure code [DX17KY] Short circuit in ASR proportional pressure reducing solenoid valve (right) output circuit 1038
Failure code [DX17MA] Trouble in ASR proportional pressure reducing solenoid valve (right) (Valve does not operate) 1039
Failure code [DX18K4] Trouble in ASR proportional pressure reducing solenoid valve (left) (Valve keeps operating) 1040
Failure code [DX18KA] Disconnection in ASR proportional pressure reducing solenoid valve (left) output circuit 1042
Failure code [DX18KB] Ground fault in ASR proportional pressure reducing solenoid valve (left) output circuit 1044
Failure code [DX18KY] Short circuit in ASR proportional pressure reducing solenoid valve (left) output circuit 1046
Failure code [DX18MA] Trouble in ASR proportional pressure reducing solenoid valve (left) (Valve does not operate) 1047
Failure code [DXH1KA] Lockup clutch solenoid output circuit: Disconnection 1048
Failure code [DXH1KB] Lock-up clutch solenoid output circuit: Short circuit 1050
Failure code [DXH1KY] Lockup clutch solenoid output circuit: Short circuit to power source line 1051
Failure code [DXH2KA] Hi clutch solenoid output circuit: Disconnection 1052
Failure code [DXH2KB] Hi clutch solenoid output circuit: Short circuit 1054
Failure code [DXH2KY] Hi clutch solenoid output circuit: Short circuit to power source line 1056
Failure code [DXH3KA] Lo clutch solenoid output circuit: Disconnection 1058
Failure code [DXH3KB] Lo clutch solenoid output circuit: Short circuit 1060
Failure code [DXH3KY] Lo clutch solenoid output circuit: Short circuit in power source line 1062
Failure code [DXH4KA] 1st clutch solenoid output circuit: Disconnection 1064
Failure code [DXH4KB] 1st clutch solenoid output circuit: Short circuit 1066
Failure code [DXH4KY] 1st clutch solenoid output circuit: Short circuit to power source line 1068
Failure code [DXH5KA] 2nd clutch solenoid output circuit: Disconnection 1070
Failure code [DXH5KB] 2nd clutch solenoid output circuit: Short circuit 1072
Failure code [DXH5KY] 2nd clutch solenoid output circuit: Short circuit in power source line 1074
Failure code [DXH6KA] 3rd clutch solenoid output circuit: Disconnection 1076
Failure code [DXH6KB] 3rd clutch solenoid output circuit: Short circuit 1078
Failure code [DXH6KY] 3rd clutch solenoid output circuit: Short circuit to power source line 1080
Failure code [DXH7KA] R clutch solenoid output circuit: Disconnection 1082
Failure code [DXH7KB] R clutch solenoid output circuit: Short circuit 1084
Failure code [DXH7KY] R clutch solenoid output circuit: Short circuit to power source line 1085
Failure code [DXHHKA] 4th clutch solenoid output circuit: Disconnection 1086
Failure code [DXHHKB] 4th clutch solenoid output circuit: Short circuit 1088
Failure code [DXHHKY] 4th clutch solenoid output circuit: Short circuit to power source line 1090
Troubleshooting of electrical system (E-mode) 1093
Fuse locations 1095
E-1 Engine does not start 1099
E-2 Automatic preheating does not operate 1102
E-3 Machine monitor does not display all, when starting switch is turned ON 1106
E-4 Machine monitor does not operate when starting switch is OFF 1108
E-5 Alarm buzzer does not stop sounding 1110
E-6 Gauges of machine monitor, caution lamps or character display section do not display properly 1112
E-7 A selection of the display in character display section cannot be changed 1113
E-8 Power mode selecting function does not operate properly 1116
E-9 AISS function does not operate properly 1117
E-10 Seat belt caution lamp does not display properly 1118
E-11 Turn signal lamp or turning lamp (hazard lamp) do not work properly 1119
E-12 Night illumination (lighting) does not work properly 1122
E-13 Emergency steering does not operate 1131
E-14 KOMTRAX system does not operate normally 1136
E-15 Electric priming pump does not operate or does not stop automatically 1138
Troubleshooting of hydraulic and mechanical system (H-mode) 1141
Contents of troubleshooting table 1143
H-1 Machine does not start 1144
H-2 Machine does not travel smoothly (hunting) 1146
H-3 Lockup cannot be cancelled 1146
H-4 Excessive shock when starting or shifting 1147
H-5 Transmission does not shift up 1148
H-6 Machine lacks power or speed when traveling 1149
H-7 Time lag is excessive when starting or shifting gear 1151
H-8 Torque converter oil temperature is high 1152
H-9 Torque converter oil pressure is low 1153
H-10 Front brake is ineffective 1154
H-11 Rear brake is ineffective 1155
H-12 Steering wheel is heavy 1156
H-13 Steering wheel does not work 1157
H-14 Steering wheel vibrates 1158
H-15 Dump body lifting speed is slow 1159
H-16 Dump body does not work 1160
H-17 Excessive hydraulic drift of dump body 1161
Troubleshooting of mechanical system (S-mode) 1163
Method of using troubleshooting chart 1165
S-1 Starting performance is poor 1168
S-2 Engine does not start 1169
S-3 Engine does not pick up smoothly 1172
S-4 Engine stops during operations 1173
S-5 Engine does not rotate smoothly 1174
S-6 Engine lacks output (or lacks power) 1175
S-7 Exhaust gas color is black (incomplete combustion) 1176
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1177
S-9 Oil becomes contaminated quickly 1178
S-10 Fuel consumption is excessive 1179
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 1180
S-12 Oil pressure drops 1181
S-13 Oil level rises (Entry of coolant/fuel) 1182
S-14 Coolant temperature becomes too high (overheating) 1183
S-15 Abnormal noise is made 1184
S-16 Vibration is excessive 1185
S-17 Air cannot be bled from fuel circuit 1186
50 Disassembly and assembly 0
General information on disassembly and assembly 1189
How to read this manual 1190
Coating materials list 1192
Special tool list 1195
Sketches of special tools 1198
Engine and cooling system 1203
Removal and installation of engine assembly 1204
Removal and installation of radiator assembly 1210
Removal and installation of output shaft assembly 1216
Disassembly and assembly of output shaft assembly 1218
Removal and installation of fuel supply pump assembly 1221
Removal and installation of fuel injector assembly 1226
Removal and installation of cylinder head assembly 1231
Removal and installation of engine front seal 1239
Removal and installation of engine rear seal 1243
Power train, Part 1 1249
Removal and installation of torque converter and transmission assembly 1250
Disassembly and assembly of torque converter and control valve assembly 1257
Disassembly and assembly of torque converter assembly 1258
Disassembly and assembly of PTO assembly 1266
Disassembly and assembly of transmission assembly 1269
Removal and installation of transmission control valve assembly (ECMV assembly) 1294
Disassembly and assembly of transmission control valve assembly (ECMV assembly) 1295
Power train, Part 2 1301
Removal and installation of differential assembly 1302
Disassembly and assembly of differential assembly 1304
Removal and installation of rear final drive carrier assembly 1317
Disassembly and assembly of rear final drive carrier assembly 1319
Disassembly and assembly of rear final drive assembly 1321
Disassembly and assembly of front wheel hub assembly 1325
Steering system 1331
Disassembly and assembly of steering cylinder assembly 1332
Removal and installation of emergency steering motor pump assembly 1335
Brake system 1337
Removal and installation of front brake caliper pad 1338
Removal and installation of front brake caliper assembly 1339
Disassembly and assembly of front brake caliper assembly 1340
Removal and installation of rear brake assembly 1342
Disassembly and assembly of rear brake assembly 1343
Removal and installation of parking brake pad 1346
Removal and installation of parking brake caliper assembly 1348
Disassembly and assembly of front brake caliper pad assembly 1349
Removal and installation of parking brake spring cylinder assembly 1350
Removal and installation of slack adjuster assembly 1351
Disassembly and assembly of slack adjuster assembly 1352
Undercarriage and frame 1355
Removal and installation of front wheel assembly 1356
Removal and installation of rear wheel assembly 1357
Removal and installation of front suspension cylinder assembly 1358
Disassembly and assembly of front suspension cylinder assembly 1360
Disassembly and assembly of variable damping selector valve assembly 1362
Removal and installation of rear suspension cylinder assembly 1364
Disassembly and assembly of rear suspension cylinder assembly 1365
Hydraulic system 1369
Disassembly and assembly of hoist cylinder assembly 1370
Body 1377
Removal and installation of body assembly 1378
Cab and its attachments 1383
Disassembly and assembly of operator’s seat assembly 1384
Removal and installation of air conditioner unit assembly 1393
Electrical system 1397
Removal and installation of engine controller assembly 1398
Removal and installation of transmission controller assembly 1399
Removal and installation of retarder controller assembly 1400
90 Diagrams and drawings 0
Hydraulic diagrams and drawings 1403
Power train hydraulic circuit diagram 1404
Steering and hoist hydraulic circuit diagram HD325-7R Serial No 11001 _ 11023 HD405-7R Serial No 11001 _ 11023 1405
Steering and hoist hydraulic circuit diagram HD325-7R Serial No 11024 – HD405-7R Serial No 11024 – 1407
Brake hydraulic circuit diagram 1409
Electrical diagrams and drawings 1413
Electrical circuit diagram for inside cab (1/5) 1415
Electrical circuit diagram for inside cab (2/5) 1417
Electrical circuit diagram for inside cab (3/5) 1419
Electrical circuit diagram for inside cab (4/5) 1421
Electrical circuit diagram for inside cab (5/5) 1423
Electrical circuit diagram for outside cab (1/3) 1425
Electrical circuit diagram for outside cab (2/3) 1427
Electrical circuit diagram for outside cab (3/3) 1429
Air conditioner electrical circuit diagram 1431
Payload meter electrical circuit diagram 1433
Connectors table and arrangement drawing 1435

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