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

Description

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

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

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

Shop Manual, contents binder, binder label and tabs SEN02373-12
00 Index and foreword SEN02374-12
Index SEN02375-12 q
Foreword and general information SEN02376-02
01 Specification SEN02377-02
Specification and technical data SEN02378-02
10 Structure, function and maintenance standard SEN02379-03
Engine and cooling system SEN03095-00
Power train, Part 1 SEN03096-00
Power train, Part 2 SEN03097-00
Steering system SEN03098-00
Brake system SEN03099-01
Undercarriage and frame SEN03100-00
Hydraulic system SEN03101-01
Cab and its attachments SEN03102-01
Electrical system, Part 1 SEN03103-00
Electrical system, Part 2 SEN03104-02
Electrical system, Part 3 SEN03105-01
Electrical system, Part 4 SEN03106-00
20 Standard value table SEN02380-03
Standard service value table SEN03705-03
30 Testing and adjusting SEN02381-07
Testing and adjusting, Part 1 SEN03706-07 q
Testing and adjusting, Part 2 SEN03707-04
Testing and adjusting, Part 3 SEN03708-03
Testing and adjusting, Part 4 SEN03709-02
40 Troubleshooting SEN02382-05
Failure code table and fuse locations SEN03710-02
General information on troubleshooting SEN03711-04
Troubleshooting by failure code, Part 1 SEN03712-02 q
00 Index and foreword SEN02375-12
HD325-7R, HD405-7R 3
Troubleshooting by failure code, Part 2 SEN03713-03
Troubleshooting by failure code, Part 3 SEN03714-03 q
Troubleshooting by failure code, Part 4 SEN03715-02
Troubleshooting by failure code, Part 5 SEN03716-02 q
Troubleshooting of electrical system (E-mode) SEN03717-02
Troubleshooting of hydraulic and mechanical system (H-mode) SEN03718-00
Troubleshooting of mechanical system (S-mode) SEN03719-02
50 Disassembly and assembly SEN02383-03
General information on disassembly and assembly SEN03720-02
Engine and cooling system SEN03721-00
Power train, Part 1 SEN03722-02
Power train, Part 2 SEN03723-01
Steering system SEN03724-00
Brake system SEN03725-02
Undercarriage and frame SEN03726-01
Hydraulic system SEN03727-00
Body SEN03728-00
Cab and its attachments SEN03729-00
Electrical system SEN03730-00
90 Diagrams and drawings SEN02384-08
Hydraulic diagrams and drawings SEN02385-01
Electrical diagrams and drawings SEN02386-07
SEN02375-12 00 Index and foreword
4 HD325-7R, HD405-7R
Table of contents 1
00 Index and foreword
Index SEN02375-12
Composition of shop manual 2
Table of contents 4
Foreword and general information SEN02376-02
Safety notice 2
How to read the shop manual 7
Explanation of terms for maintenance standard 9
Handling of electric equipment and hydraulic component 11
Handling of connectors newly used for engines 20
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 SEN02378-02
Specification drawing 2
Specifications 3
Weight table 9
Fuel, coolant and lubricants 10
10 Structure, function and maintenance standard
Engine and cooling system SEN03095-00
Radiator, oil cooler, aftercooler 2
Output shaft 4
Power train, Part 1 SEN03096-00
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 SEN03097-00
Axle 2
Differential 4
Final drive 6
Wheel 8
Steering system SEN03098-00
Steering column 2
Steering linkage 3
Brake system SEN03099-01
Brake piping 2
Brake valve 4
Secondary brake valve 7
Relay valve 8
Front brake cut valve 9
00 Index and foreword SEN02375-12
HD325-7R, HD405-7R 5
Accumulator charge valve 10
Accumulator 14
Slack adjuster 16
Brake 18
Proportional reducing valve 23
Parking brake 24
Parking brake solenoid 26
Hand brake (retarder) 27
Undercarriage and frame SEN03100-00
Suspension 2
Suspension cylinder 4
Rear axle support 12
Hydraulic system SEN03101-01
Steering, hoist oil pressure piping diagram 2
Dump body control 4
Hydraulic tank 5
Steering valve 6
Cross-over relief valve 10
Steering control valve 11
Hoist valve 20
EPC valve 26
Steering cylinder 30
Hoist cylinder 31
Work equipment and steering pump 32
Cab and its attachments SEN03102-01
ROPS cab 2
Air conditioner 3
Rear view monitor 9
Electrical system, Part 1 SEN03103-00
Machine monitor system 2
Electrical system, Part 2 SEN03104-02
Automatic shift control system 2
Transmission controller 6
Auto emergency steering system 20
Retarder control system 22
Dump control lever 34
Auto suspension system 38
Electrical system, Part 3 SEN03105-01
Payload meter (card type) 2
Payload meter (PLM) controller related 32
Electrical system, Part 4 SEN03106-00
Sensors, switches 2
KOMTRAX terminal system (If equipped) 15
20 Standard value table
Standard service value table SEN03705-03
Standard value table for engine 2
Standard value table for machine 3
30 Testing and adjusting
Testing and adjusting, Part 1 SEN03706-07
Tools for testing, adjusting, and troubleshooting 3
Sketches of special tools 9
Testing engine speed 10
Testing intake air pressure (boost pressure) 11
Testing exhaust temperature 12
SEN02375-12 00 Index and foreword
6 HD325-7R, HD405-7R
Testing exhaust gas color 14
Adjusting valve clearance 16
Testing compression pressure 17
Testing blow-by pressure 19
Testing engine oil pressure 20
Handling of fuel system devices 21
Releasing residual pressure from fuel system 21
Testing fuel pressure 22
Reduced cylinder mode operation 23
No-injection cranking 23
Testing fuel return rate and leakage 24
Bleeding air from fuel circuit 27
Testing the fuel circuit for leakage 29
Testing and adjusting alternator belt tension 30
Testing and adjusting fan belt tension 31
Testing and adjusting air conditioner compressor belt tension 33
Testing and adjusting, Part 2 SEN03707-04
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
Testing and adjusting parking brake performance 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 SEN03708-03
Setting and adjusting of devices 2
Special functions of machine monitor (EMMS) 14
Testing and adjusting, Part 4 SEN03709-02
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
Failure code table and fuse locations SEN03710-02
Failure codes table 2
Fuse locations 12
00 Index and foreword SEN02375-12
HD325-7R, HD405-7R 7
General information on troubleshooting SEN03711-04
Points to remember when performing troubleshooting 2
How to proceed in troubleshooting 4
Checks before troubleshooting 6
Classification and procedures of troubleshooting 7
Information in troubleshooting table 11
Troubleshooting method for disconnecting wiring harness of pressure sensor system 13
Contents of troubleshooting table 16
Connection table for connector pin numbers 18
T- branch box and T- branch adapter table 54
Troubleshooting by failure code, Part 1 SEN03712-02
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 SEN03713-03
Failure code [CA111] Abnormality in engine controller 4
Failure code [CA115] Engine Ne or Bkup speed sensor error 6
Failure code [CA122] Charge (boost) pressure sensor high error 8
Failure code [CA123] Charge (boost) pressure sensor low error 10
SEN02375-12 00 Index and foreword
8 HD325-7R, HD405-7R
Failure code [CA131] Throttle sensor high error 12
Failure code [CA132] Throttle sensor low error 14
Failure code [CA135] Engine oil pressure sensor high error 16
Failure code [CA141] Engine oil pressure sensor low error 18
Failure code [CA144] Coolant temperature sensor high error 20
Failure code [CA145] Coolant temperature sensor low error 22
Failure code [CA153] Charge (boost) temperature sensor high error 24
Failure code [CA154] Charge (boost) temperature sensor low error 26
Failure code [CA187] Sensor power supply 2 low error 28
Failure code [CA221] Atmospheric pressure sensor high error 30
Failure code [CA222] Atmospheric pressure sensor low error 32
Failure code [CA227] Sensor power supply 2 high error 34
Failure code [CA234] Engine overspeed 35
Failure code [CA238] Ne speed sensor power supply error 36
Failure code [CA263] Fuel Temperature Sensor High Error 38
Failure code [CA265] Fuel Temperature Sensor Low Error 40
Failure code [CA271] PCV1 Short circuit 42
Failure code [CA272] PCV1 Disconnection 43
Failure code [CA273] PCV2 Short circuit 44
Failure code [CA274] PCV2 Disconnection 45
Failure code [CA322] Injector #1 open/short error 46
Failure code [CA323] Injector #5 open/short error 48
Failure code [CA324] Injector #3 open/short error 50
Failure code [CA325] Injector #6 open/short error 52
Failure code [CA331] Injector #2 open/short error 54
Failure code [CA332] Injector #4 open/short error 56
Failure code [CA342] Calibration code inconsistency 58
Failure code [CA351] Injectors drive circuit error 59
Failure code [CA352] Sensor power supply 1 low error 60
Failure code [CA386] Sensor power supply 1 high error 62
Failure code [CA431] Idle validation switch error 63
Failure code [CA432] Idle validation action error 66
Failure code [CA441] Battery voltage low error 69
Failure code [CA442] Battery voltage high error 70
Failure code [CA449] Common rail pressure high error 2 71
Failure code [CA451] Common rail pressure sensor high error 72
Failure code [CA452] Common rail pressure sensor low error 74
Failure code [CA553] Common rail pressure high error 1 76
Failure code [CA554] Common rail pressure sensor in range error 77
Failure code [CA559] Supply pump pressure very low error 1 78
Failure code [CA689] Engine Ne speed sensor error 82
Failure code [CA731] Engine Bkup speed sensor phase error 84
Failure code [CA757] All continuous data lost error 85
Failure code [CA778] Engine Bkup speed sensor error 86
Troubleshooting by failure code, Part 3 SEN03714-03
Failure code [CA1633] KOMNET datalink timeout error 3
Failure code [CA2185] Throttle sensor power supply voltage high error 4
Failure code [CA2186] Throttle sensor power supply voltage low error 6
Failure code [CA2249] Supply pump pressure very low error 2 8
Failure code [CA2555] Intake air heater relay open circuit error 10
Failure code [CA2556] Intake air heater relay short circuit error 12
Failure code [D19HKB] Stop lamp relay output system: Short circuit 14
Failure code [D5ZKKZ] Front brake cut-off solenoid valve: Disconnection or short circuit 16
Failure code [DAF9KM] Machine monitor: Wrong operation or wrong setting 18
Failure code [DAFRKR] Abnormal CAN communication (machine monitor):
Abnormal communication 19
Failure code [DAQ0KK] Transmission controller direct power supply:
Lowering of source voltage 20
Failure code [DAQ0KT] Transmission controller nonvolatile memory:
Abnormality in controller 22
00 Index and foreword SEN02375-12
HD325-7R, HD405-7R 9
Failure code [DAQ2KK] Transmission controller solenoid power source:
Power source voltage too low 23
Failure code [DAQ9KQ] Transmission controller: Disagreement of model selection 24
Failure code [DAQRKR] Abnormal CAN communication (Transmission):
Abnormal communication 25
Failure code [DAQRMA] Transmission controller option setting: Malfunction 30
Failure code [DB10KT] Retarder controller nonvolatile memory: Abnormality in controller 31
Failure code [DB12KK] Retarder controller solenoid power source:
Power source voltage too low 32
Failure code [DB13KK] Retarder controller direct power source:
Power source voltage too low 34
Failure code [DB19KQ] Retarder controller model selection signal:
Disagreement of model selection signals 36
Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled 38
Failure code [DB1RMA] Retarder controller option setting: Defective function 42
Failure code [DB1SKQ] Model selection: Wrong information 43
Failure code [DB2RKR] CAN communication (engine controller): Communication disabled 44
Failure code [DBB0KK] PLM controller:
Low source voltage (input) or PLM controller_LED display: “n9” o “01” 50
Failure code [DBB0KQ] PLM controller:
Disagreement of model selection signals or PLM controller_LED display: “nF” o “11” 52
Failure code [DBB3KK] PLM controller battery power supply:
Low source voltage (input) or PLM controller_LED display: “n9” o “05” 54
Failure code [DBB6KP] PLM controller 24V power supply output:
Low output voltage or PLM controller_LED display: “n9” o “02” 56
Failure code [DBBQKR] PLM controller CAN communication:
Defective communication or PLM controller_LED display: “n8” o “02” 58
Failure code [DBBRKR] Abnormal CAN communication (PLM) : Defective communication 59
Failure code [DBC9KQ] Disagreement of model selection (ABS controller) 60
Failure code [DBCRMA] Disagreement of option setting (ABS controller) 61
Failure code [DDD7KX] Trouble in travel speed setting switch system:
Out of input signal range (If equipped) 62
Failure code [DDD8KA] ARSC system switch system: Disconnection 64
Failure code [DDD8KB] ARSC system switch system: Short circuit 66
Failure code [DDDAKA] ASR system switch: Disconnection (If equipped) 68
Failure code [DDDAKB] ASR system switch: Short circuit 70
Failure code [DDTHKA] Hi clutch fill switch: Disconnection 72
Failure code [DDTJKA] Lo clutch fill switch: Disconnection 74
Failure code [DDTKKA] 1st clutch fill switch: Disconnection 75
Failure code [DDTLKA] 2nd clutch fill switch: Disconnection 76
Failure code [DDTMKA] 3rd clutch fill switch: Disconnection 77
Failure code [DDTNKA] R clutch fill switch: Disconnection 78
Failure code [DDTPKA] 4th clutch fill switch : Disconnection 79
Failure code [DF10KA] Gear shift lever: Disconnection 80
Failure code [DF10KB] Gear shift lever: Short circuit 83
Failure code [DGF1KX] Transmission oil temperature sensor: Out of input signal range 86
Failure code [DGR2KZ] Retarder oil temperature sensor : Disconnection or short circuit 88
Failure code [DGR6KX] Steering oil temperature sensor: Input signal out of range 90
Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range 92
Troubleshooting by failure code, Part 4 SEN03715-02
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
SEN02375-12 00 Index and foreword
10 HD325-7R, HD405-7R
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] Suspension pressure sensor system: Disconnection or ground fault
(Left rear) or PLM controller_LED display: “n5” o “73” 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) 38
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
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 [DLT4MA] (Transmission output shaft speed sensor: Malfunction) 72
Failure code [DV00KB] (Warning buzzer output: Short circuit) 74
Failure code [DW35KZ] (Failure in output system of auto suspension solenoid 1:
Disconnection or short circuit) (If equipped) 76
Failure code [DW36KZ] (Failure in output system of auto suspension solenoid 2:
Disconnection or short circuit) (If equipped) 78
Failure code [DW72KZ] (Failure in kick-out solenoid output system:
Disconnection or short circuit) 80
00 Index and foreword SEN02375-12
HD325-7R, HD405-7R 11
Failure code [DW73KZ] (Failure in hoist select valve output system:
Disconnection or short circuit) 82
Failure code [DW78KZ] (Failure in rear brake BCV command output system:
Disconnection or short circuit) 84
Failure code [DWNBK4] Trouble in ASR shut-off valve (Valve keeps operating) 86
Failure code [DWNBKA] Disconnection in ASR shut-off valve output circuit 88
Failure code [DWNBKB] Ground fault in ASR shut-off valve output circuit 90
Failure code [DWNBKY] Short circuit in ASR shut-off valve output circuit 92
Failure code [DWNBMA] Trouble in ASR shut-off valve (Valve does not operate) 93
Failure code [DX11K4] (Rear brake proportional pressure reducing solenoid valve:
Out of control) 94
Failure code [DX11KA] (Rear brake proportional pressure reducing solenoid valve output circuit:
Disconnection) 96
Failure code [DX11KB] (Rear brake proportional pressure reducing solenoid valve:
Short circuit) 97
Failure code [DX11KY] (Rear brake proportional pressure reducing solenoid valve:
Short circuit to power source line) 98
Failure code [DX11MA] (Rear brake proportional pressure reducing solenoid valve:
Malfunction) 100
Failure code [DX13KA] (Output circuit of hoist EPC valve: Disconnection) 102
Failure code [DX13KB] (Output circuit of hoist EPC valve: Short circuit) 104
Failure code [DX13KY] (Output circuit of hoist EPC valve:
Short circuit with power source line) 106
Troubleshooting by failure code, Part 5 SEN03716-02
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
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
SEN02375-12 00 Index and foreword
12 HD325-7R, HD405-7R
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) SEN03717-02
Fuse locations 3
E-1 Engine does not start 7
E-2 Automatic preheating does not operate 10
E-3 Machine monitor does not display all, when starting switch is turned ON 14
E-4 Machine monitor does not operate when starting switch is OFF 16
E-5 Alarm buzzer does not stop sounding 18
E-6 Gauges of machine monitor, caution lamps or character display section
do not display properly 20
E-7 A selection of the display in character display section cannot be changed 21
E-8 Power mode selecting function does not operate properly 24
E-9 AISS function does not operate properly 25
E-10 Seat belt caution lamp does not display properly 26
E-11 Turn signal lamp or turning lamp (hazard lamp) do not work properly 27
E-12 Night illumination (lighting) does not work properly 30
E-13 Emergency steering does not operate 39
E-14 KOMTRAX system does not operate normally 44
E-15 Electric priming pump does not operate or does not stop automatically 46
Troubleshooting of hydraulic and mechanical system (H-mode) SEN03718-00
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
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) SEN03719-02
Method of using troubleshooting chart 3
S-1 Starting performance is poor 6
S-2 Engine does not start 7
S-3 Engine does not pick up smoothly 10
S-4 Engine stops during operations 11
S-5 Engine does not rotate smoothly 12
S-6 Engine lacks output (or lacks power) 13
S-7 Exhaust gas color is black (incomplete combustion) 14
S-8 Oil consumption is excessive (or exhaust smoke is blue) 15
00 Index and foreword SEN02375-12
HD325-7R, HD405-7R 13
S-9 Oil becomes contaminated quickly 16
S-10 Fuel consumption is excessive 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 18
S-12 Oil pressure drops 19
S-13 Oil level rises (Entry of coolant/fuel) 20
S-14 Coolant temperature becomes too high (overheating) 21
S-15 Abnormal noise is made 22
S-16 Vibration is excessive 23
S-17 Air cannot be bled from fuel circuit 24
50 Disassembly and assembly
General information on disassembly and assembly SEN03720-02
How to read this manual 2
Coating materials list 4
Special tool list 7
Sketches of special tools 10
Engine and cooling system SEN03721-00
Removal and installation of engine assembly 2
Removal and installation of radiator assembly 8
Removal and installation of output shaft assembly 14
Disassembly and assembly of output shaft assembly 16
Removal and installation of fuel supply pump assembly 19
Removal and installation of fuel injector assembly 24
Removal and installation of cylinder head assembly 29
Removal and installation of engine front seal 37
Removal and installation of engine rear seal 41
Power train, Part 1 SEN03722-02
Removal and installation of torque converter and transmission assembly 2
Disassembly and assembly of torque converter and control valve assembly 9
Disassembly and assembly of torque converter assembly 10
Disassembly and assembly of PTO assembly 18
Disassembly and assembly of transmission assembly 21
Removal and installation of transmission control valve assembly (ECMV assembly) 46
Disassembly and assembly of transmission control valve assembly (ECMV assembly) 47
Power train, Part 2 SEN03723-01
Removal and installation of differential assembly 2
Disassembly and assembly of differential assembly 4
Removal and installation of rear final drive carrier assembly 17
Disassembly and assembly of rear final drive carrier assembly 19
Disassembly and assembly of rear final drive assembly 21
Disassembly and assembly of front wheel hub assembly 25
Steering system SEN03724-00
Disassembly and assembly of steering cylinder assembly 2
Removal and installation of emergency steering motor pump assembly 5
Brake system SEN03725-02
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 4
Removal and installation of rear brake assembly 6
Disassembly and assembly of rear brake assembly 7
Removal and installation of parking brake pad 10
Removal and installation of parking brake caliper assembly 12
Disassembly and assembly of front brake caliper pad assembly 13
Removal and installation of parking brake spring cylinder assembly 14
Removal and installation of slack adjuster assembly 15
Disassembly and assembly of slack adjuster assembly 16
Undercarriage and frame SEN03726-01
Removal and installation of front wheel assembly 2
SEN02375-12 00 Index and foreword
14 HD325-7R, HD405-7R
Removal and installation of rear wheel assembly 3
Removal and installation of front suspension cylinder assembly 4
Disassembly and assembly of front suspension cylinder assembly 6
Disassembly and assembly of variable damping selector valve assembly 8
Removal and installation of rear suspension cylinder assembly 10
Disassembly and assembly of rear suspension cylinder assembly 11
Hydraulic system SEN03727-00
Disassembly and assembly of hoist cylinder assembly 2
Body SEN03728-00
Removal and installation of body assembly 2
Cab and its attachments SEN03729-00
Disassembly and assembly of operator’s seat assembly 2
Removal and installation of air conditioner unit assembly 11
Electrical system SEN03730-00
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 SEN02385-01
Power train hydraulic circuit diagram 2
Steering and hoist hydraulic circuit diagram
HD325-7R Serial No 11001 – 11023
HD405-7R Serial No 11001 – 11023 3
Steering and hoist hydraulic circuit diagram
HD325-7R Serial No 11024 –
HD405-7R Serial No 11024 – 5
Brake hydraulic circuit diagram 7
Electrical diagrams and drawings SEN02386-07
Electrical circuit diagram for inside cab (1/5) 3
Electrical circuit diagram for inside cab (2/5) 5
Electrical circuit diagram for inside cab (3/5) 7
Electrical circuit diagram for inside cab (4/5) 9
Electrical circuit diagram for inside cab (5/5) 11
Electrical circuit diagram for outside cab (1/3) 13
Electrical circuit diagram for outside cab (2/3) 15
Electrical circuit diagram for outside cab (3/3) 17
Air conditioner electrical circuit diagram 19
Payload meter electrical circuit diagram 21
Connectors table and arrangement drawing 23

Questions? Email us: [email protected]

DESCRIPTION:

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

Machine model Serial number
HD325-7R 11001 and up
HD405-7R 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.

PLEASE NOTE:

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
• You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
• Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted

S.V