Komatsu Dump Truck HD325-7R, HD405-7R Repair Service Manual

Complete service repair manual with Electrical Wiring Diagrams for Komatsu Dump Truck HD325-7R, HD405-7R, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Dump Truck HD325-7R, HD405-7R workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:
Total Pages: 1,421 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

SEN02373-08 - Dump Truck HD325-7R, HD405-7R Shop Manual.pdf
GEN00084-00 - Dump Truck GALEO HD325-7R, HD405-7R Field Assembly Instruction.pdf

MAIN SECTIONS
COVER...1
00 Index and foreword...0
  Index...2
    Composition of shop manual...3
    Table of contents...5
  Foreword and general information...16
    Safety notice...17
    How to read the shop manual...22
    Explanation of terms for maintenance standard...24
    Handling of electric equipment and hydraulic component...26
    Handling of connectors newly used for engines...35
    How to read electric wire code...38
    Precautions when carrying out operation...41
    Method of disassembling and connecting push-pull type coupler...44
    Standard tightening torque table...47
    Conversion table...51
01 Specification...0
  Specification and technical data...58
    Specification drawing...59
    Specifications...60
    Weight table...66
    Fuel, coolant and lubricants...67
10 Structure, function and maintenance standard...0
  Engine and cooling system...70
    Radiator, oil cooler, aftercooler...71
    Output shaft...73
  Power train, Part 1...76
    Power train skeleton...77
    Drive shaft...79
    Torque converter and transmission hydraulic piping...80
    Power train charge pump...81
    Retarder cooling pump...82
    Torque converter...83
    Torque converter valve...89
    Transmission...90
    Transmission control valve...106
    ECMV...107
  Power train, Part 2...116
    Axle...117
    Differential...119
    Final drive...121
    Wheel...123
  Steering system...126
    Steering column...127
    Steering linkage...128
  Brake system...132
    Brake piping...133
    Brake valve...135
    Secondary brake valve...138
    Relay valve...139
    Front brake cut valve...140
    Accumulator charge valve...141
    Accumulator...145
    Slack adjuster...147
    Brake...149
    Proportional reducing valve...154
    Parking brake...155
    Parking brake solenoid...157
    Hand brake (retarder)...158
  Undercarriage and frame...160
    Suspension...161
    Suspension cylinder...163
    Rear axle support...171
  Hydraulic system...174
    Steering, hoist oil pressure piping diagram...175
    Dump body control...177
    Hydraulic tank...178
    Steering valve...179
    Cross-over relief valve...183
    Steering control valve...184
    Hoist valve...193
    EPC valve...199
    Steering cylinder...203
    Hoist cylinder...204
    Work equipment and steering pump...205
  Cab and its attachments...208
    ROPS cab...209
    Air conditioner...210
    Rear view monitor...216
  Electrical system, Part 1...220
    Machine monitor system...221
  Electrical system, Part 2...274
    Automatic shift control system...275
    Transmission controller...279
    Auto emergency steering system...293
    Retarder control system...295
    Dump control lever...307
    Auto suspension system...311
  Electrical system, Part 3...316
    Payload meter II (card type)...317
  Electrical system, Part 4...348
    Sensors, switches...349
    KOMTRAX terminal system (If equipped)...362
20 Standard value table...0
  Standard service value table...366
    Standard value table for engine...367
    Standard value table for machine...368
30 Testing and adjusting...0
  Testing and adjusting, Part 1...374
    Tools for testing, adjusting, and troubleshooting...376
    Sketches of special tools...381
    Testing engine speed...382
    Testing intake air pressure (boost pressure)...383
    Testing exhaust temperature...384
    Testing exhaust gas color...386
    Adjusting valve clearance...388
    Testing compression pressure...389
    Testing blow-by pressure...391
    Testing engine oil pressure...392
    Handling of fuel system devices...393
    Releasing residual pressure from fuel system...393
    Testing fuel pressure...394
    Reduced cylinder mode operation...395
    No-injection cranking...395
    Testing fuel return rate and leakage...396
    Bleeding air from fuel circuit...399
    Testing the fuel circuit for leakage...401
    Testing and adjusting alternator belt tension...402
    Testing and adjusting fan belt tension...403
    Testing and adjusting air conditioner compressor belt tension...404
  Testing and adjusting, Part 2...406
    Testing torque converter stall speed...408
    Testing power train oil pressure...409
    Adjusting transmission speed sensor...416
    Testing brake oil pressure...417
    Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas...419
    Testing brake performance...424
    Testing and adjusting parking brake performance...426
    Bleeding air from brake circuit...427
    Testing wear of rear brake disc...428
    Testing wear of front brake pad...429
    Method for emergency release of parking brake...430
    Testing and adjusting front suspension cylinder...431
    Testing and adjusting inverted type rear suspension cylinder...436
    Testing and adjusting front suspension cylinder (mode selector hydraulic cylnder)...440
    Testing and adjusting hydraulic pressure in steering, hoist circuit1...441
    Testing and adjusting dump EPC circuit oil pressure...444
    Air bleeding from steering cylinder...445
    Procedure for raising body in emergency...446
    Adjusting body positioner sensor...447
    Handling of high voltage circuit of engine controller...448
    Adjusting transmission controller...448
    Method for emergency escape at electrical system failure...449
  Testing and adjusting, Part 3...454
    Setting and adjusting of devices...455
    Special functions of machine monitor (EMMS)...467
  Testing and adjusting, Part 4...526
    How to start operation of KOMTRAX terminal...527
    Lamp display of KOMTRAX terminal...532
    Pm Clinic check sheet...535
    Setting of card-type payload meter (PLM-II) after installation or replacement...537
40 Troubleshooting...0
  Failure code table and fuse locations...544
    Failure codes table...545
    Fuse locations...554
  General information on troubleshooting...560
    Points to remember when troubleshooting...561
    Sequence of events in troubleshooting...562
    Checks before troubleshooting...563
    Classification and procedures of troubleshooting...564
    Contents of troubleshooting table...565
    Connection table for connector pin numbers...567
    T- branch box and T- branch adapter table...603
  Troubleshooting by failure code, Part 1...608
    Failure code [1500L0] (Dual engagement)...610
    Failure code [15B0NX] (Transmission oil filter: Clogging)...611
    Failure code [15F0KM] (R ? F shifting abuse 1: Mistake in operation)...613
    Failure code [15F0MB] (R ? F shifting abuse 2: Mistake in operation)...613
    Failure code [15F7KM] (Forward clutch disk abuse: Mistake in operation or setting)...614
    Failure code [15G0MW] (R clutch: Slipping)...615
    Failure code [15G7KM] (Reverse clutch disk abuse: Mistake in operation or setting)...617
    Failure code [15H0MW] (Hi clutch: Slipping)...619
    Failure code [15J0MW] ( Lo clutch: Slipping)...621
    Failure code [15K0MW] (1st clutch: Slipping)...623
    Failure code [15L0MW] (2nd clutch: Slipping)...625
    Failure code [15M0MW] (3rd clutch: Slipping)...627
    Failure code [15N0MW] (4th clutch: Slipping)...629
    Failure code [15SBL1] (R clutch solenoid: Fill signal is ON when command current is OFF)...631
    Failure code [15SBMA] (R clutch solenoid: Malfunction)...635
    Failure code [15SCL1] (Hi clutch solenoid: Fill signal is ON when command current is OFF)...637
    Failure code [15SCMA] (Hi clutch solenoid: Malfunction)...641
    Failure code [15SDL1] (Lo clutch solenoid: Fill signal is ON when command current is OFF)...643
    Failure code [15SDMA] (Lo clutch solenoid: Malfunction)...647
    Failure code [15SEL1] (1st clutch solenoid: Fill signal is ON when command current is OFF)...649
    Failure code [15SEMA] (1st clutch solenoid: Malfunction)...653
    Failure code [15SFL1] (2nd clutch solenoid: Fill signal is ON when command current is OFF)...655
    Failure code [15SFMA] (2nd clutch solenoid: Malfunction)...659
    Failure code [15SGL1] (3rd clutch solenoid: Fill signal is ON when command current is OFF)...661
    Failure code [15SGMA] (3rd clutch solenoid: Malfunction)...665
    Failure code [15SHL1] (4th clutch solenoid: Command current is OFF and fill signal is ON)...667
    Failure code [15SHMA] (4th clutch solenoid: Malfunction)...671
    Failure code [15SJMA] (Lockup clutch solenoid: Malfunction)...673
    Failure code [989A00] (Engine over run prevention command signal: Operating)...675
    Failure code [989D00] (Rear section tipping over alarm: Alarm is activated)...675
    Failure code [2F00KM] (Parking brake: Mistake in operation or setting)...677
    Failure code [2G42ZG] (Front accumulator: Lowering of oil pressure)...679
    Failure code [2G43ZG] (Rear accumulator: Lowering of oil pressure)...679
    Failure code [A570NX] (Engine oil filter: Clogging)...680
    Failure code [AA10NX] (Air cleaner element: Clogging)...681
    Failure code [AB00MA] (Alternator: Malfunction)...683
    Failure code [B@BAZG] (Abnormal lowering of engine oil pressure: Lowering of oil pressure)...685
    Failure code [B@BAZK] (Engine oil: Level too low)...687
    Failure code [B@BCZK] (Lowering of radiator coolant: Lowering of level)...689
    Failure code [B@BCNS] (Engine: Overheat)...691
    Failure code [B@C7NS] (Rear brake oil: Overheat)...692
    Failure code [B@CENS] (Torque converter oil: Overheat)...692
    Failure code [B@GAZK] (Battery electrolyte level: Lowering of level)...693
    Failure code [B@JANS] (Steering oil: Overheat)...694
  Troubleshooting by failure code, Part 2...696
    Failure code [CA111] (Abnormality in engine controller)...698
    Failure code [CA115] (Abnormal engine Ne and Bkup sensors)...699
    Failure code [CA122] (Charge (boost) pressure sensor too high)...701
    Failure code [CA123] (Charge (boost) pressure sensor too low)...703
    Failure code [CA131] (Throttle sensor too high)...705
    Failure code [CA132] (Throttle sensor too low)...707
    Failure code [CA135] (Oil pressure sensor too high)...709
    Failure code [CA141] (Oil pressure sensor too low)...711
    Failure code [CA144] (Coolant temperature sensor too high)...713
    Failure code [CA145] (Coolant temperature sensor too low)...715
    Failure code [CA153] (Charge (boost) temperature sensor too high)...717
    Failure code [CA154] (Charge (boost) temperature sensor too low)...719
    Failure code [CA187] (Sensor power source 2 too low)...719
    Failure code [CA221] (Atmospheric pressure sensor too high)...721
    Failure code [CA222] (Atmospheric pressure sensor too low)...723
    Failure code [CA227] (Sensor power source 2 too high)...725
    Failure code [CA234] (Engine over speed)...727
    Failure code [CA238] (Abnormal power source for engine Ne speed sensor)...729
    Failure code [CA263] (Fuel temperature sensor too high)...731
    Failure code [CA265] (Fuel temperature sensor too low)...733
    Failure code [CA271] (PCV1 short circuit)...734
    Failure code [CA272] (PCV1 disconnection)...735
    Failure code [CA273] (PCV2 short circuit)...736
    Failure code [CA274] (PCV2 disconnection)...737
    Failure code [CA322] (Injector No. 1 system disconnection or short circuit)...739
    Failure code [CA323] (Injector No. 5 system disconnection or short circuit)...741
    Failure code [CA324] (Injector No. 3 system disconnection or short circuit)...743
    Failure code [CA325] (Injector No. 6 system disconnection or short circuit)...745
    Failure code [CA331] (Injector No. 2 system disconnection or short circuit)...747
    Failure code [CA332] (Injector No. 4 system disconnection or short circuit)...749
    Failure code [CA342] (Abnormal engine controller data consistency)...751
    Failure code [CA351] (Abnormal injector drive circuit)...752
    Failure code [CA352] (Sensor power source 1 too low)...753
    Failure code [CA386] (Sensor power source 1 too high)...755
    Failure code [CA431] (Abnormal idle validation switch)...757
    Failure code [CA432] (Abnormal process with idle validation switch)...760
    Failure code [CA441] (Power source voltage too low)...761
    Failure code [CA442] (Power source voltage too high)...761
    Failure code [CA449] (Common rail pressure too high 2)...762
    Failure code [CA451] (Common rail pressure sensor too high)...763
    Failure code [CA452] (Common rail pressure sensor too low)...765
    Failure code [CA553] (Common rail pressure too high 1)...765
    Failure code [CA554] (In-range error of common rail pressure sensor)...766
    Failure code [CA559] (Loss of pressure feed from supply pump abnormal 1)...767
    Failure code [CA689] (Abnormal engine Ne speed sensor)...771
    Failure code [CA731] (Abnormal engine Bkup speed sensor phase)...773
    Failure code [CA757] (Loss of all engine controller data)...773
    Failure code [CA778] (Abnormal engine Bkup speed sensor)...775
  Troubleshooting by failure code, Part 3...778
    Failure code [CA1633] (Abnormal KOMNET)...781
    Failure code [CA2185] (Throttle sensor power source too high)...783
    Failure code [CA2186] (Throttle sensor power source too low)...785
    Failure code [CA2249] (Loss of pressure feed from supply pump abnormal 2)...785
    Failure code [CA2555] (Intake air heater relay disconnection)...786
    Failure code [CA2556] (Intake air heater relay short circuit)...787
    Failure code [D19HKB] (Stop lamp relay output system: Short circuit)...789
    Failure code [D5ZKKZ] (Front brake cut-off solenoid valve: Disconnection or short circuit)...791
    Failure code [DAF9KM] (Machine monitor: Wrong operation or wrong setting)...793
    Failure code [DAFRKR] (Abnormal CAN communication (machine monitor): Abnormal communication)...795
    Failure code [DAQ0KK] (Transmission controller direct power supply: Lowering of source voltage)...797
    Failure code [DAQ0KT] (Transmission controller nonvolatile memory: Abnormality in controller)...799
    Failure code [DAQ2KK] (Transmission controller solenoid power source: Power source voltage too low)...800
    Failure code [DAQ9KQ] (Transmission controller: Disagreement of model selection)...801
    Failure code [DAQRKR] (COMMUNICATION LOST: Communication error)...803
    Failure code [DAQRMA] (Transmission controller option setting: Malfunction)...805
    Failure code [DB10KT] (Retarder controller nonvolatile memory: Abnormality in controller)...805
    Failure code [DB12KK] (Retarder controller solenoid power source: Power source voltage too low)...807
    Failure code [DB13KK] (Retarder controller direct power source: Power source voltage too low)...809
    Failure code [DB19KQ] (Retarder controller model selection signal: Disagreement of model selection signals)...811
    Failure code [DB1RKR] (CAN communication (retarder controller): Communication disabled)...813
    Failure code [DB1RMA] (Retarder controller option setting: Defective function)...815
    Failure code [DB1SKQ] (Model selection: Wrong information)...816
    Failure code [DB2RKR] (CAN communication (engine controller): Communication disabled)...817
    Failure code [DBC9KQ] Disagreement of model selection (ABS controller)...819
    Failure code [DBCRMA] Disagreement of option setting (ABS controller)...820
    Failure code [DDD7KX] (Trouble in travel speed setting switch system: Out of input signal range) (If equipped)...821
    Failure code [DDD8KA] (ARSC system switch system: Disconnection)...823
    Failure code [DDD8KB] (ARSC system switch system: Short circuit)...825
    Failure code [DDDAKA] (ASR system switch: Disconnection) (If equipped)...827
    Failure code [DDDAKB] (ASR system switch: Short circuit)...829
    Failure code [DDTHKA] (Hi clutch fill switch: Disconnection)...831
    Failure code [DDTJKA] (Lo clutch fill switch: Disconnection)...833
    Failure code [DDTKKA] (1st clutch fill switch: Disconnection)...835
    Failure code [DDTLKA] (2nd clutch fill switch: Disconnection)...837
    Failure code [DDTMKA] (3rd clutch fill switch: Disconnection)...839
    Failure code [DDTNKA] (R clutch fill switch: Disconnection)...841
    Failure code [DDTPKA] (4th clutch fill switch : Disconnection)...843
    Failure code [DF10KA] (Gear shift lever: Disconnection)...845
    Failure code [DF10KB] (Gear shift lever: Short circuit)...848
    Failure code [DGF1KX] (Transmission oil temperature sensor: Out of input signal range)...851
    Failure code [DGR2KZ] (Retarder oil temperature sensor : Disconnection or short circuit)...853
    Failure code [DGR6KX] (Steering oil temperature sensor: Input signal out of range)...855
    Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)...857
  Troubleshooting by failure code, Part 4...860
    Failure code [DHP6KA] (Suspension pressure sensor system (Rear right): Disconnection)...863
    Failure code [DHP6KX] (Failure in suspension pressure sensor system trouble (Rear right): Out of input signal range)...865
    Failure code [DHP7KA] (Suspension pressure sensor system (Rear left): Disconnection)...867
    Failure code [DHP7KX] (Failure in suspension pressure sensor system trouble (Rear left): Out of input signal range)...869
    Failure code [DHT5KX] (Torque converter oil pressure sensor: Out of input signal range)...871
    Failure code [DHT5L6] (Torque converter oil pressure sensor: Disagreement of run and stop condition with signal)...873
    Failure code [DHU2KX] (Front accumulator oil pressure sensor: Out of input signal range)...875
    Failure code [DHU3KX] (Rear accumulator oil pressure sensor: Out of input signal range)...877
    Failure code [DJF1KA] (Fuel level sensor: Disconnection)...879
    Failure code [DK30KX] Trouble in steering angle potentiometer...880
    Failure code [DK51L5] (Retarder lever potentiometer: Potentiometer signal is inconsistent with switch signal)...881
    Failure code [DK52KX] (Failure in hoist lever potentiometer 1: Out of input signal range)...885
    Failure code [DK53L8] (Failure in hoist lever potentiometer 2: Disagreement of analog signal)...887
    Failure code [DK54KX] (Body positioner sensor: Out of input signal range)...889
    Failure code [DKD0L6] (Failure in steering speed sensor: Disagreement of run and stop condition with signal) (If equipped)...891
    Failure code [DKH0KX] (Pitch angle sensor: Out of input signal range) (If equipped)...893
    Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection)...895
    Failure code [DLF1LC] (Transmission input shaft speed sensor: Disagreement of revolution speed signal)...897
    Failure code [DLF2KA] (Transmission intermediate shaft speed sensor: Disconnection)...899
    Failure code [DLF2LC] (Transmission intermediate shaft speed sensor: Disagreement of revolution speed signal)...901
    Failure code [DLF8KA] Disconnection in wheel speed sensor (Right rear)...903
    Failure code [DLF8LC] Trouble in wheel speed sensor system (Right rear)...904
    Failure code [DLF9KA] Disconnection in wheel speed sensor (Left rear)...905
    Failure code [DLF9LC] Trouble in wheel speed sensor system (Left rear)...906
    Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)...907
    Failure code [DLT3LC] (Transmission output shaft speed sensor: Disagreement of revolution speed signal) (If equipped)...909
    Failure code [DLT4KA] (Transmission output shaft speed sensor: Disconnection) (If equipped)...911
    Failure code [DLT4MA] (Transmission output shaft speed sensor: Malfunction)...913
    Failure code [DV00KB] (Warning buzzer output: Short circuit)...915
    Failure code [DW35KZ] (Failure in output system of auto suspension solenoid 1: Disconnection or short circuit) (If equipped)...917
    Failure code [DW36KZ] (Failure in output system of auto suspension solenoid 2: Disconnection or short circuit) (If equipped)...919
    Failure code [DW72KZ] (Failure in kick-out solenoid output system: Disconnection or short circuit)...921
    Failure code [DW73KZ] (Failure in hoist select valve output system: Disconnection or short circuit)...923
    Failure code [DW78KZ] (Failure in rear brake BCV command output system: Disconnection or short circuit)...925
    Failure code [DWNBK4] Trouble in ASR shut-off valve (Valve keeps operating)...927
    Failure code [DWNBKA] Disconnection in ASR shut-off valve output circuit...929
    Failure code [DWNBKB] Ground fault in ASR shut-off valve output circuit...931
    Failure code [DWNBKY] Short circuit in ASR shut-off valve output circuit...933
    Failure code [DWNBMA] Trouble in ASR shut-off valve (Valve does not operate)...934
    Failure code [DX11K4] (Rear brake proportional pressure reducing solenoid valve: Out of control)...935
    Failure code [DX11KA] (Rear brake proportional pressure reducing solenoid valve output circuit: Disconnection)...937
    Failure code [DX11KB] (Rear brake proportional pressure reducing solenoid valve: Short circuit)...938
    Failure code [DX11KY] (Rear brake proportional pressure reducing solenoid valve: Short circuit to power source line)...939
    Failure code [DX11MA] (Rear brake proportional pressure reducing solenoid valve: Malfunction)...941
    Failure code [DX13KA] (Output circuit of hoist EPC valve: Disconnection)...943
    Failure code [DX13KB] (Output circuit of hoist EPC valve: Short circuit)...945
    Failure code [DX13KY] (Output circuit of hoist EPC valve: Short circuit with power source line)...947
  Troubleshooting by failure code, Part 5...950
    Failure code [DX17K4] Trouble in ASR proportional pressure reducing solenoid valve (right) (Valve keeps operating)...953
    Failure code [DX17KA] Disconnection in ASR proportional pressure reducing solenoid valve (right) output circuit...955
    Failure code [DX17KB] Ground fault in ASR proportional pressure reducing solenoid valve (right) output circuit...957
    Failure code [DX17KY] Short circuit in ASR proportional pressure reducing solenoid valve (right) output circuit...959
    Failure code [DX17MA] Trouble in ASR proportional pressure reducing solenoid valve (right) (Valve does not operate)...959
    Failure code [DX18K4] Trouble in ASR proportional pressure reducing solenoid valve (left) (Valve keeps operating)...961
    Failure code [DX18KA] Disconnection in ASR proportional pressure reducing solenoid valve (left) output circuit...963
    Failure code [DX18KB] Ground fault in ASR proportional pressure reducing solenoid valve (left) output circuit...965
    Failure code [DX18KY] Short circuit in ASR proportional pressure reducing solenoid valve (left) output circuit...967
    Failure code [DX18MA] Trouble in ASR proportional pressure reducing solenoid valve (left) (Valve does not operate)...967
    Failure code [DXH1KA] (Lockup clutch solenoid output circuit: Disconnection)...969
    Failure code [DXH1KB] (Lock-up clutch solenoid output circuit: Short circuit)...971
    Failure code [DXH1KY] (Lockup clutch solenoid output circuit: Short circuit to power source line)...973
    Failure code [DXH2KA] (Hi clutch solenoid output circuit: Disconnection)...975
    Failure code [DXH2KB] (Hi clutch solenoid output circuit: Short circuit)...977
    Failure code [DXH2KY] (Hi clutch solenoid output circuit: Short circuit to power source line)...979
    Failure code [DXH3KA] (Lo clutch solenoid output circuit: Disconnection)...983
    Failure code [DXH3KB] (Lo clutch solenoid output circuit: Short circuit)...985
    Failure code [DXH3KY] (Lo clutch solenoid output circuit: Short circuit in power source line)...987
    Failure code [DXH4KA] (1st clutch solenoid output circuit: Disconnection)...991
    Failure code [DXH4KB] (1st clutch solenoid output circuit: Short circuit)...993
    Failure code [DXH4KY] (1st clutch solenoid output circuit: Short circuit to power source line)...995
    Failure code [DXH5KA] (2nd clutch solenoid output circuit: Disconnection)...999
    Failure code [DXH5KB] (2nd clutch solenoid output circuit: Short circuit)...1001
    Failure code [DXH5KY] (2nd clutch solenoid output circuit: Short circuit in power source line)...1003
    Failure code [DXH6KA] (3rd clutch solenoid output circuit: Disconnection)...1007
    Failure code [DXH6KB] (3rd clutch solenoid output circuit: Short circuit)...1009
    Failure code [DXH6KY] (3rd clutch solenoid output circuit: Short circuit to power source line)...1011
    Failure code [DXH7KA] (R clutch solenoid output circuit: Disconnection)...1015
    Failure code [DXH7KB] (R clutch solenoid output circuit: Short circuit)...1017
    Failure code [DXH7KY] (R clutch solenoid output circuit: Short circuit to power source line)...1019
    Failure code [DXHHKA] (4th clutch solenoid output circuit: Disconnection)...1021
    Failure code [DXHHKB] (4th clutch solenoid output circuit: Short circuit)...1023
    Failure code [DXHHKY] (4th clutch solenoid output circuit: Short circuit to power source line)...1025
  Troubleshooting of electrical system (E-mode)...1030
    Fuse locations...1032
    E-1 Engine does not start...1036
    E-2 Automatic preheating does not operate...1039
    E-3 Machine monitor does not display all, when starting switch is turned ON...1043
    E-4 Machine monitor does not operate when starting switch is OFF...1045
    E-5 Alarm buzzer does not stop sounding...1047
    E-6 Gauges of machine monitor, caution lamps or character display section do not display properly...1049
    E-7 A selection of the display in character display section cannot be changed...1050
    E-8 Power mode selecting function does not operate properly...1053
    E-9 AISS function does not operate properly...1054
    E-10 Seat belt caution lamp does not display properly...1055
    E-11 Turn signal lamp or turning lamp (hazard lamp) do not work properly...1056
    E-12 Night illumination (lighting) does not work properly...1059
    E-13 Emergency steering does not operate...1068
    E-14 KOMTRAX system does not operate normally...1073
    E-15 Electric priming pump does not operate or does not stop automatically...1075
  Troubleshooting of hydraulic and mechanical system (H-mode)...1078
    Contents of troubleshooting table...1080
    H-1 Machine does not start...1081
    H-2 Machine does not travel smoothly (hunting)...1083
    H-3 Lockup cannot be cancelled...1083
    H-4 Excessive shock when starting or shifting...1084
    H-5 Transmission does not shift up...1085
    H-6 Machine lacks power or speed when traveling...1086
    H-7 Time lag is excessive when starting or shifting gear...1088
    H-8 Torque converter oil temperature is high...1089
    H-9 Torque converter oil pressure is low...1090
    H-10 Front brake is ineffective...1091
    H-11 Rear brake is ineffective...1092
    H-12 Steering wheel is heavy...1093
    H-13 Steering wheel does not work...1094
    H-14 Steering wheel vibrates...1095
    H-15 Dump body lifting speed is slow...1096
    H-16 Dump body does not work...1097
    H-17 Excessive hydraulic drift of dump body...1098
  Troubleshooting of mechanical system (S-mode)...1100
    Method of using troubleshooting chart...1102
    S-1  Starting performance is poor...1105
    S-2  Engine does not start...1106
    S-3  Engine does not pick up smoothly...1109
    S-4  Engine stops during operations...1110
    S-5  Engine does not rotate smoothly...1111
    S-6  Engine lacks output (or lacks power)...1112
    S-7  Exhaust gas color is black (incomplete combustion)...1113
    S-8  Oil consumption is excessive (or exhaust smoke is blue)...1114
    S-9  Oil becomes contaminated quickly...1115
    S-10  Fuel consumption is excessive...1116
    S-11  Oil is in coolant (or coolant spurts back or coolant level goes down)...1117
    S-12  Oil pressure drops...1118
    S-13  Oil level rises (Entry of coolant/fuel)...1119
    S-14  Coolant temperature becomes too high (overheating)...1120
    S-15  Abnormal noise is made...1121
    S-16  Vibration is excessive...1122
    S-17  Air cannot be bled from fuel circuit...1123
50 Disassembly and assembly...0
  General information on disassembly and assembly...1126
    How to read this manual...1127
    Coating materials list...1129
    Special tool list...1132
    Sketches of special tools...1135
  Engine and cooling system...1140
    Removal and installation of engine assembly...1141
    Removal and installation of radiator assembly...1147
    Removal and installation of output shaft assembly...1153
    Disassembly and assembly of output shaft assembly...1155
    Removal and installation of fuel supply pump assembly...1158
    Removal and installation of fuel injector assembly...1163
    Removal and installation of cylinder head assembly...1168
    Removal and installation of engine front seal...1176
    Removal and installation of engine rear seal...1180
  Power train, Part 1...1186
    Removal and installation of torque converter and transmission assembly...1187
    Disassembly and assembly of torque converter and control valve assembly...1194
    Disassembly and assembly of torque converter assembly...1195
    Disassembly and assembly of PTO assembly...1203
    Disassembly and assembly of transmission assembly...1206
    Removal and installation of transmission control valve assembly (ECMV assembly)...1231
    Disassembly and assembly of transmission control valve assembly (ECMV assembly)...1232
  Power train, Part 2...1238
    Removal and installation of differential assembly...1239
    Disassembly and assembly of differential assembly...1240
    Removal and installation of rear final drive carrier assembly...1253
    Disassembly and assembly of rear final drive carrier assembly...1255
    Disassembly and assembly of rear final drive assembly...1257
    Disassembly and assembly of front wheel hub assembly...1261
  Steering system...1266
    Disassembly and assembly of steering cylinder assembly...1267
    Removal and installation of emergency steering motor pump assembly...1270
  Brake system...1272
    Removal and installation of front brake caliper pad...1273
    Removal and installation of front brake caliper assembly...1274
    Disassembly and assembly of front brake caliper assembly...1275
    Removal and installation of rear brake assembly...1277
    Disassembly and assembly of rear brake assembly...1278
    Removal and installation of parking brake pad...1281
    Removal and installation of parking brake caliper assembly...1283
    Disassembly and assembly of front brake caliper pad assembly...1284
    Removal and installation of parking brake spring cylinder assembly...1285
    Removal and installation of slack adjuster assembly...1286
    Disassembly and assembly of slack adjuster assembly...1287
  Undercarriage and frame...1290
    Removal and installation of front wheel assembly...1291
    Removal and installation of rear wheel assembly...1292
    Removal and installation of front suspension cylinder assembly...1294
    Disassembly and assembly of front suspension cylinder assembly...1295
    Disassembly and assembly of variable damping selector valve assembly...1297
    Removal and installation of rear suspension cylinder assembly...1299
    Disassembly and assembly of rear suspension cylinder assembly...1300
  Hydraulic system...1304
    Disassembly and assembly of hoist cylinder assembly...1305
  Body...1312
    Removal and installation of body assembly...1313
  Cab and its attachments...1318
    Disassembly and assembly of operator?s seat assembly...1319
    Removal and installation of air conditioner unit assembly...1328
  Electrical system...1332
    Removal and installation of engine controller assembly...1333
    Removal and installation of transmission controller assembly...1334
    Removal and installation of retarder controller assembly...1335
90 Diagrams and drawings...0
  Hydraulic diagrams and drawings...1338
    Power train hydraulic circuit diagram...1339
    Steering and hoist hydraulic circuit diagram HD325-7R Serial No. 11001 _ 11023 HD405-7R Serial No. 11001 _ 11023...1340
    Steering and hoist hydraulic circuit diagram HD325-7R Serial No. 11024 - HD405-7R Serial No. 11024 -...1341
    Brake hydraulic circuit diagram...1342
  Electrical diagrams and drawings...1345
    Electrical circuit diagram for inside cab (1/5)...1347
    Electrical circuit diagram for inside cab (2/5)...1348
    Electrical circuit diagram for inside cab (3/5)...1349
    Electrical circuit diagram for inside cab (4/5)...1350
    Electrical circuit diagram for inside cab (5/5)...1351
    Electrical circuit diagram for outside cab (1/3)...1352
    Electrical circuit diagram for outside cab (2/3)...1353
    Electrical circuit diagram for outside cab (3/3)...1354
    Air conditioner electrical circuit diagram...1355
    Connectors table and arrangement drawing...1356