HD325 7

SEN00486-07
DUMP TRUCK HD325 -7

HD405 -7
HD325-7001-7025
HD325-7101 and up
SERIAL NUMBERS
HD405-3001-3035
HD405-7101 and up
SEN00744-07
DUMP TRUCK 1SHOP MANUAL
HD325-7
HD405-7
Machine model Serial number

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up
00 Index and foreword 1

Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4
HD325-7, HD405-7 1
SEN00744-07 00 Index and foreword
Composition of shop manual 1

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 accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN00486-07
00 Index and foreword SEN00743-07

Index SEN00744-07 q
Foreword and general information SEN00745-04 q
01 Specification SEN00746-02
Specification and technical data SEN00747-02
10 Structure, function and maintenance standard SEN00748-04

Engine and cooling system SEN00749-02
Power train, Part 1 SEN00750-02
Steering system SEN00751-02
Brake system SEN00752-03 q
Undercarriage and frame SEN00753-03
Hydraulic system SEN00754-03 q
Cab and its attachments SEN00755-02
Electrical system, Part 1 SEN00756-02
20 Standard value table SEN00758-02

Standard service value table SEN01181-02
30 Testing and adjusting SEN00759-02

Testing and adjusting, Part 1 SEN01182-02
40 Troubleshooting SEN00760-01
General information on troubleshooting SEN01185-01
Troubleshooting by failure code, General SEN01186-01
Troubleshooting by failure code, Part 1 SEN01187-01
2 HD325-7, HD405-7

Troubleshooting of electrical system (E-mode) SEN01192-01
Troubleshooting of hydraulic and mechanical system (H-mode) SEN01193-01
Troubleshooting of mechanical system (S-mode) SEN01194-01
50 Disassembly and assembly SEN00761-01

General information on disassembly and assembly SEN01954-01
Brake system SEN01959-01
Hydraulic system SEN01961-01
Body SEN01962-01
Electrical system SEN01964-01
90 Diagrams and drawings SEN00762-05

Hydraulic diagrams and drawings SEN00763-03 q
Electrical diagrams and drawings SEN00764-03
HD325-7, HD405-7 3
Table of contents 1
00 Index and foreword
Index SEN00744-07
Composition of shop manual....................................................................................................... 2
Table of contents ......................................................................................................................... 4
Foreword and general information SEN00745-04

Safety notice................................................................................................................................ 2
How to read the shop manual ..................................................................................................... 7
Explanation of terms for maintenance standard.......................................................................... 9
Handling electric equipment and hydraulic component............................................................... 11
How to read electric wire code .................................................................................................... 23
Precautions when carrying out operation .................................................................................... 26
Method of disassembling and connecting push-pull type coupler ............................................... 29
Standard tightening torque table ................................................................................................. 32
Conversion table ......................................................................................................................... 36
01 Specification
Specification and technical data SEN00747-02
Specification drawing................................................................................................................... 2
Specifications .............................................................................................................................. 4
Weight table ................................................................................................................................ 10
Fuel, coolant and lubricants ........................................................................................................ 11
10 Structure, function and maintenance standard

Radiator, oil cooler, aftercooler .................................................................................................... 2
Output shaft................................................................................................................................. 4
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
Axle ............................................................................................................................................. 2
Differential ................................................................................................................................... 4
Final drive.................................................................................................................................... 6
Wheel .......................................................................................................................................... 8
Steering column........................................................................................................................... 2
Steering linkage........................................................................................................................... 3
Brake piping ................................................................................................................................ 2
Brake valve.................................................................................................................................. 4
Secondary brake valve................................................................................................................ 7
Relay valve.................................................................................................................................. 8
Front brake cut valve................................................................................................................... 9
Accumulator charge valve ........................................................................................................... 10
4 HD325-7, HD405-7
Accumulator ................................................................................................................................ 14
Slack adjuster.............................................................................................................................. 16
Brake........................................................................................................................................... 18
Proportional reducing valve......................................................................................................... 23
Parking brake .............................................................................................................................. 24
Parking brake solenoid................................................................................................................ 26
Hand brake (retarder).................................................................................................................. 27
Suspension ................................................................................................................................. 2
Suspension cylinder .................................................................................................................... 4
Rear axle support........................................................................................................................ 12
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
ROPS cab ................................................................................................................................... 2
Air conditioner ............................................................................................................................. 3
Rear view monitor ....................................................................................................................... 9
Machine monitor system ............................................................................................................. 2
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
Payload meter (card type) ....................................................................................................... 2
Sensors, switches ....................................................................................................................... 2
KOMTRAX terminal system (If equipped) ................................................................................... 16
20 Standard value table

Standard service value table SEN01181-02
Standard value table for engine .................................................................................................. 2
Standard value table for machine................................................................................................ 4
30 Testing and adjusting

Tools for testing, adjusting, and troubleshooting ......................................................................... 3
Testing engine speed .................................................................................................................. 9
Testing intake air pressure (boost pressure) ............................................................................... 10
Testing exhaust temperature....................................................................................................... 11
Testing exhaust gas color............................................................................................................ 13
Adjusting valve clearance ........................................................................................................... 14
HD325-7, HD405-7 5
Testing compression pressure..................................................................................................... 16

Testing blow-by pressure............................................................................................................. 18
Testing engine oil pressure.......................................................................................................... 19
Testing EGR valve and bypass valve drive oil pressure.............................................................. 20
Handling of fuel system devices.................................................................................................. 21
Releasing residual pressure from fuel system ............................................................................ 21
Testing fuel pressure ................................................................................................................... 22
Testing fuel return rate and leakage ............................................................................................ 23
Bleeding air from fuel circuit ........................................................................................................ 26
Testing the fuel circuit for leakage ............................................................................................... 28
Testing and adjusting alternator belt tension ............................................................................... 29
Testing and adjusting fan belt tension ......................................................................................... 30
Testing and adjusting air conditioner compressor belt tension.................................................... 31
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.......................................................................................................... 17
Testing and adjusting parking brake performance....................................................................... 19
Bleeding air from brake circuit..................................................................................................... 20
Testing wear of rear brake disc ................................................................................................... 21
Testing wear of front brake pad ................................................................................................... 22
Method for emergency release of parking brake......................................................................... 23
Testing and adjusting front suspension cylinder.......................................................................... 24
Testing and adjusting inverted type rear suspension cylinder ..................................................... 29
Testing and adjusting front suspension cylinder (mode selector hydraulic cylnder).................... 33
Testing and adjusting hydraulic pressure in steering, hoist circuit............................................... 34
Testing and adjusting dump EPC circuit oil pressure .................................................................. 37
Air bleeding from steering cylinder .............................................................................................. 38
Procedure for raising body in emergency.................................................................................... 39
Adjusting body positioner sensor ................................................................................................ 40
Handling of high voltage circuit of engine controller.................................................................... 41
Adjusting transmission controller................................................................................................. 41
Method for emergency escape at electrical system failure ......................................................... 42
Setting and adjusting of devices.................................................................................................. 2
Special functions of machine monitor (EMMS)............................................................................ 14
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
40 Troubleshooting
General information on troubleshooting SEN01185-01
Points to remember when troubleshooting.................................................................................. 2
Sequence of events in troubleshooting ....................................................................................... 3
Checks before troubleshooting.................................................................................................... 4
Classification and procedures of troubleshooting........................................................................ 5
Connection table for connector pin numbers............................................................................... 6
T-adapter box and T-adapter table .............................................................................................. 29
6 HD325-7, HD405-7
Troubleshooting by failure code, General SEN01186-01

Failure codes table...................................................................................................................... 2
Before troubleshooting by failure codes...................................................................................... 10
Contents of troubleshooting table................................................................................................ 14
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) ............................................................ 28
Failure code [15SCL1] (Hi clutch solenoid: Fill signal is ON when command current is OFF) ... 30
Failure code [15SCMA] (Hi clutch solenoid: Malfunction) ........................................................... 34
Failure code [15SDL1] (Lo clutch solenoid: Fill signal is ON when command current is OFF) ... 36
Failure code [15SDMA] (Lo clutch solenoid: Malfunction) .......................................................... 40
Failure code [15SEL1] (1st clutch solenoid: Fill signal is ON when command current is OFF) .. 42
Failure code [15SEMA] (1st clutch solenoid: Malfunction).......................................................... 46
Failure code [15SFL1] (2nd clutch solenoid: Fill signal is ON when command current is OFF).... 48
Failure code [15SFMA] (2nd clutch solenoid: Malfunction)......................................................... 52
Failure code [15SGL1] (3rd clutch solenoid: Fill signal is ON when command current is OFF) .... 54
Failure code [15SGMA] (3rd clutch solenoid: Malfunction) ......................................................... 58
Failure code [15SHL1] (4th clutch solenoid: Command current is OFF and fill signal is ON) ..... 60
Failure code [15SHMA] (4th clutch solenoid: Malfunction (MA))................................................. 64
Failure code [15SJMA] (Lockup clutch solenoid: Malfunction).................................................... 66
Failure code [989A00] (Engine over run prevention command signal: Operating) ..................... 68
Failure code [989D00] (Rear section tipping over alarm: Alarm is activated) ............................. 68
Failure code [2F00KM] (Parking brake: Mistake in operation or setting) .................................... 70
Failure code [2G42ZG] (Front accumulator: Lowering of oil pressure) ....................................... 72
Failure code [2G43ZG] (Rear accumulator: Lowering of oil pressure)........................................ 72
Failure code [A570NX] (Engine oil filter: Clogging) ..................................................................... 73
Failure code [AA10NX] (Air cleaner element: Clogging) ............................................................. 74
Failure code [AB00MA] (Alternator: Malfunction)........................................................................ 76
Failure code [B@BAZG] (Abnormal lowering of engine oil pressure: Lowering of oil pressure) ... 78
Failure code [B@BAZK] (Engine oil: Level too low).................................................................... 80
Failure code [B@BCZK] (Lowering of radiator coolant: Lowering of level) ................................. 82
Failure code [B@BCNS] (Engine: Overheat) .............................................................................. 84
Failure code [B@GAZK] (Battery electrolyte level: Lowering of level) ........................................ 85
Failure code [B@JANS] (Steering oil: Overheat) ........................................................................ 86
Failure code [CA111] (Abnormality in engine controller) ............................................................. 3
Failure code [CA115] (Abnormal engine Ne and Bkup sensors)................................................. 4
Failure code [CA122] (Charge pressure sensor too high)........................................................... 6
Failure code [CA123] (Charge pressure sensor too low) ............................................................ 8
Failure code [CA131] (Throttle sensor too high) ......................................................................... 10
Failure code [CA132] (Throttle sensor too low)........................................................................... 12
Failure code [CA135] (Oil pressure sensor too high) .................................................................. 14
Failure code [CA141] (Oil pressure sensor too low) ................................................................... 16
Failure code [CA144] (Coolant temperature sensor too high)..................................................... 18
HD325-7, HD405-7 7
Failure code [CA145] (Coolant temperature sensor too low) ...................................................... 20

Failure code [CA153] (Charge temperature sensor too high) ..................................................... 22
Failure code [CA154] (Charge temperature sensor too low)....................................................... 24
Failure code [CA187] (Sensor power source 2 too low).............................................................. 24
Failure code [CA221] (Atmospheric pressure sensor too high)................................................... 26
Failure code [CA222] (Atmospheric pressure sensor too low) .................................................... 28
Failure code [CA227] (Sensor power source 2 too high) ............................................................ 30
Failure code [CA234] (Engine over speed) ................................................................................. 32
Failure code [CA238] (Abnormal power source for engine Ne speed sensor) ............................ 34
Failure code [CA263] (Fuel temperature sensor too high) .......................................................... 36
Failure code [CA265] (Fuel temperature sensor too low)............................................................ 38
Failure code [CA271] (PCV1 short circuit) .................................................................................. 39
Failure code [CA272] (PCV1 disconnection)............................................................................... 40
Failure code [CA273] (PCV2 short circuit) .................................................................................. 41
Failure code [CA274] (PCV2 disconnection)............................................................................... 42
Failure code [CA322] (Injector No. 1 system disconnection or short circuit)............................... 44
Failure code [CA342] (Abnormal engine controller data consistency) ........................................ 56
Failure code [CA351] (Abnormal injector drive circuit) ................................................................ 57
Failure code [CA352] (Sensor power source 1 too low).............................................................. 58
Failure code [CA386] (Sensor power source 1 too high) ............................................................ 60
Failure code [CA431] (Abnormal idle validation switch) .............................................................. 62
Failure code [CA432] (Abnormal process with idle validation switch) ......................................... 64
Failure code [CA441] (Power source voltage too low) ................................................................ 65
Failure code [CA442] (Power source voltage too high)............................................................... 65
Failure code [CA449] (Common rail pressure too high 2) ........................................................... 66
Failure code [CA451] (Common rail pressure sensor too high) .................................................. 68
Failure code [CA452] (Common rail pressure sensor too low).................................................... 70
Failure code [CA553] (Common rail pressure too high 1) ........................................................... 70
Failure code [CA554] (In-range error of common rail pressure sensor)...................................... 71
Failure code [CA559] (Loss of pressure feed from supply pump abnormal 1) ............................ 72
Failure code [CA689] (Abnormal engine Ne speed sensor)........................................................ 76
Failure code [CA731] (Abnormal engine Bkup speed sensor phase) ......................................... 78
Failure code [CA757] (Loss of all engine controller data) ........................................................... 78
Failure code [CA778] (Abnormal engine Bkup speed sensor) .................................................... 80
Failure code [CA1228] (Abnormal EGR valve servo 1)............................................................... 82
Failure code [CA1625] (Abnormal EGR valve servo 2)............................................................... 83
Failure code [CA1626] (Short circuit of bypass valve solenoid drive) ......................................... 84
Failure code [CA1627] (Disconnection in bypass valve solenoid drive) ...................................... 86
Failure code [CA1628] (Abnormal bypass valve servo 1) ........................................................... 87
Failure code [CA1629] (Abnormal bypass valve servo 2) ........................................................... 88
Failure code [CA1631] (Bypass valve lift sensor too high) .......................................................... 4
Failure code [CA1632] (Bypass valve lift sensor too low) ........................................................... 6
Failure code [CA1633] (Abnormal KOMNET) ............................................................................. 8
Failure code [CA1642] (EGR inlet pressure sensor too low)....................................................... 10
Failure code [CA1653] (EGR inlet pressure sensor too high) ..................................................... 12
Failure code [CA2185] (Throttle sensor power source too high)................................................. 14
Failure code [CA2186] (Throttle sensor power source too low) .................................................. 16
Failure code [CA2249] (Loss of pressure feed from supply pump abnormal 2) .......................... 16
Failure code [CA2271] (EGR valve lift sensor too high).............................................................. 18
Failure code [CA2272] (EGR valve lift sensor too low) ............................................................... 20
Failure code [CA2351] (EGR valve solenoid drive short circuit) ................................................. 22
Failure code [CA2352] (EGR valve solenoid drive disconnection).............................................. 24
8 HD325-7, HD405-7
Failure code [CA2555] (Intake air heater relay disconnection) ................................................... 24

Failure code [CA2556] (Intake air heater relay short circuit) ....................................................... 26
Failure code [D19HKB] (Stop lamp relay output system: Short circuit)....................................... 28
Failure code [D5ZKKZ] (Front brake cut-off solenoid valve: Disconnection or short circuit) ....... 30
Failure code [DAFRKR] (Abnormal CAN communication (machine monitor):
Abnormal communication) ................................................................................................... 32
Failure code [DAQ0KK] (Transmission controller direct power supply:
Lowering of source voltage) ................................................................................................. 34
Failure code [DAQ0KT] (Transmission controller nonvolatile memory:
Abnormality in controller) ..................................................................................................... 36
Failure code [DAQ2KK] (Transmission controller solenoid power source:
Power source voltage too low) ............................................................................................. 37
Failure code [DAQ9KQ] (Transmission controller: Disagreement of model selection)................ 38
Failure code [DAQRMA] (Transmission controller option setting: Malfunction) .......................... 39
Failure code [DB10KT] (Retarder controller nonvolatile memory: Abnormality in controller) ...... 39
Failure code [DB12KK] (Retarder controller solenoid power source:
Failure code [DB13KK] (Retarder controller direct power source:
Failure code [DB1RKR] (CAN communication (retarder controller): Communication disabled).. 44
Failure code [DB1SKQ] (Model selection: Wrong information) ................................................... 46
Failure code [DB2RKR] (CAN communication (engine controller): Communication disabled) ... 48
Failure code [DDD7KX] (Trouble in travel speed setting switch system:
Out of input signal range) (If equipped) ............................................................................... 50
Failure code [DDD8KA] (ARSC system switch system: Disconnection) ..................................... 52
Failure code [DDD8KB] (ARSC system switch system: Short circuit)......................................... 54
Failure code [DDDAKA] (ASR system switch: Disconnection) (If equipped) .............................. 56
Failure code [DDDAKB] (ASR system switch: Short circuit) ....................................................... 58
Failure code [DDTHKA] (Hi clutch fill switch: Disconnection) ..................................................... 60
Failure code [DDTJKA] (Lo clutch fill switch: Disconnection)...................................................... 62
Failure code [DDTKKA] (1st clutch fill switch: Disconnection) .................................................... 64
Failure code [DDTLKA] (2nd clutch fill switch: Disconnection) ................................................... 66
Failure code [DDTMKA] (3rd clutch fill switch: Disconnection) ................................................... 68
Failure code [DDTNKA] (R clutch fill switch: Disconnection) ...................................................... 70
Failure code [DDTPKA] (4th clutch fill switch : Disconnection) ................................................... 72
Failure code [DF10KA] (Gear shift lever: Disconnection) ........................................................... 74
Failure code [DF10KB] (Gear shift lever: Short circuit) ............................................................... 77
Failure code [DGF1KX] (Transmission oil temperature sensor: Out of input signal range) ........ 80
Failure code [DGR2KZ] (Retarder oil temperature sensor : Disconnection or short circuit)........ 82
Failure code [DGR6KX] (Steering oil temperature sensor: Input signal out of range)................. 84
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range) ... 86
Failure code [DHP6KA] (Suspension pressure sensor system (Rear right): Disconnection) ...... 4
Failure code [DHP6KX] (Failure in suspension pressure sensor system trouble
(Rear right): Out of input signal range) ................................................................................ 6
Failure code [DHP7KA] (Suspension pressure sensor system (Rear left): Disconnection) ........ 8
Failure code [DHP7KX] (Failure in suspension pressure sensor system trouble
(Rear left): Out of input signal range)................................................................................... 10
Failure code [DHT5KX] (Torque converter oil pressure sensor: Out of input signal range) ........ 12
Failure code [DHT5L6] (Torque converter oil pressure sensor:
Disagreement of run and stop condition with signal) ........................................................... 14
Failure code [DHU2KX] (Front accumulator oil pressure sensor: Out of input signal range) ...... 16
Failure code [DHU3KX] (Rear accumulator oil pressure sensor: Out of input signal range) ...... 18
Failure code [DJF1KA] (Fuel level sensor: Disconnection)......................................................... 20
Failure code [DK51L5] (Retarder lever potentiometer:
Potentiometer signal is inconsistent with swich signal)........................................................ 21
Failure code [DK52KX] (Failure in hoist lever potentiometer 1: Out of input signal range) ......... 24
Failure code [DK53L8] (Failure in hoist lever potentiometer 2: Disagreement of analog signal)... 26
HD325-7, HD405-7 9
Failure code [DK54KX] (Body positioner sensor: Out of input signal range)............................... 28
Failure code [DKD0L6] (Failure in steering speed sensor:
Disagreement of run and stop condition with signal) (If equipped) ...................................... 30
Failure code [DKH0KX] (Pitch angle sensor: Out of input signal range) (If equipped)................ 32
Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection)....................... 34
Failure code [DLF1LC] (Transmission input shaft speed sensor:
Disagreement of revolution speed signal)............................................................................ 36
Failure code [DLF2KA] (Transmission intermediate shaft speed sensor: Disconnection)........... 38
Failure code [DLF2LC] (Transmission intermediate shaft speed sensor:
Disagreement of revolution speed signal)............................................................................ 40
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)..................... 42
Failure code [DLT3LC] (Transmission output shaft speed sensor:
Disagreement of revolution speed signal) (If equipped)....................................................... 44
Failure code [DLT4KA] (Transmission output shaft speed sensor: Disconnection) (If equipped) .. 46
Disagreement of revolution speed signal) (If equipped)....................................................... 48
Failure code [DW35KZ] (Failure in output system of auto suspension solenoid 1:
Disconnection or short circuit) (If equipped)......................................................................... 50
Disconnection or short circuit) (If equipped)......................................................................... 52
Failure code [DW72KZ] (Failure in kick-out solenoid output system:
Disconnection or short circuit).............................................................................................. 54
Failure code [DW73KZ] (Failure in hoist select valve output system:
Failure code [DW78KZ] (Failure in rear brake BCV command output system:
Failure code [DX11K4] (Rear brake proportional pressure reducing solenoid valve:
Out of control) ...................................................................................................................... 60
Failure code [DX11KA] (Rear brake proportional pressure reducing solenoid valve
output circuit: Disconnection) ............................................................................................... 62
Failure code [DX11KB] (Rear brake proportional pressure reducing solenoid valve:
Short circuit) ......................................................................................................................... 63
Failure code [DX11KY] (Rear brake proportional pressure reducing solenoid valve:
Short circuit to power source line)........................................................................................ 64
Failure code [DX11MA] (Rear brake proportional pressure reducing solenoid valve:
Malfunction).......................................................................................................................... 66
Failure code [DX13KA] (Output circuit of hoist EPC valve: Disconnection) ................................ 68
Failure code [DX13KB] (Output circuit of hoist EPC valve: Short circuit).................................... 70
Failure code [DX13KY] (Output circuit of hoist EPC valve: Short circuit with power source line) .. 72
Failure code [DXH1KA] (Lockup clutch solenoid output circuit: Disconnection) ......................... 4
Failure code [DXH1KB] (Lock-up clutch solenoid output circuit: Short circuit)............................ 6
Failure code [DXH1KY] (Lockup clutch solenoid output circuit:
Short circuit to power source line)........................................................................................ 8
Failure code [DXH2KA] (Hi clutch solenoid output circuit: Disconnection).................................. 10
Failure code [DXH2KB] (Hi clutch solenoid output circuit: Short circuit) ..................................... 12
Failure code [DXH2KY] (Hi clutch solenoid output circuit: Short circuit to power source line) .... 14
Failure code [DXH3KA] (Lo clutch solenoid output circuit: Disconnection) ................................. 18
Failure code [DXH3KB] (Lo clutch solenoid output circuit: Short circuit)..................................... 20
Failure code [DXH3KY] (Lo clutch solenoid output circuit: Short circuit in power source line).... 22
Failure code [DXH4KA] (1st clutch solenoid output circuit: Disconnection) ................................ 26
Failure code [DXH4KB] (1st clutch solenoid output circuit: Short circuit).................................... 28
Failure code [DXH4KY] (1st clutch solenoid output circuit: Short circuit to power source line)... 30
Failure code [DXH5KA] (2nd clutch solenoid output circuit: Disconnection) ............................... 34
Failure code [DXH5KB] (2nd clutch solenoid output circuit: Short circuit)................................... 36
Failure code [DXH5KY] (2nd clutch solenoid output circuit: Short circuit in power source line).. 38
Failure code [DXH6KA] (3rd clutch solenoid output circuit: Disconnection)................................ 42
Failure code [DXH6KB] (3rd clutch solenoid output circuit: Short circuit) ................................... 44
10 HD325-7, HD405-7
Failure code [DXH6KY] (3rd clutch solenoid output circuit: Short circuit to power source line) .. 46
Failure code [DXH7KA] (R clutch solenoid output circuit: Disconnection) .................................. 50
Failure code [DXH7KB] (R clutch solenoid output circuit: Short circuit)...................................... 52
Failure code [DXH7KY] (R clutch solenoid output circuit: Short circuit to power source line)..... 54
Failure code [DXHHKA] (4th clutch solenoid output circuit: Disconnection) ............................... 58
Failure code [DXHHKB] (4th clutch solenoid output circuit: Short circuit) ................................... 60
Failure code [DXHHKY] (4th clutch solenoid output circuit: Short circuit to power source line).. 62
Troubleshooting of electrical system (E-mode) SEN01192-01
Before troubleshooting of electric system ................................................................................... 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 sound............................................................................................... 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
Troubleshooting of hydraulic and mechanical system (H-mode) SEN01193-01
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) SEN01194-01
Method of using troubleshooting charts ...................................................................................... 4
S-1 Starting performance is poor ................................................................................................ 8
S-2 Engine does not start............................................................................................................ 10
S-3 Engine does not pick up smoothly........................................................................................ 14
S-4 Engine stops during operations ............................................................................................ 15
S-5 Engine does not rotate smoothly .......................................................................................... 16
S-6 Engine lacks output (or lacks power).................................................................................... 17
S-7 Exhaust gas color is black (incomplete combustion)............................................................ 18
S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................... 20
S-9 Oil becomes contaminated quickly ....................................................................................... 21
S-10 Fuel consumption is excessive........................................................................................... 22
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................. 23
S-12 Oil pressure drops .............................................................................................................. 24
HD325-7, HD405-7 11
S-13 Oil level rises (Entry of coolant/fuel) ................................................................................... 26

S-14 Coolant temperature becomes too high (overheating) ....................................................... 28
S-15 Abnormal noise is made ..................................................................................................... 29
S-16 Vibration is excessive ......................................................................................................... 30
50 Disassembly and assembly

General information on disassembly and assembly SEN01954-01
How to read this manual.............................................................................................................. 2
List of adhesives.......................................................................................................................... 4
Special tool list............................................................................................................................. 7
Sketches of special tools............................................................................................................. 10
Removal and installation of engine assembly ............................................................................. 2
Removal and installation of radiator assembly............................................................................ 8
Removal and installation of output shaft assembly ..................................................................... 16
Disassembly and assembly of output shaft assembly ................................................................. 18
Removal and installation of fuel supply pump assembly ............................................................. 21
Removal and installation of fuel injector assembly...................................................................... 25
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
Removal and installation of differential assembly........................................................................ 2
Disassembly and assembly of differential assembly ................................................................... 3
Removal and installation of rear final drive carrier assembly ...................................................... 16
Disassembly and assembly of rear final drive carrier assembly.................................................. 18
Disassembly and assembly of rear final drive assembly............................................................. 20
Disassembly and assembly of front wheel hub assembly ........................................................... 24
Disassembly and assembly of steering cylinder assembly ......................................................... 2
Removal and installation of emergency steering motor pump assembly .................................... 5
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
Removal and installation of front wheel assembly ...................................................................... 2
Removal and installation of rear wheel assembly ....................................................................... 3
Removal and installation of front suspension cylinder assembly ................................................ 5
Disassembly and assembly of front suspension cylinder assembly............................................ 6
Disassembly and assembly of variable damping selector valve Disassembly ............................ 8
Removal and installation of rear suspension cylinder assembly ................................................. 10
12 HD325-7, HD405-7
Disassembly and assembly of rear suspension cylinder assembly ............................................ 11

Disassembly and assembly of hoist cylinder assembly .............................................................. 2
Body SEN01962-01
Removal and installation of body assembly ................................................................................ 2
Disassembly and assembly of operator's seat assembly............................................................ 2
Removal and installation of air conditioner unit assembly .......................................................... 11
Electrical system SEN01964-01
Removal and installation of engine controller assembly ............................................................. 2
Removal and installation of transmission controller assembly .................................................... 3
Removal and installation of retarder controller assembly............................................................ 4
90 Diagrams and drawings

Hydraulic diagrams and drawings SEN00763-03
Power train hydraulic circuit diagram .......................................................................................... 2
Steering and hoist hydraulic circuit diagram
HD325-7 Serial No. 7001 – 7025, 7101 – 7522
HD405-7 Serial No. 3001 – 3035, 7101 – 7522 ...................................................................... 3
HD325-7 Serial No. 7253 –
HD405-7 Serial No. 7253 – ..................................................................................................... 5
Brake hydraulic circuit diagram ................................................................................................... 7
Electrical diagrams and drawings SEN00764-03
Electrical circuit diagram for inside cab (1/5) .............................................................................. 3
Electrical circuit diagram for inside cab (2/5)
HD325-7 Serial No. 7001 – 7025, 7101 – 7161
HD405-7 Serial No. 3001 – 3035, 7101 – 7157 ...................................................................... 5
HD405-7 Serial No. 7158 – ..................................................................................................... 7
HD325-7 Serial No. 7001 – 7025, 7101 – 7161
HD405-7 Serial No. 3001 – 3035, 7101 – 7157 ....................................................................... 9
HD405-7 Serial No. 7158 – ..................................................................................................... 11
Electrical circuit diagram for outside cab (1/3) ............................................................................ 17
Connectors table and arrangement drawing ............................................................................... 23
HD325-7, HD405-7 13
HD325-7, HD405-7 Dump truck

Form No. SEN00744-07
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 09-08 (02)
14 HD325-7, HD405-7
SEN00745-04
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up
00 Index and foreword 1

Foreword and general information
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
HD325-7, HD405-7 1
Safety notice 1
(Rev. 2008/08)
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before weld in g wo rk , al way s wear wel din g
operating the machine. In addition, gloves, apron, shielding goggles, cap and
read this manual and understand its other clothes suited for welding work.
contents before starting the work. 8) Before starting work, warm up your body
1) Before carrying out any greasing or thoroughly to start work under good condi-
repairs, read all the safety labels stuck to tion.
the machine. For the locations of the 9) Avoid continuing work for long hours and
safety labels and detailed explanation of take rests at proper intervals to keep your
precautions, see the Operation and Main- body in good condition. Take rests in
tenance Manual. specified safe places.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always Safety points
keep the tools and parts in their correct
places. Always keep the work area clean 1 Good arrangement
and make sure that there is no dirt, water, 2 Correct work clothes
or oil on the floor. Smoke only in the areas 3 Following work standard
provided for smoking. Never smoke while
working. 4 Making and checking signs
3) When carrying out any operation, always Prohibition of operation and handling by
5
wear safety shoes and helmet. Do not unlicensed workers
wear loose work clothes, or clothes with 6 Safety check before starting work
buttons missing.
Wearing protective goggles
q Always wear safety glasses when hit- 7
(for cleaning or grinding work)
ting parts with a hammer.
q Always wear safety glasses when Wearing shielding goggles and protectors
8
grinding parts with a grinder, etc. (for welding work)
4) When carrying out any operation with 2 or 9 Good physical condition and preparation
more workers, always agree on the oper- Precautions against work which you are
ating procedure before starting. Always 10
not used to or you are used to too much
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, fork-
lift, service car, etc.
2 HD325-7, HD405-7
2. Preparations for work 6) When removing a cover which is under

1) Before adding oil or making any repairs, internal pressure or under pressure from a
park the machine on a hard and level spring, always leave 2 bolts in diagonal
ground, and apply the parking brake and positions. Loosen those bolts gradually
block the wheels or tracks to prevent the and alternately to release the pressure,
machine from moving. and then remove the cover.
2) Before starting work, lower the work 7) When removing components, be careful
equipment (blade, ripper, bucket, etc.) to not to break or damage the electrical wir-
the ground. If this is not possible, insert ing. Damaged wiring may cause electrical
the lock pin or use blocks to prevent the fires.
work equipment from falling. In addition, 8) When removing piping, stop the fuel or oil
be sure to lock all the control levers and from spilling out. If any fuel or oil drips
hang warning signs on them. onto the floor, wipe it up immediately. Fuel
3) When disassembling or assembling, sup- or oil on the floor can cause you to slip
port the machine with blocks, jacks, or and can even start fires.
stands before starting work. 9) As a general rule, do not use gasoline to
4) Remove all mud and oil from the steps or wash parts. Do not use it to clean electri-
other places used to get on and off the cal parts, in particular.
machine. Always use the handrails, lad- 10) Be sure to assemble all parts again in their
ders or steps when getting on or off the original places. Replace any damaged
m a c h i n e . N e v e r j u m p o n o r o ff t h e parts and parts which must not be reused
machine. If it is impossible to use the with new parts. When installing hoses and
handrails, ladders or steps, use a stand to wires, be sure that they will not be dam-
provide safe footing. aged by contact with other parts when the
machine is operated.
3. Precautions during work 11) When installing high pressure hoses,
1) Before disconnecting or removing compo- make sure that they are not twisted. Dam-
nents of the oil, water, or air circuits, first aged tubes are dangerous, so be
release the pressure completely from the extremely careful when installing tubes for
circuit. When removing the oil filler cap, a high pressure circuits. In addition, check
drain plug, or an oil pressure pickup plug, t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
loosen it slowly to prevent the oil from installed.
spurting out. 12) When assembling or installing parts,
2) The coolant and oil in the circuits are hot always tighten them to the specified
when the engine is stopped, so be careful torques. When installing protective parts
not to get scalded. Wait for the oil and such as guards, or parts which vibrate vio-
coolant to cool before carrying out any lently or rotate at high speed, be particu-
work on the oil or water circuits. l a r ly c a r e fu l t o c he c k t h a t t h e y ar e
3) Before starting work, stop the engine. installed correctly.
When working on or around a rotating 13) When aligning 2 holes, never insert your
part, in particular, stop the engine. When fingers or hand. Be careful not to get your
checking the machine without stopping fingers caught in a hole.
the engine (measuring oil pressure, 14) When measuring hydraulic pressure,
revolving speed, temperature, etc.), take check that the measuring tools are cor-
extreme care not to get rolled or caught in rectly assembled.
rotating parts or moving parts. 15) Take care when removing or installing the
4) Before starting work, remove the leads tracks of track-type machines. When
from the battery. Always remove the lead removing the track, the track separates
from the negative (–) terminal first. suddenly, so never let anyone stand at
5) When raising a heavy component (heavier either end of the track.
than 25 kg), use a hoist or crane. Before 16) If the engine is operated for a long time in
starting work, check that the slings (wire a place which is not ventilated well, you
ropes, chains, and hooks) are free from may suffer from gas poisoning. Accord-
damage. Always use slings which have ingly, open the windows and doors to ven-
ample capacity and install them to proper tilate well.
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.
HD325-7, HD405-7 3
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is well seen
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
4 HD325-7, HD405-7
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven- 18 28.6 2.9
tion earth leakage breaker, crane collision 20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
HD325-7, HD405-7 5
8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
6 HD325-7, HD405-7
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
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 dis-
assembly and service.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
HD325-7, HD405-7 7
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 HD325-7, HD405-7
Explanation of terms for maintenance standard 1

The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.
1. Standard size and tolerance

q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
q The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.
Example:
Standard size Tolerance
–0.022
120
–0.126
a The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
HD325-7, HD405-7 9
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the “interference”.
q The range (A – B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the “standard interference”.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value or allow-

able dimension
q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit, it must
be replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value which
the product can be used without causing a
problem is called the “allowable value” or
“allowable dimension”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
10 HD325-7, HD405-7
Handling of electric equipment and hydraulic component 1

To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and
“Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
HD325-7, HD405-7 11
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
12 HD325-7, HD405-7
3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
q When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3] Action to take after removing connec-

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
HD325-7, HD405-7 13
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14 HD325-7, HD405-7
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
HD325-7, HD405-7 15
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oi l a nd wa ter fr om t he c om -
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
16 HD325-7, HD405-7
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
HD325-7, HD405-7 17
Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4. Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
18 HD325-7, HD405-7
5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
HD325-7, HD405-7 19
Handling of connectors newly used for engines 1

a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 95 – 170, 12V140 engines
q 95E-5 q Various temperature sensors
q 107E-1 Example)
q 114E-3 Intake air temperature sensor in
q 125E-5 intake manifold: TIM
q 140E-5 Fuel temperature sensor: TFUEL
q 170E-5 Oil temperature sensor: TOIL
q 12V140E-3 Coolant temperature sensor: TWTR,
etc.
1. Slide lock type Disconnect the connector by pulling lock
(FRAMATOME-3, FRAMATOME-2) (B) (on the wiring harness side) of connec-
q 95 – 170, 12V140 engines tor (2) outward.
q Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure sensor in intake
manifold: PIM
(125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing:
NE (95 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
20 HD325-7, HD405-7
3. Push lock type

q 95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107, 114 engines

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3) While pressing lock (D), pull out connector

(4) in the direction of the arrow.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
HD325-7, HD405-7 21
q 95, 125 – 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it “clicks”.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 HD325-7, HD405-7
How to read electric wire code 1

a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
HD325-7, HD405-7 23
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
24 HD325-7, HD405-7
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
HD325-7, HD405-7 25
Precautions when carrying out operation 1

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work

q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234
2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
26 HD325-7, HD405-7
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, “Bleeding air”.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
HD325-7, HD405-7 27
4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly
and assembly”.
28 HD325-7, HD405-7
Method of disassembling and connecting push-pull type coupler 1

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
HD325-7, HD405-7 29
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
30 HD325-7, HD405-7
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
HD325-7, HD405-7 31
Standard tightening torque table 1

1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below.
a The following table applies to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 157 – 196 16 – 20
16 24 245 – 309 25 – 31.5
18 27 343 – 427 35 – 43.5
20 30 490 – 608 50 – 62
22 32 662 – 829 67.5 – 84.5
24 36 824 – 1,030 84 – 105
27 41 1,180 – 1,470 120 – 150
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table applies to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
32 HD325-7, HD405-7
2. Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. Table of tightening torques for O-ring boss piping joints

a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Thread diameter Width across flats Tightening torque Nm {kgm}

Nominal No.
mm mm Range Target
02 14 35 – 63 { 3.5 – 6.5} 44 { 4.5}
03,04 20 Varies depending 84 – 132 { 8.5 – 13.5} 103 {10.5}
05,06 24 on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
HD325-7, HD405-7 33
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. –
No. of across Thread
Thread size Number of
hose flats Range Target diameter (mm)
(mm) threads, type of
(Reference)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torques for face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to
be used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Outer Width Tightening torque Nm {kgm} Face seal

diameter across Nominal No. – Thread diameter
of pipe flats Range Target Number of threads, (mm)
(mm) (mm) type of thread (Reference)
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16-16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1-14UN 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 1-3/16-12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
34 HD325-7, HD405-7
8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
HD325-7, HD405-7 35
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
36 HD325-7, HD405-7
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
HD325-7, HD405-7 37
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
38 HD325-7, HD405-7
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
HD325-7, HD405-7 39
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
40 HD325-7, HD405-7
HD325-7, HD405-7 41

© 2008 KOMATSU
All Rights Reserved
42 HD325-7, HD405-7
SEN00747-02
DUMP TRUCK
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up
01 Specification 1
Specification and technical data
Specification drawing ...................................................................................................................................... 2
Specifications .................................................................................................................................................. 4
Weight table .................................................................................................................................................. 10
Fuel, coolant and lubricants ...........................................................................................................................11
HD325-7, HD405-7 1
SEN00747-02 01 Specification
Specification drawing 1
HD325-7
HD405-7
2 HD325-7, HD405-7
q For EU
HD325-7
HD405-7
HD325-7, HD405-7 3
Specifications 1
Machine model HD325-7
Serial numbers 7001 – 7025, 7101 and up
Standard For EU
Unloaded kg 31,600 32,400

Maximum load kg 32,000 32,000
Weight
Overall weight kg 63,680 64,480
Unloaded (front) kg 16,335 (51.7 %) 17,105 (52.8 %)

Weight distribu- (rear) kg 15,265 (48.3 %) 15,295 (47.2 %)
tion Fully loaded (front) kg 21,020 (33 %) 21,990 (34.1 %)
(rear) kg 42,660 (67 %) 42,490 (65.9 %)
Dump body Struck m³ 18 18
capacity Heaped (2:1) m³ 24 24
Performance
Maximum travel speed (power mode) km/h 70 70

Gradeability (sin ) When empty % 35 35
When loaded % 45 45
Minimum turning radius m 7.2 7.2
Dumping angle (angle to ground) degrees 48 48
Overall length mm 8,465 8,800

Overall width mm 3,660 3,660
Overall height mm 4,150 4,150
Dimensions
Wheel base mm 3,750 3,750
Front wheel mm 3,150 3,150

Tread
Rear wheel mm 2,550 2,550
Minimum ground clearance mm 500 500

Model KOMATSU SAA6D140E-5
4-cycle, water-cooled, in-line 6-cylinder,

Type direct injection, with turbocharger, after-
cooler and EGR • CRI
Engine
No. of cylinders – Bore × stroke mm 6 – 140 × 165

Piston displacement l {cc} 15.2 {15,200}
Flywheel horsepower kW/rpm {HP/rpm} 386/2,000 {517.6/2,000}
Maximum torque Nm/rpm {kgm/rpm} 2,166/1,400 {221/1,400}
Fuel consumption (Rated) g/kWh {g/HPh} 212 {156}
Stating motor 24 V, 11 kW × 1 unit
Alternator 24 V, 50 A
Battery 12 V, 170 Ah × 2 units
4 HD325-7, HD405-7

Standard For EU
Torque converter Structure 3-element, 1-stage, 2-phase

Lock-up clutch Hydraulically actuated, wet-type, single-disc
clutch
TORQFLOW planetary gear
Power train
Type Fully automatic, electrically-hydraulically

Transmission
actuated, force-feed type pump
No. of speeds F7, R1
Type Spiral bevel gear, splash lubrication

Reduction gear Reduction ratio 3.125
Differential type Straight bevel gear, splash lubrication
Type Planetary gear, splash lubrication
Final drive
Reduction ratio 4.737
Steering
system
Type Fully hydraulic

Suspension
Axle type Front axle Independent suspension (Mac Pherson type)

Rear axle Axle type
Suspension Front axle Hydropneumatic type
method Rear axle Hydropneumatic type
Size and No. Front tire 18.00 – 33-32PR × 2

Tires
Rear tire 18.00 – 33-32PR × 4

Tire pressure Front and rear tire kPa {kg/cm²} 560 {5.75}
Single dry disc type
Front wheel
Fully hydraulic
Main brake
Brake system
Wet-type multiple disc

Rear wheel
Fully hydraulic

Parking brake
Hydraulically released spring type
Retarder Oil cooled multiple disc type
HD325-7, HD405-7 5

For work equipment and Standard For EU

steering
Type Gear pump
Discharge amount l/min 255.0
Hydraulic pump
(When engine is at rated speed

of 2,000 rpm)
For power train charge
Hydraulic system
Type Gear pump

For retarder cooling
Type Gear pump
Hoist cylinder
Type 2-stage piston type
(only 2nd stage: double-acting)
Cylinder
No. – bore (1st – 2nd) × stroke 2 – (140 mm – 120 mm) × 1,494 mm

Steering cylinder
Type Piston type, double acting
No. – bore × stroke 2 – 75 mm × 377 mm
6 HD325-7, HD405-7

Standard For EU
Unloaded kg 34,400 34,900

Maximum load kg 40,000 40,000
Weight
Overall weight kg 74,480 74,980
Unloaded (front) kg 17,440 (50.7 %) 18,150 (52.0 %)

Weight distribu- (rear) kg 16,960 (49.3 %) 16,750 (48.0 %)
tion Fully loaded (front) kg 24,430 (32.8 %) 25,120 (33.5 %)
(rear) kg 50,050 (67.2 %) 49,860 (66.5 %)
Dump body Struck m³ 20 20
capacity Heaped (2:1) m³ 27.3 27.3
Performance
Maximum travel speed (power mode) km/h 70 70

Gradeability (sin ) When empty % 35 35
When loaded % 45 45
Minimum turning radius m 7.2 7.2
Dumping angle (angle to ground) degrees 48 48
Overall length mm 8,465 8,800

Overall width mm 3,660 3,660
Overall height mm 4,150 4,150
Dimensions
Wheel base mm 3,750 3,750
Front wheel mm 3,150 3,150

Tread
Rear wheel mm 2,550 2,550
Minimum ground clearance mm 500 500
Model KOMATSU SAA6D140E-5
4-cycle, water-cooled, in-line 6-cylinder,

Type direct injection, with turbocharger, after-
cooler and EGR • CRI
Engine
No. of cylinders – Bore × stroke mm 6 – 140 × 165

Piston displacement l {cc} 15.2 {15,200}
Flywheel horsepower kW/rpm {HP/rpm} 386/2,000 {517.6/2,000}
Maximum torque Nm/rpm {kgm/rpm} 2,166/1,400 {221/1,400}
Fuel consumption (Rated) g/kWh {g/HPh} 212 {156}
Stating motor 24 V, 11 kW × 1 unit
Alternator 24 V, 50 A
Battery 12 V, 170 Ah × 2 units
HD325-7, HD405-7 7

Standard For EU
Torque converter Structure 3-element, 1-stage, 2-phase

Lock-up clutch Hydraulically actuated, wet-type, single-disc
clutch
TORQFLOW planetary gear
Power train
Type Fully automatic, electrically-hydraulically

Transmission
actuated, force-feed type pump
No. of speeds F7, R1
Type Spiral bevel gear, splash lubrication

Reduction gear Reduction ratio 3.125
Differential type Straight bevel gear, splash lubrication
Type Planetary gear, splash lubrication
Final drive
Reduction ratio 4.737
Steering
system
Type Fully hydraulic

Suspension
Axle type Front axle Independent suspension (Mac Pherson type)

Rear axle Axle type
Suspension Front axle Hydropneumatic type
method Rear axle Hydropneumatic type
Size and No. Front tire 18.00 R33 × 2

Tires
Rear tire 18.00 R33 × 4

Tire pressure Front and rear tire kPa {kg/cm²} 690 {7.0}
Front wheel
Fully hydraulic
Main brake
Brake system
Wet-type multiple disc

Rear wheel
Fully hydraulic

Parking brake
Hydraulically released spring type
Retarder Oil cooled multiple disc type
8 HD325-7, HD405-7

For work equipment and Standard For EU

steering
Type Gear pump
Hydraulic pump
(When engine is at rated speed

of 2,000 rpm)
For power train charge
Hydraulic system
Type Gear pump

For retarder cooling
Type Gear pump
Hoist cylinder
Type 2-stage piston type
(only 2nd stage: double-acting)
Cylinder
No. – bore (1st – 2nd) × stroke 2 – (140 mm – 120 mm) × 1,494 mm

Steering cylinder
Type Piston type, double acting
No. – bore × stroke 2 – 75 mm × 377 mm
HD325-7, HD405-7 9
Weight table 1
Unit: kg
Machine model HD325-7 HD405-7

Serial Number 7001 – 7025, 7101 and up 3001 – 3035, 7101 and up
Standard For EU Standard For EU
Engine assembly 1,300 1,300
Output shaft assembly 90 90
Coolong assembly 60 60
Radiator assembly 470 470
Fuel tank (individual part) 130 130
Torque converter assembly 390 390
Transmission assembly 1,000 1,000
Drive shaft assembly (front) 25 25
Drive shaft assembly (rear) 65 65
Rear axle assembly 3,850 3,850
• Differential 650 650
• Rear axle housing 1,050 1,050
• Final drive (one-side) 700 × 2 700 × 2
• Rear brake (one-side) 380 × 2 380 × 2
• Parking brake 100 100
Front axle assembly 750 750
• Front axle (one-side) 230 × 2 230 × 2
• Front brake (one-side) 150 × 2 150 × 2
Front suspension cylinder (one-side) 290 × 2 290 × 2
Front suspension cylinder (one-side) (For auto suspension) 300 × 2 300 × 2
Rear suspension cylinder 110 × 2 110 × 2
Frame assembly (cab rear support) 3,750 3,750
Cab (platform and interior components) 1,340 1,340
Operator's seat 45 45
Steering cylinder (one-side) 35 × 2 35 × 2
Hoist cylinder (one-side) 140 × 2 140 × 2
Steering control valve 30 30
Hoist valve 35 35
Hydraulic pump (SDR(30)63+50+SB(1)6) 35 35
Hydraulic pump (SDR(30)63+63) 35 35
Hydraulic pump (SAR(3)80+(1)18) 25 25
Body assembly 8,000 10,100
10 HD325-7, HD405-7
Fuel, coolant and lubricants 1

a Regarding the details of notes (note1, note 2, ...), refer to "Operation and Maintenance Manual".
q SAE:Society of Automotive Engineers

q ASTM:American Society of Testing and Material
a SAE10W30DH and SAE15W40DH are specified as the engine oil for the engine oil pan. SAE10W30
(API CH4, CI-4) and SAE15W40 (API CH4, CI-4) may be used respectively in place of SAE10W30DH
and SAE15W40DH.
HD325-7, HD405-7 11
Reservoir Transmission
Front Rear
case
Engine oil pan Hydraulic tank suspension suspension
(Including brake
(each) (each)
Capacity sub tank)
Liters 58 211 165 13.8 8.3
Specified
US gal 15.32 55.78 43.56 3.64 2.19
Liters 50 90 129 – –
Refill
US gal 13.21 23.78 34.06 – –
Reservoir
Final drive case
Differential case Fuel tank Cooling system
(each)
Capacity
Liters 50 15 500 138
Specified
US gal 13.2 3.96 132.1 36.46
Liters 45 15 – 134
Refill
US gal 11.88 3.96 – 35.40
12 HD325-7, HD405-7
HD325-7, HD405-7 13

© 2007 KOMATSU
All Rights Reserved
14 HD325-7, HD405-7
SEN00749-02
DUMP TRUCK
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up
10 Structure, function and

maintenance standard 1
Engine and cooling system
Radiator, oil cooler, aftercooler ....................................................................................................................... 2
Output shaft .................................................................................................................................................... 4
HD325-7, HD405-7 1
SEN00749-02 10 Structure, function and maintenance standard
Radiator, oil cooler, aftercooler 1
2 HD325-7, HD405-7
1. Pick-up for radiator coolant level sensor Specifications

2. Upper tank Radiator
3. Core Core type: 4 aluminum louvers
4. Oil cooler Total radiation surface: 119.64 m²
5. Reservoir tank
6. Aftercooler Oil cooler
7. Air condition condenser Core type : PTO-LS
Radiation surface : 7.48 m²
A: Coolant inlet port (From engine)
B: Aftercooler inlet port (From turbocharger) Aftercooler
C: Aftercooler outlet port (To engine air intake) Total radiation surface: 34.50 m²
D: Coolant bypass inlet port (For engine)
E: Coolant outlet port (To water pump)
F: Oil inlet port (From rear brake)
G: Oil outlet port (To transmission)
HD325-7, HD405-7 3
Output shaft 1
1. Rubber cushion (large) FUNCTION

2. Rubber cushion (small) q The output shaft is installed to the engine fly-
3. Outer body wheel, and absorbs the torsional vibration
4. Flange caused by changes in the engine torque.
5. Breather
6. Bearing
7. Shaft
8. Coupling
9. Inner body
10. Cover
4 HD325-7, HD405-7
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between flywheel size Shaft Hole clearance limit
11
and bearing 0 0 0.013 –
80 0.02
– 0.013 – 0.030 – 0.030
Clearance between shaft and – 0.009 0 0.025 – Replace
12 40 0.10
bearing – 0.025 – 0.012 – 0.003
Clearance between bearing + 0.170 0.006 0.009 –
13 120 0.09
and cover + 0.080 – 0.028 – 0.028
Clearance between bearing + 0.012 0 0.007 –
14 65 0.025
and shaft – 0.007 – 0.015 – 0.027
Standard size Repair limit
Wear of oil seal contact Repair or
15 0
surface of coupling 95 94.7 replace
– 0.087
Standard backlash Backlash limit
16 Backlash at spline
0.099 – 0.202 0.4
Standard backlash
Original dimension: Lo
Defomation (Dimension at smallest width: L) Replace
of rubber Rubber (large) 85 76
17 cushion
Rubber (small) 58 52
External No cracks
HD325-7, HD405-7 5

© 2007 KOMATSU
All Rights Reserved
6 HD325-7, HD405-7
SEN00750-02
DUMP TRUCK
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up

Power train, Part 1
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
HD325-7, HD405-7 1
Power train skeleton 1
2 HD325-7, HD405-7
1. Engine
2. Output shaft
3. Front drive shaft
4. Retarder cooling pump (SDR (30) 63 +63)
5. Power train, charge pump (SAR (3) 80 + (1) 18)
6. PTO
7. Torque converter
8. Transmission
9. Rear drive shaft
10. Differential gear
11. Drive shaft
12. Rear brake
13. Rear tire
14. Final drive (rear)
15. Parking brake
16. Work equipment and steering pump
(SDR (30) 63 + 50 + SB (1) 6)
HD325-7, HD405-7 3
Drive shaft 1
1. Output shaft
2. Front drive shaft
3. Torque converter
4. Transmission
5. Rear drive shaft
6. Differential
4 HD325-7, HD405-7
Torque converter and transmission hydraulic piping 1
1. Retarder cooling pump (SDR (30) 63 + 63) 5. Transmission

2. Torque converter 6. Power train, charge pump (SAR (3) 80 + (1) 18)
3. Transmission valve 7. Oil cooler (radiator in built)
4. Hydraulic tank
HD325-7, HD405-7 5
Power train charge pump 1

SAR (3) 80 + (1) 18
Unit: mm
Model Standard clearance Clearance limit
1 Side clearance SAR(3)-80
0.10 – 0.15 0.19
SAR(1)-18
Clearance between inside SAR(3)-80
diameter of plain bearing and
2 0.06 – 0.149 0.20 Replace
outside of diameter of gear
SAR(1)-18
shaft
Model Standard size Tolerance Repair limit
3 Depth for knocking in pin SAR(3)-80 14 0
–
SAR(1)-18 10 –0.5
4 Rotating torque of spline shaft 8.8 – 16.7 Nm {0.9 – 1.7 kgm}
Delivery Standard
Rotating Delivery
pressure delivery
Model speed amount limit
{MPa amount
Discharge amount (rpm) (l/min)
(kg/cm2)} (l/min) –
– Oil: EO10-CD
20.6
Oil temperature: 45 – 55 °C SAR(3)-80 184.0 170.0
{210}
2,500
24.5
SAR(1)-18 40.5 36.3
{250}
6 HD325-7, HD405-7
Retarder cooling pump 1

SDR (30) 63 + 63
Unit: mm
1 Side clearance SDR(30)-63
0.16 – 0.20 0.24
SDR(30)-63
Clearance between inside SDR(30)-63
diameter of plain bearing and
2 0.06 – 0.131 0.20 Replace
SDR(30)-63
shaft
3 Depth for knocking in pin SDR(30)-63 0
10 –
SDR(30)-63 –0.5
Delivery Standard
Rotating Delivery
pressure delivery
Discharge amount Model speed amount limit
{MPa amount –
– Oil: EO10-CD (rpm) (l/min)
(kg/cm2)} (l/min)
Oil temperature: 45 – 55 °C
SDR(30)-63 20.6
2,500 145.8 134.7
SDR(30)-63 {210}
HD325-7, HD405-7 7
Torque converter 1
A: Main oil pressure pickup port Specifications

B: Torque converter oil inlet port Type : 3-elements, 1-stage, 2-phases
C: Torque converter inlet oil pressure pickup port wi th m odul ati on and loc ku p
D: Torque converter oil outlet port clutch
E: To transmission control valve Lockup clutch : wet type single-disc clutch hy-
F: To lockup clutch draulic control (with modulation
G: Torque converter outlet oil pressure pickup port valve)
H: To transmission lubrication circuit Stall torque ratio : 2.63
1. PTO gear (number of teeth: 43)

2. Retarder cooling pump mounting port
3. Work equipment and steering pump mounting
port
4. Power train charge pump mounting port
5. Torque converter valve
6. Torque converter intermediate oil pressure sen-
sor
7. Torque converter outlet oil temperature sensor
8 HD325-7, HD405-7
1. Coupling 10. Stator shaft

2. Input shaft (number of teeth: 51) 11. Sleeve
3. Case 12. Inner race
4. Drive case 13. Free wheel
5. Boss 14. Stator
6. Turbine 15. Lockup clutch disc
7. Outer race 16. Lockup clutch piston
8. Pump 17. Lockup clutch housing
9. Retainer 18. Retainer
HD325-7, HD405-7 9
10 HD325-7, HD405-7
Unit: mm
Standard size Tolerance Repair limit
Outer diameter of oil seal
1 0
contact surface of the coupling 95 94.8
–0.087
Inner diameter of the seal ring
+0.025
2 contact surface of the input 35 35.1
0
shaft
Clearance between clutch size Shaft Hole clearance limit
3
housing and piston (outside) –0.5 +0.097 0.500 –
420 0.88
–0.7 0 0.797
Clearance between clutch –0.110 +0.081 0.110 –
4 295 0.30
housing and piston (inside) –0.191 0 0.272
Inner diameter of the seal ring +0.040
5 135 135.5
contact surface of the retainer 0
Inner diameter of the seal ring +0.030
6 75 75.1
contact surface of the sleeve 0
0
Width 3.95 3.55
Wear of the stator –0.1
7
shaft seal ring Thick- Replace
5.1 ±0.1 4.59
ness
Inner diameter of outer race
8 127.844 ±0.013 127.874
free wheel transmission surface
Outer diameter of inner race
9 108.883 ±0.013 108.853
free wheel transmission surface
Inner diameter of sliding por- +0.015
10 109 109.08
tion of bushing 0
Thickness of sliding portion of 0
11 5 4.5
bushing –0.1
12 Thickness of the clutch disc 5.4 ±0.1 4.8
Backlash between
13 0.26 – 0.56
input shaft and PTO gear
Clearance between PTO gear size Shaft Hole clearance limit
14
and bearing +0.018 0 –0.030 –
50 —
+0.002 – 0.012 –0.002
Clearance between bearing and 0 +0.004 –0.018 –
15 90 —
case –0.015 –0.018 0.019
HD325-7, HD405-7 11
Power transmitting route
When lockup clutch is “disengaged“ When lockup clutch is “engaged“
Drive case (4) is disconnected from turbine (6) and Drive case (4) is connected to turbine (6) and
lockup torque converter works as an ordinary lockup torque converter is locked up.
torque converter.
The power from engine
The power from engine O
O Coupling (1)
Coupling (1) O
O Input shaft (2), clutch housing (3), drive case (4)
Input shaft (2), clutch housing (3), drive case (4) and pump (5) rotate together
and pump (5) rotate together O
O Lockup clutch (9)
Oil is used as medium O
O Turbine (6) and boss (7)
Turbine (6) and boss (7) O
O Transmission input shaft (8)
Transmission input shaft (8)
12 HD325-7, HD405-7
Oil flow
q The oil flows through the main relief valve and

its pressure is reduced to below the set pres-
sure by the torque converter relief valve. It then
flows into inlet port (A), goes through the oil
passages of stator shaft (1), and flows into
pump (2).
q The oil is given centrifugal force by pump (2)
and flows into turbine (3) to transmit its energy
to turbine (3).
q The oil from turbine (3) is sent to stator (4) and
flows into pump (2) again. However, part of the
oil passes between turbine (3) and stator (4)
and is sent from outlet port (B) to the oil cooler
to be cooled. It is then used to lubricate the
transmission.
HD325-7, HD405-7 13
Torque converter valve 1
Unit: mm
Clearance between the torque size clearance limit
Shaft Hole
1 converter relief valve and the
valve body –0.035 +0.016 0.035 –
32 0.081
–0.045 0 0.061
Clearance between the main –0.035 +0.016 0.035 –
2 32 0.081
relief valve and the valve body –0.045 0 0.061
Installation Installation Installation Replace
Main relief valve Free length Free length
3 length load load
spring
1213.2 N 1153.8 N
118 94.5 114.5
{123.8 kg} {117.6 kg}
Torque converter relief valve 295.0 N 280.0 N
4 144 95.0 139.7
spring {30.1 kg} {28.6 kg}
Poppet spring 32.0 N 30.8 N
5 26 17.0 25.2
(T/C relief and main relief) {3.3 kg} {3.1 kg}
14 HD325-7, HD405-7
Transmission 1
A: Speed sensor (for input shaft speed) 1. Transmission input shaft

B: Speed sensor (for intermediate shaft speed) 2. Transmission control valve
C: Speed sensor (for output shaft speed) 3. Transmission output shaft
D: Lubricating oil temperature sensor 4. Strainer
E: Lubricating oil pressure pickup port 5. Drain valve
F: To pump (suction)
G: To lockup
H: From torque converter (main circuit)
J: From torque converter (lubrication circuit)
K: From oil cooler
L: From torque converter (drain circuit)
M: Retarder relief valve
N: Lubricating oil relief valve
P: To breather
HD325-7, HD405-7 15
16 HD325-7, HD405-7
1. Transmission input shaft Outline

2. H sun gear (number of teeth: 34) q The transmission consists of planetary gear
3. H ring gear (hub) systems and disc clutches and has “7 forward
4. H clutch gear speeds and 1 reverse gear speed“.
5. H planetary pinion (number of teeth: 32) q Among the 7 sets of planetary gear system
6. H Carrier and disc clutches of the transmission, 2
7. L ring gear (hub) clutches are fixed hydraulically with the ECMV
8. L clutch to select 1 rotating direction and gear speed.
9. H ring gear (number of teeth: 98) q The transmission transmits the power received
10. L clutch housing by the transmission input shaft to the output
11. 4th clutch housing shaft while changing the gear speed (forward
12. 4th clutch drum 1st-7th or reverse 1st) by any combination of
13. 4th clutch the H, L, R clutches and 4 speed clutches.
14. 4th ring gear (hub)
15. 3rd planetary pinion (number of teeth: 21)
16. 3rd clutch Number of plates and discs used
17. 3rd ring gear (number of teeth: 91)
Number of
18. 3rd sun gear (number of teeth: 49) Clutch No. Number of discs
plates
19. R clutch
20. R planetary pinion B (number of teeth: 21) H clutch 2 3
21. R sun gear (number of teeth: 39) L clutch 3 4
22. R ring gear (number of teeth: 91) 4th clutch 2 3
23. 2nd clutch
3rd clutch 2 3
24. 2nd ring gear (number of teeth: 90)
25. 2nd planetary pinion (number of teeth: 26) R clutch 4 5
26. 2nd sun gear (number of teeth: 38) 2nd clutch 3 4
27. 2nd and 1st carrier 1st clutch 3 4
28. 1st clutch
29. 1st ring gear (number of teeth: 90)
30. Transmission output shaft Combinations of clutches at respective gear
31. 1st planetary pinion (number of teeth: 33) speeds and reduction ratio
32. 1st clutch piston Reduction
33. 2nd clutch piston Gear speed Operated clutches
ratio
34. Intermediate shaft (1st sun gear number of
Forward 1st
teeth: 24) L x 1st 4.750
speed
35. R clutch piston
36. R planetary pinion A (number of teeth: 21) Forward 2nd
L x 2nd 3.368
speed
37. 3rd and R carrier
38. 4th clutch piston Forward 3rd
H x 2nd 2.501
39. L clutch piston speed
40. H clutch piston Forward 4th
L x 3rd 1.842
41. 3rd clutch piston speed
Forward 5th
H x 3rd 1.367
speed
Forward 6th
L x 4th 1.000
speed
Forward 7th
H x 4th 0.742
speed
Reverse 1st
LxR 4.339
speed
HD325-7, HD405-7 17
18 HD325-7, HD405-7
Unit: mm
Installation Installation Installation
Free length Free length
1 H clutch spring length load load
57.9 N 49.0 N
62.6 42.9 58.8
{5.9 kg} {5.0 kg}
83.7 N 71.2 N
2 3rd clutch spring 54.0 42.0 50.8
{8.5 kg} {7.3 kg}
78.3 N 66.5 N
3 R clutch spring 77.0 66.0 72.4
{8.0 kg} {6.8 kg}
76.9 N 65.3 N
4 2nd clutch spring 58.0 48.0 54.5
{7.8 kg} {6.7 kg}
76.9 N 65.3 N
5 1st clutch spring 58.0 48.0 54.5
{7.8 kg} {6.7 kg}
Total thickness of 3 discs and Standard size Tolerance Repair limit
6
2 plates for H clutch 25.0 ±0.22 24.2
Total thickness of 4 discs and
7 35.0 ±0.26 33.9
3 plates for L clutch
8 25.0 ±0.22 24.2
2 plates for 4th clutch Replace
9 25.0 ±0.22 24.2
2 plates for 3rd clutch
10 45.0 ±0.30 43.7
4 plates for R clutch
11 35.0 ±0.26 33.9
3 plates for 2nd clutch
12 35.0 ±0.26 33.9
3 plates for 1st clutch
13 Thickness of a disc 5.0 ±0.10 4.73
14 Thickness of a plate 5.0 ±0.10 4.8
–0.01
Wear of the Width 2.56 2.30
–0.03
15 transmission input
shaft seal ring (small) Thick-
1.7 ±0.10 1.55
ness
–0.01
–0.03
16 transmission input
shaft seal ring (large) Thick-
3.1 ±0.10 2.95
ness
HD325-7, HD405-7 19
Unit: mm
Wear of the 0
Width 3.95 3.56
17 H carrier and –0.1
4th ring gear seal ring Thick-
4.95 ±0.1 4.46
ness
–0.01
–0.03
18 L and 4th clutch
collar seal ring Thick-
4.9 ±0.12 4.80
ness
–0.01
Width 3.0 2.70
Wear of the 3rd sun –0.03
19
gear seal ring Thick-
4.0 ±0.12 3.85
ness
–0.01
Width 4.0 3.60
Wear of the 3rd and –0.04
20
R carrier seal ring Thick-
4.0 ±0.15 3.85
ness
–0.01
Width 4.0 3.60
Wear of the 2nd and –0.04
21
1st carrier seal ring Thick-
4.0 ±0.15 3.85
ness
Backlash between H sun gear
22 0.13 – 0.36
and planetary pinion
Backlash between H planetary
23 0.15 – 0.39
pinion and ring gear
Backlash between 3rd sun gear Replace
24 0.15 – 0.34
Backlash between 3rd
25 0.17 – 0.39
planetary pinion and ring gear
Backlash between R sun gear
26 0.15 – 0.34
Backlash between R planetary
27 0.14 – 0.31
pinion and planetary pinion
Backlash between R planetary
28 0.17 – 0.39
Backlash between 2nd sun gear
29 0.14 – 0.35
Backlash between 2nd
30 0.15 – 0.38
planetary pinion and ring gear
Backlash between 1st sun gear
31 0.13 – 0.32
Backlash between 1st planetary
32 0.15 – 0.38
Deterioration of disc internal
33 Repair limit: 0.3
teeth
Thickness of thrust washer Standard size Tolerance Repair limit
34
(H planetary pinion) 2 ±0.1 1.6
Thickness of thrust washer
35 2 ±0.1 1.6
(3rd, R planetary pinion)
Thickness of thrust washer
36 2 ±0.1 1.6
(2nd, 1st planetary pinion)
20 HD325-7, HD405-7
Unit: mm
Standard
Location Clearance limit
clearance
H gear
0.30 – 0.80 1.5
train
3rd gear
0.30 – 0.80 1.5 Replacement of
Side clearance train
37 thrust washer
of planetary pinion R gear
0.30 – 0.80 1.5 or carrier
train
2nd gear
0.30 – 0.80 1.5
train
1st gear
0.30 – 0.80 1.5
train
Stepped-type wear of seal ring Standard size Amount of wear
38
mating surface — Max 0.05
Replace
Contact surface of Standard size Amount of wear
39
output shaft oil seal 120 119.8
Clutch Standard Tolerance Standard Clearance
No. size Shaft Hole clearance limit
H –0.5 +0.089 0.5 –
395 0.87
(outside) –0.7 0 0.789
H –0.125 +0.089 0.125 –
375 0.33
(inside) –0.214 0 0.303 In case there is
L and damage on the
–0.5 +0.081 0.5 –
4th 275 0.86 surface such as
–0.7 0 0.781
(outside) streaks by
L and seizure, but the
–0.5 +0.072 0.5 – clearance can be
Clearance between 4th 250 0.85
40 –0.7 0 0.772 maintained within
cylinder and piston (Middle)
the specified limit
L and after the repair,
–0.085 +0.063 0.085 –
4th 170 0.23 the parts can be
–0.148 0 0.211
(inside) reused.
3rd, R, Replace if dam-
2nd –0.5 +0.089 0.5 – aged severely.
375 0.87
and 1st –0.7 0 0.789
(outside)
3rd, R,
2nd –0.125 +0.089 0.125 –
325 0.33
and 1st –0.214 0 0.303
(inside)
HD325-7, HD405-7 21
Disc clutch
Structure Operation
When clutch is “engaged“ (fixed)
q Disc clutch is used for fixing ring gear (1). It q The oil from ECMV is sent with pressure to the
consists of piston (2), plate (3), disc (4), pin (5), rear side of piston (2) through oil the passage
return spring (6) and washer (8). of housing (7) and pushes piston (2) leftward.
q Inside teeth of disc (4) are engaged with out- q Piston (2) contacts plate (3) closely against
side teeth of ring gear (1). disc (4) to stop rotation of disc (4) by use of the
q Plate (3) is assembled to clutch housing (7) friction force generated between them.
with pin (5). q Since inside teeth of disc (4) are engaged with
outside teeth of ring gear (1), move of ring gear
(1) is stopped.
When clutch is “disengaged“ (released)
q As the oil from ECMV is stopped, piston (2) is

pushed back rightward by return spring (6).
q The friction force between plates (3) and discs
(4) is released and ring gear (1) is released.
q Washer spring (8) is installed between plate (3)
of the pin block and plate (3). This spring
quickens return of piston (2) as the clutch is
disengaged by providing smooth separation of
plate (3) and disc (4). At the same time, it is
used for preventing the dragging.
22 HD325-7, HD405-7
Power transmitting route

Forward 1st speed
L clutch (5) and 1st clutch are fixed hydraulically.
The power from torque converter

O
Input shaft (1)
O
H carrier (2)
O
L ring gear (3)
O
L clutch (5)
O
H ring gear (6)
O
L clutch housing (7)
O
Intermediate shaft (8)
O
1st planetary pinion (21)
O
1st, 2nd carrier (22)
O
Output shaft (23)
HD325-7, HD405-7 23
Forward 2nd speed
L clutch (5) and 2nd clutch are fixed hydraulically.

O
Input shaft (1)
O
H carrier (2)
O
L ring gear (3)
O
L clutch (5)
O
H ring gear (6)
O
O
O
2nd sun gear (19)
O
2nd planetary pinion (20)
O
O
Output shaft (23)
24 HD325-7, HD405-7
Forward 3rd speed
H clutch and 2nd clutch are fixed hydraulically.

O
Input shaft (1)
O
H carrier (2)
O
H planetary pinion (4)
O
H ring gear (6)
O
O
O
2nd sun gear (19)
O
2nd planetary pinion (20)
O
O
Output shaft (23)
HD325-7, HD405-7 25
Forward 4th speed
L clutch (5) and 2nd clutch are fixed hydraulically.

O O
Input shaft (1) Intermediate shaft (8) o
O O O
H carrier (2) 3rd sun gear (13)
O O
L ring gear (3) 3rd planetary pinion (14)
O O
L clutch (5) 3rd, R carrier (17)
O O O
H ring gear (6) 2nd sun gear (18) 2nd sun gear (19)
O O
L clutch housing (7) 2nd planetary pinion (20) i i
O
O
Output shaft (23)
26 HD325-7, HD405-7
Forward 5th speed
H clutch and 3rd clutch are fixed hydraulically.

O O
O O O
H carrier (2) 3rd sun gear (13)
O O
H planetary pinion (4) 3rd planetary pinion (14)
O O
H ring gear (6) 3rd, R carrier (17)
O O O
L clutch housing (7) 2nd sun gear (18) 2nd sun gear (19)
O
2nd planetary pinion (20) i i
O
O
Output shaft (23)
HD325-7, HD405-7 27
Forward 6th speed
L clutch (1) and 4th clutch are fixed hydraulically.

O O
O O O
H carrier (2) 4th clutch housing (9)
O O
L ring gear (3) 4th clutch drum (10)
O O
L clutch (5) 4th clutch (11)
O O
H ring gear (6) 4th ring gear (12)
O O
L clutch housing (7) 3rd, R carrier (17)
O O
2nd ring gear (18) 2nd sun gear (19)
O
O
O
Output shaft (23)
28 HD325-7, HD405-7
Forward 7th speed
H clutch and 4th clutch are fixed hydraulically.

O O
O O O
H carrier (2) 4th clutch housing (9)
O O
H planetary pinion (4) 4th clutch drum (10)
O O
H ring gear (6) 4th clutch (11)
O O
L clutch housing (7) 4th ring gear (12)
O
3rd, R carrier (17)
O O
2nd sun gear (18) 2nd sun gear (19)
O
O
O
Output shaft (23)
HD325-7, HD405-7 29
Reverse 1st speed
L clutch (5) and R clutch are fixed hydraulically.

O O
Input shaft (1) Intermediate shaft (8) i i
O O
H carrier (2) R sun gear (15)
O O I
L ring gear (3) R planetary pinion A (16)
O O
L clutch (5) R planetary pinion B (17)
O O
H ring gear (6) 3rd, R carrier (18)
O (R ring gear is fixed with
L clutch housing (7) R clutch = 3rd, R carrier (18) is
rotated reverse to input shaft (1))
O
2nd ring gear (19) 2nd sun gear (20)
O I
2nd planetary pinion (21) o
O
O
Output shaft (24)
30 HD325-7, HD405-7
Transmission control valve 1
A: H clutch oil pressure pickup port Operation table of ECMV

B: Lockup clutch oil pressure pickup port ECMV
C: L clutch oil pressure pickup port
L H 1st 2nd 3rd 4th R L/U
D: 4th clutch oil pressure pickup port Gear
speed
E: 3rd clutch oil pressure pickup port
F: R clutch oil pressure pickup port F1 Q Q Q
G: 2nd clutch oil pressure pickup port F2 Q Q Q
H: 1st clutch oil pressure pickup port F3 Q Q Q
J: To breather
F4 Q Q Q
1. H clutch ECMV F5 Q Q Q
2. Lockup clutch ECMV F6 Q Q Q
3. L clutch ECMV F7 Q Q Q
4. 4th clutch ECMV
N
5. 3rd clutch ECMV
6. R clutch ECMV R1 Q Q
7. 2nd clutch ECMV L/U: lockup clutch ECMV
8. 1st clutch ECMV
9. Last chance filter Outline
10. Valve seat q Lockup clutch ECMV operates when traveling
forward at the speed higher than the set speed
of transmission controller.
HD325-7, HD405-7 31
ECMV 1
For H, L, 4th, 3rd, Rev, 2nd and 1st clutches
a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A: To clutch *1: Pressure control valve spool of the unit for H,

P: From pump 3rd, R, 2nd and 1st clutches is different from
T: Drain one for L and 4th clutches.
Dr: Drain
P1: Clutch oil pressure pickup port *2: Nameplate stamp of the unit for H, 3rd, R, 2nd
and 1st clutch is different from one for L and 4th
1. Fill switch connector clutches.
2. Proportional solenoid connector
Stamp of the
3. Flow detection valve Operated clutches
nameplates
4. Fill switch
5. Proportional solenoid H, 1st, 2nd, 3rd, R D*******
6. Pressure control valve (*1) L, 4th Q*******
7. Nameplate (*2)
32 HD325-7, HD405-7
Outline of ECMV ECMV and proportional solenoid

q The ECMV consists of 1 pressure control valve q For each ECMV, 1 proportional solenoid is
and 1 fill switch. installed.
q Pressure control valve The proportional solenoid generates thrust
This valve receives the current sent from the shown below according to the command cur-
transmission controller with a proportional rent from the controller.
solenoid, and then converts it into oil pressure. The thrust generated by the proportional sole-
q Fill switch noid is applied to the pressure control valve
This switch detects that the clutch is filled with spool to generate oil pressure as shown in the
oil and has the following functions. figure below. Accordingly, the thrust is changed
1. Outputs a signal (a fill signal) to the controller by controlling the command current to operate
to notify that filling is completed when the the pressure control valve to control the flow
clutch is filled with oil. and pressure of the oil.
2. Keeps outputting signals (fill signals) to the
controller to notify whether oil pressure is Current – propulsion force characteristics of
applied or not while oil pressure is applied to proportional solenoid
the clutch.
Propulsion force – Hydraulic pressure charac-

teristics of proportional solenoid
Range A: Before shifting gear (When draining)

Range B: During filling
ECMV and fill switch
Range C: Pressure regulation
Range D: During filling (During triggering) q For each ECMV, 1 fill switch is installed.
Point E: Start of filling If the clutch is filled with oil, the fill switch is
Point F: Finish of filling turned “ON“ by the pressure of the clutch. The
oil pressure is built up according to this signal.
a The logic is so made that the controller will not
recognize completion of filling even if the fill
switch is turned “ON“ during triggering (Range
D).
HD325-7, HD405-7 33
Operation of ECMV Before shifting gear (when draining) (Range A

q ECMV is controlled with the command current in chart)
sent from the controller to the proportional
solenoid and the fill switch output signal.
The relationship between the proportional
solenoid command current of ECMV, clutch
input pressure, and fill switch output signal is
shown below.
q While no current is flowing in proportional sole-

noid (1), pressure control valve (3) drains the
oil from clutch port (A) through drain port (T).
At this time, since no oil pressure is applied to
flow rate pickup valve (4), fill switch (5) is
turned “OFF“.
Range A: Before shifting gear (When draining)
Range B: During filling
Range C: Pressure regulation
Range D: During filling (During triggering)
Point E: Start of filling
Point F: Finish of filling
a The logic is so made that the controller will not

recognize completion of filling even if the fill
switch is turned “ON“ during triggering (Range
D).
34 HD325-7, HD405-7
During filling (Range B in chart) Pressure regulation (Range C in chart)
q If a current is given to proportional solenoid (1) q If current flows in proportional solenoid (1), the
while there is no oil in the clutch, a hydraulic solenoid generates thrust in proportion to the
force balanced with the solenoid force is current. This thrust of the solenoid is balanced
applied to chamber (B) and it pushes pressure with the sum of the thrust generated by the oil
control valve (3) to the left. This conducts oil pressure in clutch port and the tension of pres-
through pump port (P) and orifice (a) of flow sure control valve spring (2), and then the
rate pickup valve (4) to start filling the oil to the pressure is settled.
clutch chamber. At this time, differential pres-
sure is generated between the upper stream
and down stream of orifice (a) of flow rate
pickup valve (4). This differential pressure
pushes flow rate pickup valve (4) leftward.
As the clutch chamber is filled up with oil and
oil flow from pump port (P) to clutch port (A) is
stopped, differential pressure before and after
orifice (a) of flow rate pickup valve (4) disap-
pears. As the result, flow rate pickup valve (4)
is pushed rightward, turning “ON“ fill switch (5).
HD325-7, HD405-7 35
For lockup clutch

a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A: To clutch
*1:
P: From pump
T: Drain Stamp of the name-
Operated clutches
Dr: Drain plates
P1: Clutch oil pressure pickup port Lockup K*******
1. Proportional solenoid connector

2. Sleeve
3. Proportional solenoid
4. Pressure control valve
5. Nameplate (*1)
36 HD325-7, HD405-7
Outline Operation
q This valve is used to switch the clutch in order When traveling in torque converter range
to regulate the clutch oil pressure to the set
pressure.
Since the modulation waveform is used for the
pressure application characteristics to the
clutch, ECMV is capable of connecting the
lockup clutch smoothly, thereby reducing
shocks resulting from gear shift. Above also
prevents generation of peak torque in the
power train. These arrangements make the
machine comfortable to operator and enhance
durability of the power train.
When changing from torque converter travel to

direct travel
At gear shift (in direct travel)

q While no current is flowing in to proportional
solenoid (1), pressure control valve (3) drains
the oil from clutch port (A) through drain port
(T).
HD325-7, HD405-7 37
When traveling in direct range

(Torque converter travel o direct travel)
q As current is conducted to proportional sole-

noid (1), the oil pressure being balanced with
the solenoid force is applied to chamber (B),
pushing pressure control valve (3) leftward.
Above opens pump port (P) and clutch port (A)
to start filling oil to the clutch.
q As the clutch is filled with oil, the solenoid
thrust is balanced with the sum of the thrust
generated from oil pressure of the clutch port
and the tension of the pressure control valve
spring (2), and then the pressure is settled.
38 HD325-7, HD405-7
HD325-7, HD405-7 39

© 2007 KOMATSU
All Rights Reserved
40 HD325-7, HD405-7
SEN00853-02
DUMP TRUCK
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up

Power train, Part 2
Axle ................................................................................................................................................................. 2
Differential ....................................................................................................................................................... 4
Final drive ....................................................................................................................................................... 6
Wheel.............................................................................................................................................................. 8
HD325-7, HD405-7 1
Axle 1
Front
1. Cover
2. Retainer
3. Wheel hub
4. Retainer
Unit: mm
Repair or
5 Wear of oil seal sliding surface 0
220 — replace
–0.115
Wear of outside diameter of por- 0
6 130 129.83
tion of shaft inserted into bearing –0.025
Wear of outside diameter of Repair
0
7 portion of shaft inserted into 120 119.86
–0.022
bearing
2 HD325-7, HD405-7
Rear
1. Parking brake Specifications

2. Differential Reduction ratio
3. Axle housing Differential : 3.125
4. Rear brake Final drive : 4.737
5. Final drive
Oil
Differential : TO30 (45 l)
Final drive : TO30 (15 l each side)
Tire size : 18.00-33

Rim size : 13.00 × 33
HD325-7, HD405-7 3
Differential 1
1. Coupling Specifications
2. Cage Type : Spiral bevel gear, splash-type
3. Cage lubrication
4. Case Reduction ratio: 3.125
5. Nut Differential : Spiral bevel gear, splash-type
6. Cap lubrication
7. Differential gear case Oil : TO30 (45 l)
8. Cross shaft
9. Bevel gear (No. of teeth: 50)
10. Differential gear case
11. Side gear (No. of teeth: 24)
12. Washer
13. Pinion gear (No. of teeth: 17)
14. Bevel pinion (No. of teeth: 16)
15. Spacer
16. Collar
17. Holder
4 HD325-7, HD405-7
Unit: mm
Wear of oil seal contact surface Repair or
1 0
of coupling 110 109.9 replace
–0.087
Thickness of side gear thrust 0
2 5 4.5 Replace
washer –0.050
Backlash between bevel gear
3 0.3 – 0.4 Adjust
and pinion
HD325-7, HD405-7 5
Final drive 1
1. Ring gear (No. of teeth: 71) Specifications

2. Cover Type : Planetary gear, splash-type lubrication
3. Sun gear (No. of teeth: 19) Reduction : 4.737
4. Button Oil : TO30 (15 l each side)
5. Planetary gear shaft
6. Planetary gear (No. of teeth: 25)
7. Carrier
8. Spacer
9. Retainer
10. Inner hub
11. Drive shaft
12. Wheel hub
13. Retainer
6 HD325-7, HD405-7
Unit: mm
Backlash between planetary Standard backlash Repair limit
1
gear and sun gear 0.19 – 0.45 0.8
Replace
Backlash between planetary
2 0.21 – 0.65 1.0
gear and ring gear
3 Curvature of drive shaft Repair limit: 1.5 TIR Repair or replace
4 Thickness of spacer Replace
36 ±0.1 35.5
Wear of outside diameter of
–0.015
5 portion of axle tube inserted into 200 199.8
–0.061
bearing
Repair
Wear of outside diameter of
–0.015
6 portion of axle tube inserted into 220 219.8
–0.061
bearing
HD325-7, HD405-7 7
Wheel 1
Front Rear
1. Tire 1. Tire
2. Rim assembly 2. Rim assembly
3. Valve 3. Valve
Specifications
Specifications Rim size : 13.00 × 33
Rim size : 13.00 × 33 Tire size : 18.00-33
Tire size : 18.00-33
8 HD325-7, HD405-7
HD325-7, HD405-7 9

© 2007 KOMATSU
All Rights Reserved
10 HD325-7, HD405-7
SEN00751-02
DUMP TRUCK
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up

Steering system
Steering column .............................................................................................................................................. 2
Steering linkage .............................................................................................................................................. 3
HD325-7, HD405-7 1
Steering column 1
1. Steering wheel Specifications

2. Steering shaft Tilting range : 80 mm
3. Steering column Telescoping range : 50 mm
4. Steeering post
5. Lock lever
6. Yoke
7. Joint shaft
8. Steering valve
2 HD325-7, HD405-7
Steering linkage 1
1. Center lever
2. Tie rod
3. Arm (A-frame)
4. Knuckle arm
HD325-7, HD405-7 3
4 HD325-7, HD405-7
Unit: mm
Inner and outer ring clearances size clearance limit
Shaft Hole
5 between the kcuckle arm and
arm bushing 0.12 –
135 — — 0.7
0.25
Clearance between steering –0.025 +0.039 0.025 –
6 40 0.4
cylinder bushing and pin –0.064 0 0.103
Clearance between the tie rod –0.025 +0.039 0.025 –
7 40 0.4
bushing and pin –0.064 0 0.103
Replace
Clearance between inner and 0.10 –
8 70 — — 0.4
outer rings for bushing 0.20
Clearance between the center –0.025 +0.300 0.025 –
9 55 1.0
lever bushing and pin –0.064 +0.200 0.364
Clearance between arm –0.025 +0.039 0.025 –
10 60 0.6
bushing and pin –0.064 0 0.103
11 — — — 0.6
outer rings for the bushing 0.25
Clearance between pin and lock
12 Clearance must be 0 —
plate
HD325-7, HD405-7 5

© 2007 KOMATSU
All Rights Reserved
6 HD325-7, HD405-7
SEN00752-03
DUMP TRUCK
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up

Brake system
Brake piping .................................................................................................................................................... 2
Brake valve ..................................................................................................................................................... 4
Secondary brake valve ................................................................................................................................... 7
Relay valve ..................................................................................................................................................... 8
Front brake cut valve ...................................................................................................................................... 9
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
HD325-7, HD405-7 1
Brake piping 1
2 HD325-7, HD405-7
1. Front brake OFF valve

2. Relay valve
3. Slack adjuster
4. Secondary brake valve
5. Brake valve
6. Parking brake valve
7. Accumulator charge valve
8. Accumulator (parking brake)
9. Accumulator (rear brake)
10. Accumulator (front brake)
11. Proportional reducing valve (for retarder)
HD325-7, HD405-7 3
Brake valve 1
1. Pilot piston A: To rear brake

2. Rod B: To front brake
3. Lower cylinder T: To brake sub tank
4. Spool PA: From front accumulator
5. Upper cylinder PB:Front rear accumulator
6. Spool
4 HD325-7, HD405-7
Operation Applying brake when upper valve fails

Upper portion q Even if there is leakage of oil in the upper pip-
q When brake pedal (1) is depressed, the oper- ing, spool (5) is moved down mechanically
ating force is transmitted to spool (3) through when pedal (1) is depressed, and the lower
rod (2) and spring (4). When spool (3) goes portion is actuated normally.
down, drain port (a) is closed, and the oil from The upper brake is not actuated.
the pump and accumulator flows from port (A)
to port (C) and actuates the rear brake pistons. Applying brake when lower valve fails
q Even if there is leakage of oil in the lower pip-
Lower portion ing, the upper portion is actuated normally.
q When brake pedal (1) is depressed, the oper-
ating force is transmitted to spool (3) through
rod (2) and spring (4). When spool (3) goes
down, spool (5) is also pushed down by
plunger (6). When this happens, drain port (b)
is closed, and the oil from the pump and accu-
mulator flows from port (B) to port (D) and
actuates the front brake pistons.
When actuation is balanced

Upper portion
q When oil fills the rear brake cylinders and the
pressure between por t ( A) and por t ( C)
becomes high, the oil entering port (H) from
orifice (e) of spool (3) pushes against spring
(4). It pushes up spool (3) and shuts off the cir-
cuit between port (A) and port (C). When this
happens, drain port (a) stays closed, so the oil
entering the brake cylinder is held and the
brake remains applied.
HD325-7, HD405-7 5
Lower portion Brake released

q When spool (3) in the upper portion moves up Upper portion
and the circuit between port (A) and port (C) is q When pedal (1) is released and the operating
shut off, oil also fills the front brake cylinder at force is removed from the top of the spool, the
the same time, so the pressure in the circuit back pressure from the brake cylinder and the
between port (B) and port (D) rises. The oil force of the spool return spring move spool (3)
entering port (J) from orifice (f) of spool (5) up. Drain port (a) is opened and the oil from
pushes up spool (5) by the same amount that the rear brake cylinder flows to the transmis-
spool (3) moves, and shuts off port (B) and port sion oil pan return circuit to release the rear
(D). Drain port (b) is closed, so the oil entering brakes.
the brake cylinder is held, and the brake is
applied. Lower portion
q The pressure in the space in the upper portion q When the pedal is released, spool (3) in the
is balanced with the operating force of the upper portion moves up. At the same time, the
pedal, and the pressure in the space in the back pressure from the brake cylinder and the
lower portion is balanced with the pressure in force of the spool return spring move spool (5)
the space in the upper portion. When spools up. Drain port (b) is opened and the oil from
(3) and (5) move to the end of their stroke, the the front brake cylinder flows to the transmis-
circuits between ports (A) and (C) and between sion oil pan return circuit to release the front
ports (B) and (D) are fully opened, so the pres- brake.
sure in the space in the upper and lower por-
tions and the pressure in the left and right
brake cylinders is the same as the pressure
from the pump.
Therefore, up to the point where the piston
moves to the end of its stroke, the effect of the
brake can be adjusted by the amount that the
pedal is depressed.
6 HD325-7, HD405-7
Secondary brake valve 1
1. Rod Function
2. Spool q If the pedal is pressed, the parking brake
3. Lower cylinder release pressure and tandem relay valve actu-
4. Upper cylinder ating pressure lower to operate the parking
brake and tandem relay valve according to the
A: To parking brake valve and tandem relay valve pedal pressing ratio.
P: From accumulator
T: To brake sub tank
HD325-7, HD405-7 7
Relay valve 1
1. Spool Function
2. Upper cylinder q This valve operates the front and rear brake
3. Spool depending on the parking brake release pres-
4. Lower cylinder sure controlled by the secondary brake pedal.
PP:From secondary brake valve

PA: From rear accumulator
PB:From front accumulator
A: To rear brake
B: To front brake
8 HD325-7, HD405-7
Front brake cut valve 1
1. Connector Function
2. Solenoid q This valve is installed on the brake oil circuit
between the brake valve and the front brake.
A: To front brake When the front brake off switch of the opera-
P: From brake valve tor's seat is pressed, the solenoid is energized,
T: To brake sub tank and the valve cuts off the circuit between the
brake valve and the front brake.
Thus, the front brakes are not applied.
HD325-7, HD405-7 9
Accumulator charge valve 1
ACC: To accumulator Specification

P: From hydraulic pump q Cut in pressure: 14.2 MPa {145 kg/cm²}
PP: From accumulator q Cut out pressure: 20.6 MPa {210 kg/cm²}
H1: Relief valve Function
R1: Relief valve q The accumulator charge valve is actuated to
R3: Main relief valve maintain the oil pressure from the pump at the
specified pressure and to store it in the accu-
mulator.
q When the oil pressure reaches the specified
pressure, the oil from the pump is connected to
the drain circuit to reduce the load of the pump.
10 HD325-7, HD405-7
1. Main relief valve (R3) 4. Relief valve (H1)

2. Valve body 5. Filter
3. Relief valve (R1) 6. Filter
HD325-7, HD405-7 11
Operation
1. When no oil is supplied to accumulator 2. When oil is supplied to accumulator
(cut-out condition) 1) Cut-in condition
q The pressure at port (B) is higher than the set q When the pressure at port (B) is lower than the
pressure of the relief valve (R1), so piston (8) set pressure of the relief valve (R1), piston (8)
is forcibly pushed up by the oil pressure at port is pushed back down by spring (5).
(B). Poppet (6) is opened, so port (C) and port Valve seat (7) and poppet (6) are brought into
(T) are short circuited. tight contact, and port (C) and port (T) are shut
q The spring chamber at the right end of spool off.
(15) is connected to port (C) of the relief valve q The spring chamber at the right end of spool
(R1), so the pressure becomes the tank pres- (15) is also shut off from port (T), so the pres-
sure. The oil from the pump enters port (P), sure rises, and the pressure at port (P) also
pushes spool (15) to the right at a low pressure rises in the same way.
equivalent to the load on spring (14). q When the pressure at port (P) goes above the
It also passes through orifices (17), (18) and pressure at port (B) (accumulator pressure),
(16), and flows to the tank. the supply of oil to the accumulator starts
immediately. In this case, it is decided by the
size (area) of orifice (17) and the pressure dif-
ference (equivalent to the load on spring (14))
generated on both sides of the orifice. (A) fixed
amount is supplied regardless of the engine
speed.
12 HD325-7, HD405-7
2) When cut-out pressure is reached 3. Main relief valve (R3)

q When the pressure at port (B) (accumulator q If the pressure at port (P) (pump pressure)
pressure) reaches the set pressure of the relief goes above the set pressure of the relief valve
valve (R1), poppet (6) separates from valve (R3), the oil from the pump pushes spring (3).
seat (7), so an oil flow is generated and the cir- Ball (11) is pushed up and the oil flows to the
cuit is relieved. tank circuit, so this sets the maximum pressure
q When the circuit is relieved, a pressure differ- in the brake circuit and protects the circuit.
ence is generated above and below piston (8),
so piston (8) moves up, poppet (6) is forcibly
opened, and port (C) and port (T) are short cir-
cuited.
q The spring chamber at the right end of spool
(15) is connected to port (C) of the relief valve
(R1), so the pressure becomes the tank pres-
sure.
q The pressure at port (P) drops in the same way
to a pressure equivalent to the load on spring
(14), so the supply of oil to port (B) is stopped.
HD325-7, HD405-7 13
Accumulator 1
1. Valve
2. Top cover
3. Cylinder
4. Piston
Function
q The accumulator is installed between the accu-
mulator charge valve and the brake valve. It is
charged with nitrogen gas between cylinder (3)
and free piston (4), and uses the compressibil-
ity of the gas to absorb the pulse of the hydrau-
lic pump.
If the engine stops, pressure is not supplied by
the hydraulic pump. In this case, the accumu-
lator pressure is used to secure the braking
force.
Specifications
Front brake
Gas used : Nitrogen gas
Charge amount : 3,000 cc
Charging pressure : 11.8 MPa {120 kg/cm²}
Rear brake, Parking brake

Gas used : Nitrogen gas
Charge amount : 4,000 cc
Charging pressure : 6.9 MPa {70 kg/cm²}
14 HD325-7, HD405-7
HD325-7, HD405-7 15
Slack adjuster 1
1. Cylinder A: Inlet port

2. Check valve B: Outlet port
3. Piston
Unit: mm
Clearance between body and size Shaft Hole clearance limit
4
piston –0.030 +0.074 0.030 –
80 0.25
–0.076 0 0.150
Standard size Repair limit Replace
Spring Installed Installed Installed
Free length
5 Slack adjuster spring coefficient length load load
0.745 N/mm 118 N
88 — —
{0.076 kg/mm} {12 kg}
16 HD325-7, HD405-7
Specifications q If the brake pedal is depressed further, and the

Effective area: 50.3 cm² oil pressure discharged from the brake valve
Delivery: 115.6 cc (one side) goes above to set pressure, check valve (3)
Service pressure: 5.2 MPa {53 kg/cm²} opens and the pressure is applied to port (C) to
Stroke: 36.5 mm act as the braking force.
Check valve cracking pressure: 0.93 ± 0.15 MPa Therefore, when the brake is applied, opera-
{9.5 ± 1.5 kg/cm²} tion time lag of right and left brakes is a fixed
Check valve closing pressure: 0.59 ± 0.05 MPa value.
{6.0 ± 0.5 kg/cm²}
Function
q The slack adjuster is installed in the brake oil
line from the brake valve to the brake piston. It
acts to keep a constant operation time lag of
right and left brakes when the brake is oper-
ated.
Operation
1. When brake pedal is depressed
q Before the brake is depressed, piston (4) is
returned by the distance of stoke (S) (full
stroke). When the brake pedal is depressed, 2. When brake pedal is released
the oil discharged from the brake valve flows q When the brake is released, piston (4) is
from port (P) of the slack adjuster and is returned by brake return spring (8) by an
divided to left and right cylinders (2), where it amount equivalent to the oil for the stroke (S),
moves piston (4) by stroke (S) to the left and and the brake is released.
right. In other words, return stroke (T) of brake piston
(7) is determined by the amount of oil for
stroke (S) of the slack adjuster. The time lag of
the brake is always kept constant regardless of
the wear of the brake disc.
q When this is done, brake piston (7) moves by a

distance of stroke (S). At this time, the clear-
ance between the brake piston and disc is
reduced to 0 but no braking force is generated.
HD325-7, HD405-7 17
Brake 1
Front
1. Plate Specifications
2. Pin Type: Caliper disc type
3. Plate
4. Bleeder
5. Piston
6. Pad
7. Disc
8. Seal
9. Ring
10. Seal
18 HD325-7, HD405-7
Unit: mm
Wear of pad (remaining thick- Standard size Repair limit
11
ness of wear material) 19.5 3.0 Replace
12 Missing portion of pad — Ratio of surface: 10%
13 Face runout of disc (Note 1) 0.15 0.50 Correct or replace
14 Wear of disc (thickness of disc) 30 Less than 27
Replace
Open crack in radial direction
15 Damage to disc surface — Uneven wear, marked damage
Correct
(Note 2)
Note 1: When there is excessive facial runout of the disc, check the front wheel bearing also.
Note 2: • When the depth of the scratch exceeds 1.5 mm.
• When the pad is worn totally and the backing is melted and deposited on the disc because of fric-
tion.
• When there are vertical scratches other than concentric scratches.
HD325-7, HD405-7 19
Rear
1. Inner gear Specifications

2. Floating seal Type : Wet multi-disc brake
3. Retainer Oil : Brake oil EO30-CD
4. Oil seal Cooling oil EO30-CD
5. Hub
6. Plate
7. Disc
8. Outer gear
9. Damper
10. Piston
11. Cylinder
20 HD325-7, HD405-7
Unit: mm
Backlash between outer gear Standard backlash Repair limit
1
and plate 0.52 – 0.90 1.5
Backlash between inner gear and
2 0.52 – 0.90 1.5
plate
3 Thickness of plate
2.4 2.15
4 Thickness of disc 5.1 4.6
Replace
5 Thickness of damper 6.9 5.1
Standard distortion Repair limit
6 Distortion of disc friction surface
Max. 0.45 0.7
Distortion of plate and damper
7 Max. 0.50 0.7
friction surface
Assemble thickness of plate and Standard size Repair limit
8
disc 123.9 114.4
9 Wear of oil seal contact surface 430 0 – -0.155 Repair or replace
HD325-7, HD405-7 21
Operation
Operation of brake
q When the brake pedal is depressed, pressure
oil from the brake valve moves brake piston
(10) to the right in the direction of the arrow.
This presses disc (7) and plate (6) together
and generates friction between the disc and
plate. The wheel is rotating together with the
disc, so this friction reduces the travel speed
and stops the machine.
q When the brake pedal is released, the pres-

sure at the back face of brake piston (10) is
released, so the piston is moved to the left in
the direction of the arrow by the internal pres-
sure, and this releases the brake.
22 HD325-7, HD405-7
Proportional reducing valve 1
1. Filter Function
2. Connector q The proportional reducing valve is a valve
3. Solenoid assembly used for retarder control. It is installed
between the accumulator and the slack
A : To slack adjuster adjuster in the brake circuit.
P : From accumulator It varies the discharge pressure of the pres-
T : To transmission oil pan sure oil in accordance with the turning angle of
the retarder control lever, so the retarder con-
trol can be carried out as desired.
HD325-7, HD405-7 23
Parking brake 1
1. Brake caliper assembly Specifications

2. Spring Type: Spring boosted type
3. Spring cylinder Caliper disc brake
4. Pad
5. Disc
6. Plate
24 HD325-7, HD405-7
Unit: mm
Standard backlash Repair limit Repair or
7 Face runout of disc
0.4 0.8 replace
Rebuild
(Thickness of
Min. 20
8 Thickness of disc 25 disc must not be
under 20 mm)
Max. 20
Thickness of pad Replace
9 21.5 11.5
(including thickness of plate)
Standard size Standard Clearance
Repair limit
of plate clearance limit
0
22.3
–0.3
Clearance between plate and Correct or
10 Standard value
brake assembly replace
of brake Repair limit 1.0 ± 0.4 1.5
assembly
+0.4
23
–0.1
HD325-7, HD405-7 25
Parking brake solenoid 1
1. Solenoid valve assembly Function

2. Relief valve q The parking brake solenoid valve is installed
3. Block between the secondary brake valve and park-
ing brake.
A: Outlet port If the parking brake switch is set to "Travel",
P: Inlet port the solenoid valve is energized and the brake
T: Drain port oil pressure is sent to the parking brake spring
cylinder to release the parking brake.
If the parking brake switch is set to "Park", the
solenoid valve is de-energized and the brake
oil pressure is relieved from the parking brake
spring cylinder to operate the parking brake.
26 HD325-7, HD405-7
Hand brake (retarder) 1
1. Retarder lever
2. Auto retarder set lever
3. Lamp switch
4. Wiper switch
Function
q The hand brake is used to control the retarder
and installed to the steering column.
q The retarder is controlled freely with the lever
operation quantity.
HD325-7, HD405-7 27

© 2008 KOMATSU
All Rights Reserved
28 HD325-7, HD405-7
SEN00753-03
DUMP TRUCK
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up

Undercarriage and frame
Suspension ..................................................................................................................................................... 2
Suspension cylinder........................................................................................................................................ 4
Rear axle support.......................................................................................................................................... 12
HD325-7, HD405-7 1
Suspension 1
1. Front suspension cylinder 4. Radius rod (Lower rod)

2. Radius rod (Upper rod) 5. Arm (A-frame)
3. Rear suspension cylinder
Outline
q The suspension system supports the weight of q The suspension cylinder to dampen impacts is
the chassis, and absorbs the shock from of hydro-pneumatic type. It is filled with oil and
uneven road surfaces to provide a comfortable nitrogen gas and sealed. When the nitrogen
ride for the operator. At the same time, it main- gas receives loads from the road surface, they
tains the stability of the machine by ensuring are compressed and expanded and work as a
that all wheels are always in contact with the spring. If the suspension cylinder is extracted
ground surface. In this way, it allows the or retracted, oil in it flows. The orifice in the oil
machine to demonstrate its full performance in passage generates resistance and works as a
items such as acceleration, braking, and turn- damper. With this mechanism, the suspension
ing, even when traveling at high speed. cylinder dampens impacts.
q The front suspension is equipped with the
automatic suspension system, as well as the
above function, which automatically changes
the damping factor according to the travel con-
dition and load condition of the machine to fur-
ther improve the operator comfort and travel
stability.
2 HD325-7, HD405-7
Function
1. Front suspension
The front suspension cylinder functions as a
shock absorber and spring, and is connected
by spherical bearings to the lower arm (A-
frame) and main frame. The lower arms rock
according to extension and retraction of the
suspension cylinders to keep the alignment of
the wheels and improve the stability of the
machine.
2. Rear suspension
The differential housing is supported by the
frame and two radius rods at the bottom, and
at the top by two inverted-V-shaped rods and
two suspension cylinders. It is connected to
these at both ends by spherical bearings. It
transmits the load and motive force through
the top and bottom rods.
The inverted-V-shaped rods at the top also
function to maintain the center of the machine
(axle).
Employment of the new inverted-V-shaped link
improves the rolling steering characteristics.
HD325-7, HD405-7 3
Suspension cylinder 1
Front
1. Feed valve 5. Air bleeding valve A: Port (A)

2. Cylinder 6. Tube B: Port (B)
3. Rod 7. Valve assembly
4. Valve (for bleeding air)
4 HD325-7, HD405-7
Unit: mm
Clearance between piston rod size Shaft Hole clearance limit Replace
8
and bushing –0.043 +0.240 +0.103 bushing
160 0.4
–0.106 +0.060 +0.346
Clearance between piston rod –0.043 +0.540 +0.403 Replace
9 160 0.7
Clearance between cylinder –0.050 +0.115 +0.050 Replace
10 200 0.8
and wear ring –0.260 0 +0.375 wear ring
Measuring method: Repair limit
• Place the spring on a flat bench
11 Elasticity of leaf spring
and measure the amount that the Max. 0.3 mm
spring curves. (See fig. 1) Replace
Measuring method: Elongation : Max. 5 mm
12 Deformation of stopper • Measure protrusion and elongation Protrusion : Min. 2 mm
of stopper. (See fig. 2) No cracks
Fig. 1 Fig. 2
HD325-7, HD405-7 5
q Auto suspention
1. Feed valve 7. Hydraulic cylinder A: Port (A)

2. Cylinder 8. Valve assembly B: Port (B)
3. Rod 9. Damping force selector
4. Valve (for bleeding air) valve
5. Air bleeding valve 10. Damping force selector
6. Tube valve lever
6 HD325-7, HD405-7
Unit: mm
Clearance between piston rod size Shaft Hole clearance limit Replace
11
160 0.4
–0.106 +0.060 +0.346
Clearance between piston rod –0.043 +0.540 +0.403 Replace
12 160 0.7
Clearance between cylinder –0.050 +0.115 +0.050 Replace
13 200 0.8
and wear ring –0.260 0 +0.375 wear ring
Measuring method: Repair limit
• Place the spring on a flat bench
14 Elasticity of leaf spring
and measure the amount that the Max. 0.3 mm
spring curves. Replace
Measuring method: Elongation : Max. 5 mm
15 Deformation of stopper • Measure protrusion and elongation Protrusion : Min. 2 mm
of stopper. No cracks
Fig. 1 Fig.e 2
HD325-7, HD405-7 7
Structure and operation 2. Principle of generation of damping force

q The suspension cylinder acts as a shock Inside of valve body (8) are orifice plate (8a)
absorber and spring. The inside of the cylinder and leaf springs (8b) and (8c). They restrict
is divided into gas chamber (A) which is the flow of oil between oil chamber (B) and oil
charged with nitrogen gas, and oil chamber (B) chamber (C), and create a damping force.
which is filled with oil. Oil chamber (B) and oil 1) Action when retracting
chamber (C) are connected by tube (6) and When the nitrogen gas is compressed by
valve body (8). the external force from the road surface,
the oil in oil chamber (B) flows from oil
chamber (B) through the valve (8) and
tube (6) to oil chamber (C). The oil flowing
1. Nitrogen gas through the valve from direction (Y) to ori-
While the machine is traveling, the wheels fol- fice plate (8a) is throttled by orifices in four
low the unevenness of the road surface, and places to generate a damping force.
an external force in the updown direction is 2) Action when extending
applied to the suspension cylinder. When this When the external force from the road sur-
happens, the volume of the nitrogen gas in gas face gets weak, the pressure of the nitro-
chamber (A) changes elastically under the gen gas extends the rod, and the oil in oil
input force, and absorbs the external force. chamber (C) passes through tube (6) and
The nitrogen gas is sealed by a rod and oil, so valve (8) and flows to oil chamber (B).
it is always subjected to a pressure corre- The oil inside the valve flows from direc-
sponding to the external force, and acts as an tion (Z) and passes through two orifices
air spring. from orifice plate (8a) to generate a damp-
ing force.
8 HD325-7, HD405-7
3. Variable shaft mechanism

In the valve body, bypass circuit (D) is provided
before and after orifice plate (8a), so the oil
flow is divided into oil flowing through orifice
plate (8a) and oil flowing through the bypass
circuit (D).
The oil flowing through bypass circuit (D)
passes through a shaft with orifices at two
places on the inside circumference, and flows
to oil chamber (C) or oil chamber (B) according
to whether it is retracting or extending.
The shaft is connected to an hydraulic cylinder
driven by a signal from the retarder controller,
and the size of the orifices automatically
changes according to the condition of the
machine.
The damping force is set at three levels (ME-
DIUM, HARD, SOFT) according to the size of
the orifices through which the oil is passing.
HD325-7, HD405-7 9
Rear
1. Feed valve
2. Cylinder
3. Rod
4. Valve (for bleeding air and mounting pressure sensor)
5. Ball
10 HD325-7, HD405-7
Unit: mm
Clearance between piston rod size Shaft Hole clearance limit
6
and bushing –0.043 +0.240 0.103 –
160 0.4
–0.106 +0.060 0.346
Replace
Clearance between piston rod –0.043 +0.240 0.103 –
7 160 0.4
and bushing –0.106 +0.060 0.346
Clearance between cylinder –0.050 +0.115 0.05 –
8 200 0.8
and wear ring –0.260 0 0.375
Structure and operation

q The suspension cylinder has the function of
both a shock absorber and spring.
When a fixed amount of oil is sent from oil
chamber (6) through orifices (4) and (5) to cav-
ity (2), the oil is throttled by the orifices and a
shock-absorbing effect is obtained.
1. Retracting action
While the machine is traveling if it hits a bump
or object on the road, the wheels are pushed
up, and the cylinder rod is pushed into the cyl-
inder.
When this happens, the nitrogen gas in cham-
ber (7) is compressed, the oil in chamber (6) is
sent through both orifices (4) and (5) to cavity
(2), and cavity (2) is filled more quickly than
when extending.
2. Extending action
When the machine has passed any bump or
object on the road surface, the cylinder rod is
pushed up by the weight of the wheels and
axle and the pressure of the nitrogen in cham-
ber (7).
As a result, the amount of oil in cavity (2) is
reduced, and pressure is applied to the oil
remaining in cavity (2). 1. Air intake valve 8. Cylinder rod
This pressurized oil closes orifice (4) with 2. Cavity 9. Cylinder
check ball (3), and is sent to chamber (6) 3. Check ball 10. Air bleed valve
through only orifice (5), so the flow of oil pass- 4. Orifice
ing through the orifice is controlled so that it is 5. Orifice a: When extending
less than during retraction. 6. Oil chamber b: When retracting
In this way, the amount of oil returning to 7. Nitrogen gas
chamber (6) is restricted to provide a shock chamber
absorbing effect.
HD325-7, HD405-7 11
Rear axle support 1
1. Rod
2. Rod
3. Axle
4. Suspension cylinder
12 HD325-7, HD405-7
Unit: mm
Clearance between rod size Shaft Hole clearance limit
5
mounting pin and bushing –0.030 +0.046 0.030 –
60 0.6
–0.076 0 0.122
6 — — — 0.6 Replace
outer bushing 0.25
Clearance between
–0.030 +0.046 0.030 –
7 suspension cylinder mounting 60 0.6
–0.076 0 0.122
pin and frame or axle
8 — — — 0.6
outer bushing 0.25
HD325-7, HD405-7 13

© 2008 KOMATSU
All Rights Reserved
14 HD325-7, HD405-7
SEN00754-03
DUMP TRUCK
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up

Hydraulic system
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
HD325-7, HD405-7 1
Steering, hoist oil pressure piping diagram 1
2 HD325-7, HD405-7
1. Steering cylinder
2. Work equipment and steering pump
(SDR (30) 63 + 50 + SB (1) 6)
3. Hoist cylinder
4. Hydraulic tank
5. Hoist valve
6. Steering control valve
7. Steering valve
8. Cross-over relief valve
HD325-7, HD405-7 3
Dump body control 1
1. Dump body control lever Function

2. Work equipment and steering pump q The positioner sensor senses the body opera-
(SDR (30) 63 + 50 + SB (1) 6) tion, and from this data the retarder controller
3. EPC valve controls output to the EPC valve.
4. Hoist valve q The signal from the dump body control lever is
5. Body positioner sensor controlled by the retarder controller, and actu-
ates the EPC valve. The pilot pressure gener-
6. Hoist cylinder
ated by the EPC valve moves the spool of the
hoist valve and controls the hoist cylinder.
4 HD325-7, HD405-7
Hydraulic tank 1
1. Filter element
2. Breather
3. Oil filler cap
4. Hydraulic filter
5. Oil level gauge
6. Drain plug
HD325-7, HD405-7 5
Steering valve 1
1. Input shaft P: From steering control valve

2. Upper cover R: To hydraulic tank
3. Valve spool LS: To steering control valve
4. Housing RT: To steering cylinder
5. Ball LT: To steering cylinder
6. Stator
7. Lower cover
8. Ball
9. Torsion bar
10. Link
11. Sleeve
12. Rotor
13. Manifold
14. Commutator
6 HD325-7, HD405-7
Operation
1. When at neutral
q The oil from the pump passes through the

steering control valve and enters port (P) to the
steering valve.
q Valve spool (3) is at the neutral position, so
port (P) and the ports ((RT) and (LT)) to the cyl-
inder are closed. No oil flows to the cylinder,
so the cylinder does not move.
q At the same time, port (LS) is connected
through port (R) to the tank. As a result there
is no oil pressure at port (LS), so all the oil from
the pump at the steering control valve flows to
the hoist valve.
HD325-7, HD405-7 7
2. When turning right
q When the steering wheel is turned (to the q In this way, the two cylinders are actuated and
right), input shaft (1) rotates. When this hap- the wheels turn to the right.
pens, valve spool (3) moves down. q The oil returning from the steering cylinder
(Input shaft (1) has a spiral groove in which flows from port (LT) through port (E) and port
ball (8) moves, so when input shaft (1) rotates, (R) and goes back to the tank.
torsion bar (9) is twisted, and ball (8) moves up q At the same time, the oil pressure at port (P) is
or down to move valve spool (3).) restricted by valve spool (3), and passes
q The oil from the steering control valve flows through port (A), so a lower oil pressure (the
from port (P) through port (A) and port (G) and drop in pressure (pressure difference) differs to
goes to port (F). according to the area of the opening of the
q The oil at port (F) then passes between stator spool) than the pressure at port (P) is applied
(6) and rotor (12) in the metering portion. to port (LS).
After the amount of oil flowing to the steering q The steering control spool is actuated by the
cylinder is measured here, it enters the inside difference in pressure between the oil pressure
of valve spool (3), passes through hole (a) in at port (P) end and the oil pressure at the port
the valve spool through port (RT) and flows to (LS) end. As a result, only the necessary
the steering cylinder. amount of oil flows to the steering circuit, and
remaining oil flows from the steering control
valve to the hoist valve.
8 HD325-7, HD405-7
3. When turning left
q When the steering wheel is turned (to the left), q The oil returning from the steering cylinder
input shaft (1) rotates. When this happens, flows from port (RT) through port (D) and port
valve spool (3) moves up. (R) and goes back to the tank.
q The oil from the steering control valve flows q At the same time, the oil pressure at port (P) is
from port (P) enters port (B), passes through restricted by valve spool (3), so a lower oil
hole (a) in valve spool (3), and enters the pressure than the pressure at port (P) is
inside of the valve spool. applied to port (LS).
q The oil inside valve spool (3) passes between q The steering control spool is actuated by the
stator (6) and rotor (12) in the metering portion. difference in pressure between the oil pressure
After the amount or oil flowing to the steering at port (P) end and the oil pressure at the port
cylinder is measured here, it flows to port (F). (LS) end. As a result, only the necessary
q The oil at port (F) passes through port (LT) and amount of oil flows to the steering circuit, and
flows to the steering cylinder. remaining oil flows from the steering control
q In this way, the two cylinders are actuated and valve to the hoist circuit.
the wheels turn to the left.
HD325-7, HD405-7 9
Cross-over relief valve 1
SC1: To steering cylinder 1. Valve body

SC2: To steering cylinder 2. Valve seat
SC3: To steering cylinder 3. Relief valve
SC4: To steering cylinder
4. Valve spring
SV1: To steering valve
5. Sleeve
SV2: To steering valve
6. Adjustment screw
7. Lock nut
10 HD325-7, HD405-7
Steering control valve 1
LS: LS port
P1: From work equipment and steering pump
P2: From work equipment and steering pump
PE: From emergency steering pump
PH: To hoist valve
PST: To steering valve
PT: Drain port
HD325-7, HD405-7 11
1. Spool
2. Check valve
3. Plug
4. Relief valve
12 HD325-7, HD405-7
Unit: mm
Free
length x Installed Installed Free Installed
5 Spool return spring Outside length load length load If damaged or
diameter deformed,
364 N 291 N replace spring
213.6 x 32.5 140 —
{37.1 kg} {29.7 kg}
3.38 N 2.71 N
6 Check valve spring 42.2 x 17 33.5 —
{0.345 kg} {0.276 kg}
Function
q The steering control valve distributes the
hydraulic oil from the work equipment and
steering pump to the steering circuit and hoist
circuit according to pressure signals from the
steering valve.
q The steering control valve is a load sensing
type valve, which controls spool (1) by operat-
ing the steering system.
q While the machine is not being steered (While
the steering circuit does not need the pressur-
ized oil), the steering control valve supplies all
of the pressurized oil from the pump to the
hoist valve.
q If the machine is steered, the steering control
valve supplies the necessary hydraulic oil for
the steering operation to the steering valve and
supplies the rest to the hoist valve.
q The above operation reduces the hydraulic
horsepower lost in the steering circuit.
HD325-7, HD405-7 13
14 HD325-7, HD405-7
Operation
1. When steering valve is in neutral
q The pressurized oil from the work equipment
and steering pump flows in ports (A) and (B).
q Since port (P) of the steering valve is closed
while the steering valve is in neutral, the pres-
sure in port P rises.
q The pressurized oil in port (A) flows through
orifice (a) to chamber (C) and moves spool (1)
to the right.
q Since port (LS) and chamber (D) are con-
nected to the tank, only the force of spool
return spring (5) is used to move spool (1) to
the left.
q The pressure in chamber (C) rises until it
exceeds the force of spool return spring (5).
q Spool (1) stops in the position shown in the fig-
ure and all of the pressurized oil from the work
equipment and steering pump flows to the
hoist valve.
2. When steering valve is operated

q If the machine is steered, port (P) is connected
to port (LS) and tank port (R) is disconnected
from port (LS).
q The pressurized oil in port (P) of the steering
valve acts on chamber (C) of spool (1).
q The pressurized oil in port (LS) of the steering
valve acts on chamber (D).
q The open area of port (b) changes according to
the turning speed of the steering wheel.
q The pressurized oil changes when it flows
through port (b) and consequently differential
pressure is generated.
q Spool (1) moves until [the rightward force of
the pressurized oil in chamber (C)] is balanced
with [the leftward force of the pressurized oil in
chamber (D) + the force of spool return spring
(5)].
q The higher the pressurized oil in port (P) of the
steering valve is, the more spool (1) moves to
the right.
HD325-7, HD405-7 15
1) When steering wheel is turned quickly
q The open area of port (b) is wide.

q Spool (1) moves much to the right until the dif-
ferential pressure between before and after
port (b) is balanced with spool return spring
(5).
q The pressurized oil flows according to the
operation of steering wheel (7).
16 HD325-7, HD405-7
2) When steering wheel is turned slowly
q The open area of port (b) is narrow.

q Spool (1) moves a little to the right until the dif-
ferential pressure between before and after
port (b) is balanced with spool return spring
(5).
q The pressurized oil flows according to the
operation of steering wheel (7).
HD325-7, HD405-7 17
Steering relief valve q If the pressure in ports (A and B) reaches the

set poppet spring force (set pressure), pilot
poppet (3) opens and the pressurized oil in
port (B) is relieved through port (D) to port C,
and consequently the pressure in port (B) low-
ers.
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
q If the pressure in port (B) lowers, differential
Function pressure is generated in ports (A and B)
q The steering relief valve is in the demand because of the orifice of main valve (1), and
valve. When the steering cylinder is at the then main valve (1) is pushed open by the
stroke end or when abnormal pressure is gen- pressure of port (A) and the pressurized oil in
erated, the pressurized oil sent from the pump port (A) is relieved.
is relieved through this valve to prevent break-
age of the pump etc. (This valve sets the maxi-
mum circuit pressure).
Operation
q Port (A) is connected to the pump circuit and
port (C) is connected to the tank drain circuit.
q The pressurized oil fills port (B) through the ori-
fice of main valve (1).
q Pilot poppet (3) is in contact with valve seat
(2).
18 HD325-7, HD405-7
HD325-7, HD405-7 19
Hoist valve 1
a ADT: Set pressure is increased or decreased by 4.2 MPa {42.8 kg/cm2} per turn.
20 HD325-7, HD405-7
A1: To hoist cylinder bottom

B1: To hoist cylinder head
P: From steering control valve
PA: From EPC valve (LOWER, FLOAT)
PB: From EPC valve (RAISE)
T: To tank
1. Retainer
2. Spool
3. Body
4. Retainer
5. Retainer
6. Retainer
7. Relief valve
8. Check valve
Unit: mm
Free
length x Installed Installed Free Installed
9 Spool return spring (FLOAT) Outside length load length load
diameter
927 N 741 N If damaged or
74.0 x 36.0 55.5 —
{94.5 kg} {75.6 kg} deformed,
1,254 N 100 N replace spring
10 Spool return spring (LOWER) 34.2 x 28.7 32 —
{12.7 kg} {10.2 kg}
525 N 420 N
11 Spool return spring (RAISE) 51.3 x 34.5 47 —
{53.5 kg} {42.8 kg}
44.1 N 35.31 N
12 Check valve spring 32.6 x 10.9 24.5 —
{4.5 kg} {3.6 kg}
HD325-7, HD405-7 21
Operation
1. When hoist valve is in "HOLD" position
q The pressurized oil from the steering control

valve flows in chamber (C). Since the passage
to the hoist cylinder is blocked by hoist spool
(2), the pressurized oil flows through chamber
(D) to the tank.
q Since the port to the hoist cylinder is blocked
on both bottom side and head side, the hoist
cylinder is held in the current position.
22 HD325-7, HD405-7
2. When hoist valve is in "RAISE" position
q If the hoist lever in the cab is set in the q The pressurized oil returning from the head
"RAISE" position, the pressurized oil from the side flows through chambers (B) and (D) to the
EPC valve moves hoist spool (2) to the left. tank.
q Accordingly, the pressurized oil flows through
chamber (C), opens check valve (8), and
enters chamber (A).
q The pressurized oil flows through chamber (A)
to the bottom side of the hoist cylinder to
extend the hoist cylinder and raise the body.
HD325-7, HD405-7 23
3. When hoist valve is in "FLOAT" position
q If the hoist lever in the cab is set in the q The pressurized oil from the steering control
"FLOAT" position, the pressurized oil from the valve flows through chambers (C) and (B) to
EPC valve moves hoist spool (2) to the right. the hoist cylinder. A part of it flows through
Then, chamber (C) is connected to chamber chambers (C) and (D) to the tank, too.
(D), and chambers (B) and (H) are connected q Since the bottom side and head side of the
to chamber (D). hoist cylinder are connected by the hoist valve,
the hoist cylinder is free.
24 HD325-7, HD405-7
4. When hoist valve is in "LOWER" position
q If the hoist lever in the cab is moved from the q The pressurized oil flows through chamber (B)
"FLOAT" position to the "LOWER" position, the to the head side of the hoist cylinder to retract
pressurized oil from the EPC valve moves the hoist cylinder and lower the body.
hoist spool (2) to the right further from the q The pressurized oil returning from the head
"FLOAT" position. Accordingly, the pressur- side of the hoist cylinder flows through cham-
ized oil flows through chamber (C), opens ber (A) to chamber (H).
check valve (8), and enters chamber (B).
HD325-7, HD405-7 25
EPC valve 1
HD325-7 Serial No. 7001 – 7025, 7101 – 7522
HD405-7 Serial No. 3001 – 3035, 7101 – 7522
1. Manual operation button Function

2. Solenoid assembly q The EPC valve sends the oil from the hydraulic
3. Relief valve pump to the hoist valve spool to change the
4. Solenoid assembly (EPC) pilot pressure and control the hoist valve.
A: To hoist valve
B: From hoist valve
P1: From hydraulic tank
T1: To hydraulic tank
26 HD325-7, HD405-7
HD325-7, HD405-7 27

28 HD325-7, HD405-7
1. Manual operation button

2. Solenoid assembly
3. Relief valve
4. Solenoid assembly (EPC)
5. Strainer
A: To hoist valve
B: From hoist valve
P1: From hydraulic tank
Function
q The EPC valve sends the oil from the hydraulic
pump to the hoist valve spool to change the
pilot pressure and control the hoist valve.
HD325-7, HD405-7 29
Steering cylinder 1
Unit: mm
Clearance between piston rod size Shaft Hole clealance limit Replace
1
and bushing –0.025 +0.164 0.032 – bushing
50 0.551
–0.087 +0.007 0.251
Clearance between piston rod +0.039
2 40 — — 1.0
support shaft and bushing 0
Replace
Clearance between cylinder bot- +0.039
3 40 — — 1.0
tom support shaft and bushing 0
30 HD325-7, HD405-7
Hoist cylinder 1
Unit: mm
Clearance between cylinder size Shaft Hole clealance limit
1
and bushing –0.043 +0.277 0.104 –
140 0.720
–0.143 +0.061 0.420
Clearance between piston rod –0.036 +0.270 0.097 – Replace
2 90 0.693
and bushing –0.123 +0.061 0.393
Clearance between rod +0.004
3 60 — — 1.0
support pin and bushing –0.019
Clearance between cylinder +0.004
4 60 — — 1.0
support pin and bushing –0.019
HD325-7, HD405-7 31
Work equipment and steering pump 1

SDR (30) 63 + 50 + SB (1) 6
Unit: mm
SDR(30)-63
1 Side clearance 0.16 – 0.20 0.24
SDR(30)-50
SBR (1)-6 0.10 – 0.15 0.19
Clearance between inside SDR(30)-63
diameter of plain bearing and 0.06 – 0.131
2 SDR(30)-50 0.20 Replace
shaft SBR (1)-6 0.06 – 0.119
SDR(30)-63
3 Depth for knocking in pin 10 0
SDR(30)-50 –
-0.5
SBR (1)-6 7
Delivery Standard
Rotating Delivery
pressure delivery
Model speed amount limit
{MPa amount
Discharge amount (rpm) (l/min) –
– Oil: EO10-CD (kg/cm2)} (l/min)
Oil temperature: 45 – 55 °C SDR(30)-63 145.8 134.7
20.6
SDR(30)-50 2,500 115.5 106.7
{210}
SBR(1)-6 13.8 12.6
32 HD325-7, HD405-7
HD325-7, HD405-7 33

© 2008 KOMATSU
All Rights Reserved
34 HD325-7, HD405-7
SEN00755-02
DUMP TRUCK
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up

Cab and its attachments
ROPS cab ....................................................................................................................................................... 2
Air conditioner ................................................................................................................................................. 3
Rear view monitor ........................................................................................................................................... 9
HD325-7, HD405-7 1
ROPS cab 1
1. Front wiper
2. Front glass
3. Air conditioner fresh filer
4. Room (Left)
5. Rear glass
6. Door (Right)
7. Washer tank
2 HD325-7, HD405-7
Air conditioner 1
1. Receiver dryer Function

2. Air conditioner unit q The air conditioner makes a pleasant operating
3. Compressor environment in the cab for the operator and
4. Condenser acts to reduce fatigue.
HD325-7, HD405-7 3
Refrigerant flow system
4 HD325-7, HD405-7
Air conditioner unit
1. Hot water outlet port Outline

2. Hot water inlet port q The vertical air conditioner unit on which evap-
3. Refrigerant gas inlet side orator and heater core is synchronized with the
4. Refrigerant gas outlet side blower and intake unit to generate cool and hot
air.
q The temperature adjusting switch on the air
conditioner panel controls air mix dampers to
adjust the spurting out temperature.
Cooler
q The cooler circulates refrigerant through evap-
orator to cause heat exchange (dehumidifica-
tion and cooling).
q Air taken in by the blower and intake unit is
cooled with evaporator and then blown out
from the grill through the duct.
Heater
q The heater circulates engine coolant in heater
core to cause heat exchange (heating).
q Air taken in by the blower and intake unit is
heated with heater core and then blown out
from the grill through the duct.
HD325-7, HD405-7 5
Receiver dryer
1. Sight glass Function

q It is used to store liquefied high-pressure, high-
A: Refrigerant gas inlet port temperature refrigerant from the condenser. It
B: Refrigerant gas outlet port is capable of completely liquefying the refriger-
ant even when bubbles are contained in refrig-
erant due to the condenser condition in heat
dissipation.
q It eliminates foreign substances in the circula-
tion circuit and water content in the refrigerant
by use of the built-in filter and desiccating
agent.
q Sight glass (1) allows inspecting flow of the
refrigerant.
Specifications
Effective cubic capacity (cm3) 578

Mass of desiccating agent (g) 300
6 HD325-7, HD405-7
Condenser
1. Fin Function
2. Tube q It cools and liquefies the high-pressure and
high-temperature gas which compressed by
A: Refrigerant gas inlet port compressor.
B: Refrigerant gas outlet port a If the fin crushes or is clogged with dusts, heat
exchange efficiency is degraded and complete
liquefaction of refrigerant becomes unavail-
able. As the result, pressure in the refrigerant
circulation circuit will be increased, applying
extra load to the engine or degrading the cool-
ing effect. Thus, care must be used in its han-
dling and daily inspection.
Specifications
Fin pitch (mm) 1.5
Total heat dissipation surface (m )
2
6.55
Max. pressure used (MPa {kg/cm }) 2 3.6 {3.6}
HD325-7, HD405-7 7
Compressor
1. Case Function
2. Clutch q Other than circulating the refrigerant, it com-
presses the refrigerant gas from the evapora-
A: Suction service valve tor to high-pressure, high-temperature gas so
B: Discharge service valve that it may be easily regenerated (liguefied) at
normal temperature.
q Its built-in magnet clutch turns on or off
depending on the evaporator temperature and
refrigerant pressure.
Specifications
Number of cylinder – Bore x Stroke
5 – 35 x 28.6
(mm)
Piston capacity (cc/rev) 138
Allowable maximum speed (rpm) 4,000
Refrigerant oil used Sanden: SP-10
Refrigerant oil refilling volume (cc) 175
8 HD325-7, HD405-7
Rear view monitor 1

(If equipped)
1. Monitor
2. Camera
3. Cable
HD325-7, HD405-7 9
Monitor
1. Auto switch Specifications

2. Manual switch TV signal method:
3. Zoom/Iris switch As per Japanese standard TV method
(Reverse light compensation switch) Scanning method: 2:1 Interlace method
4. Bright/Dim light selector switch CRT: 4.5 inch, black and white, 90-deg. deflection
5. Mark switch Resolution:
Horizontal 400 lines and vertical 300 lines
6. Contrast adjustment knob
Power supply voltage: DC 24/12 V
7. Brightness adjustment knob
10 HD325-7, HD405-7
Camera
1. Camera Specifications
2. Connector TV signal method:
As per Japanese standard TV method
Scanning method: 2:1 Interlace method
Image sensor:
1/4 inch color CCD with 250,000 pixels
Lens: 1.7 mm, 1:2.8
Angle of view: Horizontal; Approx. 118 deg.,
Vertical; Approx. 97.6 deg.
Electronic zoom: Approx. 1.4 power
Using luminance range:
Min. luminance of object; 3 lux
Power supply voltage:
DC 5.5 V – 99.5 V for main unit
(supplied by monitor)
Power consumption: Max. 120 mA
HD325-7, HD405-7 11

© 2007 KOMATSU
All Rights Reserved
12 HD325-7, HD405-7
SEN00756-02
DUMP TRUCK
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up

Electrical system, Part 1
Machine monitor system ................................................................................................................................. 2
HD325-7, HD405-7 1
Machine monitor system 1
Network data
1. From machine monitor to each controller
q Switch input data
q Option setting data
2. From each controller to machine monitor
q Display data related to each controller
q Service mode data
q Troubleshooting data
3. From transmission controller to machine monitor
q Model selection data
2 HD325-7, HD405-7
Outline
q The machine monitor system is comprised of q To make it easier to carry out troubleshooting
controllers and a machine monitor. The con- of the controllers on the network (including the
trollers on the network use the data from the machine monitor itself), a service mode func-
sensors installed to all parts of the machine to tion is provided. Its main content is as follows.
observe and control the condition of the vehi- 1. Displaying failure history data for electrical
cle and transmit those data as network data to components
the machine monitor. The machine monitor, in q Displays electrical component failure
return, displays these data and informs the occurrence data from each controller
operator of the condition of the machine. that is saved in machine monitor.
q There are two types of display on the machine q Deletes data from memory
monitor: the normal mode and the service 2. Displaying failure history data for machine
mode. Displays machine failure occurrence data
q The items that are always displayed for the from each controller that is saved in
operator are the normal mode items. Their machine monitor.
main content is as follows. 3. Real-time monitor
1. Normal display items Takes input, output signal, and calculation
q Meters (speedometer, tachometer) values recognized by each controller on
q Gauges (engine coolant tempera- network and displays them in real time.
ture, torque converter oil temperature, 4. Reduced cylinder mode
retarder oil temperature, fuel level) This function is used to stop the supply of
q Pilot display fuel sprayed from the fuel injector to each
q Service meter, odometer (character of the cylinders. This function is used for
display) the purpose of, for example, determining
2. Items displayed when there is abnormality the cylinder where there is defective com-
Caution, action code display (while an bustion.
action code is being displayed, press 5. No injection cranking
machine monitor mode selector switch (>). This function is used to lubricate an
A failure code (6-digit) is then displayed.) engine without starting the engine to drive
a vehicle after a long-term storage.
3. Maintenance monitor function
6. Adjusting function
When the filter, oil replacement interval is
This function is used to correct installation
reached, the item needing replacement is
errors of sensors, solenoid valves, and
displayed in the character display.
compensate production tolerances of
4. Others parts and components. This function is
In combination with the character display also used to change control characteristic
and the machine monitor mode selector data in response to user's request.
switch, which is used to operate the char- 7. Maintenance monitor
acter display, the following items can be This function is used to change filter and
displayed, set, and adjusted. oil replacement interval and stop the func-
1) Dozing counter (option) tion.
2) Display reverse travel distance mea- 8. Operation information display function
surement value This function is used to display fuel con-
3) Reset filter, oil replacement interval sumption amount per operation hour.
4) Input telephone number 9. Engine mode fixing function
5) Select language This function is used to check the perfor-
mance.
10. Option selection function
This function is used to select controller
information and optional equipment to be
operated.
11. Model selection function
Input model information to be mounted.
12. Initialize
This function is used to set the machine
monitor when the machine is shipped from
the factory.
HD325-7, HD405-7 3
Machine monitor
1. Speedometer 26. Emergency steering pilot lamp

2. Engine tachometer 27. Turn signal pilot lamp (right)
3. Retarder oil temperature gauge 28. Turn signal pilot lamp (left)
4. Torque converter oil temperature gauge 29. Head lamp high beam pilot lamp
5. Coolant temperature gauge 30. Shift lever position pilot lamp
6. Fuel gauge 31. Shift indicator
7. Character display 32. Retarder pilot lamp
8. Centralized warning lamp 33. Lockup pilot lamp
9. Retarder oil temperature caution lamp 34. Output mode pilot lamp (power mode)
10. Torque converter oil temperature caution lamp 35. Output mode pilot lamp (economy mode)
11. Coolant temperature caution lamp 36. Suspension mode pilot lamp (hard)
12. Fuel level caution lamp (if equipped)
13. Maintenance caution lamp 37. Suspension mode pilot lamp (medium)
14. Battery charging circuit caution lamp (if equipped)
15. Steering oil temperature caution lamp 38. Suspension mode pilot lamp (soft) (if equipped)
(if equipped) 39. ABS pilot lamp (if equipped)
16. Engine oil pressure caution lamp 40. ASR pilot lamp (if equipped)
17. Retarder oil pressure caution lamp 41. Preheater pilot lamp
18. Parking brake caution lamp 42 Automatic retarder READY pilot lamp
19. Machine monitor option system caution lamp (if equipped)
20. Engine system caution lamp 43. Automatic retarder set speed indicator
21. Transmission system caution lamp (if equipped)
22. Retarder system caution lamp 44. Automatic retarder set speed unit indicator (km/h)
23. Inclination caution lamp (if equipped)
24. Seat belt caution lamp 45. Automatic retarder set speed unit indicator (MPH)
25. Body caution lamp (if equipped)
4 HD325-7, HD405-7
46. Rotary switch [SW1] a When setting, follow the instruction in TEST-
47. Rotary switch [SW2] ING AND ADJUSTING, Adjusting machine
48. Rotary switch [SW3] monitor, and do not change them.
49. Dipswitch [SW5-4] a When moving the switches, use a precision
50. Dipswitch [SW5-3] screwdriver and turn slowly.
51. Dipswitch [SW5-2] a Be careful not to touch anything except the
52. SI Spec, Non-SI Spec selection switch [SW5-1] switches inside the grommet.
53. Dipswitch [SW6-4] a Be careful not to let any dirt or dust get in.
54. Dipswitch [SW6-3] a After completing the setting, return the grom-
55. Dipswitch [SW6-2] met securely to its original position.
56. Dipswitch [SW6-1]
HD325-7, HD405-7 5
Machine monitor normal display functions

: Lighted up : Discontinuous sounds
A1: The mark shows that the light is lit up while the machine monitor check switch is ON.
A2: The mark shows that all lights are lit up for 2 seconds at start-up and then go off for 1 second.
Related A1
operation When A2
machine Immedi-
Display Display Display range/ Display Central monitor ately
No. item category Device Color conditions method Remarks
warn- Alarm check after
ing buzzer switch is turning
lamp oper- key ON.
ated.
Note: When machine

monitor check
Scale: switch is oper-
white 0 – 80 km/h or ated, pointer
Move- Back- 0 – 50 MPH Analog starts at current
Meter ment ground (MPH is dis- display — — — position and
played when (Note)
1 Machine color: moves around
speed black non-SI is used.) indication range
and then returns
to starting point.
When the
Backlight LED Amber small lamp is Lit up during — —
lit up. operation
Analog display Note: When machine

monitor check
Scale: * When the switch is oper-
white, red overrun pre- ated, pointer
Move- Back- vention brake starts at current
Meter 0 – 3,400 rpm is operated, —
ment ground (Note) position and
Engine color: the buzzer and moves around
2 speed central warn-
black indication range
ing lamp are and then returns
turned ON. to starting point.
When the Lit up during

Backlight LED Amber small lamp is operation — —
lit up.
Note: When machine

monitor check
white, red 50 – 150°C ated, pointer
Gauge Move- Back- (120°C or higher Analog — — — starts at current
ment ground in the red zone) display (Note) position and
Oil tem- color: moves around
3 perature black indication range
9 of and then returns
retarder to starting point.
Caution LED Red At 120°C Lit up during

or higher warning
When the
lit up. operation.
Note: When machine

monitor check
white, red ated, pointer
Move- Back- 50 – 135°C Analog starts at current
Gauge ment ground (120°C or higher display — — — position and
Oil tem- color: in the red zone) (Note)
moves around
black
4 perature indication range
of torque and then returns
10 con- to starting point.
verter
At 120°C Lit up during
Caution LED Red or higher warning
When the
lit up. operation.
6 HD325-7, HD405-7
Related When
operation machine Immedi-
Display Display Display range/ Display monitor ately
No. item category Device Color conditions method check after Remarks
Central switch is turning
warn- Alarm oper-
ing buzzer ated. key ON.
lamp
Note: When machine
monitor check
white, red 50 – 135°C ated, pointer
Gauge Move- Back- (102°C or higher Analog — — — starts at current
ment ground in the red zone) display (Note) position and
Coolant color: moves around
5 temper- black indication range
11 ature and then returns
to starting point.
At 102°C or Lit up during
Caution LED Red higher warning
When the
lit up. operation.
Note: When machine

monitor check
white ated, pointer
Move- Back- Analog starts at current
Gauge ment ground EMPTY – FULL display — — — position and
(Note)
color: moves around
black indication range
6 Fuel and then returns
12 level to starting point.
Specified level
Caution LED Red or less Lit up during — —
(At 67 z or operation
higher)
Backlight LED Amber When the small Lit up during — —

lamp is lit up. operation.
Service 0 – 65535.0h Operates
meter when the
(Regu- Service * Displayed in engine is
When 65535.0h is
the "upper col- — — exceeded, fixed at
lar dis- meter running. 65535.0h.
play umn" on the 1:1 against
item) character display clock time
Odome- 0 – 999999.9 km
ter
(Regu- Odometer * Displayed in Operates dur- When 999999.9 km is
the "lower col- — — exceeded, fixed at
lar dis- ing traveling. 999999.9 km.
play umn" on the
item) character display
When any
problem or
When any prob- failure occurs,
Display lem or failure the action
code is dis- Note 1:"KOMATSU" is
charac- occurs on the displayed in the
ter: played in the
Action Action machine, * Dis- upper col- — — Note 1 Note 2 upper column.
7 code code LCD black played in the Note 2:"Program No." is
Back- umn and rem-
upper and lower edies or displayed in the
ground columns on the lower column.
color: character display. description of
green problem in
the lower col-
umn.
The failure
Press machine code
monitor mode (6 digits) and
selector switch > detection
during the occur- controller are
rence of the displayed in For information on how
Failure Failure problem or the upper col- to operate display, see
code code failure on the umn and the — — the Operation & Main-
machine. faulty system tenance Manual.
* Appears in the or descrip-
upper and lower tion of prob-
columns on the lem in the
character display. lower
column.
HD325-7, HD405-7 7
Related When
Central Warn- switch is turning
warning oper- key ON.
ing buzzer ated.
lamp
Reverse
travel
integrating
meter Display Switch screen
Reset of character: Press machine by operating
time to black monitor mode machine For details, see the
Other selector switch
displays change fil- LCD Back- monitor mode Operation & Mainte-
ter and oil. ground " " selector nance Manual.
Telephone color: switch
7 number green ">" or "<".
setting
Language
selection
Dimmed
When the down by a
Night Backlight LED Green small lamp is step when the — —
lighting lit up. small lamp is
lit up.
Central
8 warning LED Red During system Lit up when
lamp is abnormal abnormal.
Note 1:The moment

when the lamp
lights up, the
action code: E01
and the location
When mainte- where an alarm
nance-related has been given
Mainte- alarm is given or Lit up or appear on the
13 nance LED Red the time to flashed — — character
caution change filter and display.
oil has elapsed. Note 2:For details on
the target items,
etc., see the
Operation &
Maintenance
Manual.
Battery
During battery
charging Lit up when
14 LED Red charging circuit
circuit abnormal.
being abnormal
caution
Steer-
When the
ing oil
steering oil Lit up when
15 tempera- Caution LED Red
temperature abnormal.
ture
rises.
caution
Engine
When the engine
oil pres- Lit up when
16 LED Red oil pressure
sure abnormal.
drops.
caution
Retarder When the
Operates when the
oil pres- retarder Lit up when
17 LED Red alternator R terminal is
sure oil pressure abnormal. (Note) (Note) ON.
caution drops.
Operates when the
Parking When the parking brake is oper-
Lit up during
18 brake LED Red parking brake is ated and the shift lever
operation. (Note) (Note)
caution operated. is in other than the "N"
position.
Machine
During being
monitor Under present condi-
abnormal in
or Lit up when tions, used in the event
19 LED Red machine moni-
optional abnormal. of failure of the
tor or optional
system machine monitor.
controller system
caution
During being
Engine
abnormal in Lit up when
20 system LED Red
engine control abnormal.
caution
system.
8 HD325-7, HD405-7
Related When
ing buzzer ated.
lamp
Trans-
When transmis-
mission Lit up when
21
system
LED Red sion control sys-
abnormal.
tem is abnormal
caution
Retarder When retarder
Lit up when
22 system LED Red control system is
abnormal.
caution abnormal
When the body is
Inclina-
lifted and inclined Lit up when
23 tion LED Red
excessively abnormal.
caution
from side to side.
Caution
During
operation:
Seat- When the seat-
lit up
24 belt LED Red belt is not — —
During non-
caution fastened.
operation:
turned OFF.
During
See the operation: Note: Operates when
Body lit up the shift lever is in
25 LED Red instruction
caution manual During non- (Note) (Note) other than the "N"
operation: position.
turned OFF.
During
operation:
Emer- When the emer- lit up
26 gency LED Red gency steering is During non- — —
steering operated. operation:
turned OFF.
During
Turn operation:
lit up
27 signal, LED Green During operation During non- — —
right operation:
turned OFF.
During
Turn operation:
lit up
28 signal, LED Green During operation During non- — —
left operation:
turned OFF.
During
Head- operation:
light, lit up
29 LED Blue During operation During non- — —
high
beam Pilot operation:
turned OFF.
Shift
30 When the shift
lever
LED Green lever is in the "R" Lit up (*) — — * Blinks when the neu-
(R) position position tral safety is operated.
R
Shift
30 When the shift
lever
LED Orange lever is in the "N" Lit up — —
(N) position position
N
Shift
30 When the shift
lever
LED Green lever is in the "D" Lit up (*) — — * Blinks when the neu-
(D) position position tral safety is operated.
D
Shift
30 When the shift
lever
LED Green lever is in the "6" Lit up (*) — — * Blinks when the neu-
(6) position position tral safety is operated.
6
Shift
30 When the shift
lever
5
HD325-7, HD405-7 9
Related opera- When

tion machine Immedi-
ing buzzer ated.
lamp
Shift
30 When the shift
lever
4
Shift
30 lever
When the shift * Blinks when the neu-
LED Green lever is in the "3" Lit up (*) — — tral safety is operated.
(3) position position
3
Shift
30 lever
LED Green lever is in the "2" Lit up (*) — — tral safety is operated.
(2) position position
2
Shift
30 lever
LED Green lever is in the "L" Lit up (*) — — tral safety is operated.
(L) position position
L
Pilot
F1, F2, F3, F4,
F5, F6, F7, N, R
* According to
the gear shift
signal received
from the When the
transmission gear shift
Back- controller. range
Shift LCD ground * When an alarm signal is — — All lit All lit
indicator color: is raised in the received
gray from the up. up.
31 event of
emergency transmission
escape, "E-" and controller.
the
"gear speed
range" are alter-
natively
displayed.
When the During
Night
Backlight LED Amber small lamp is operation: — —
lighting
lighted up. lit up
During
operation:
When the
lit up
32 Retarder LED Orange retarder brake is — —
During non-
operated.
operation:
turned OFF
When lockup of During
the torque con- operation:
verter is acti- lit up
33 Lockup LED Green — —
vated During non-
and direct drive operation:
is effective turned OFF
High-power
mode
Output
in operation:
mode Pilot At high-power
34 LED Green lit up — —
(power mode
During non-
mode)
operation:
turned OFF
Economy
Output mode
mode in operation:
At economy
35 (econ- LED Green lit up — —
mode
omy During non-
mode) operation:
turned OFF
Suspen-
sion mode At suspension Lit up in
36 LED Green — —
(hard) (if "hard" mode "hard" mode
equipped)
10 HD325-7, HD405-7
Related opera- When

tion machine Immedi-
ing buzzer ated.
lamp
Suspen-
sion
Lit up in
mode In suspension
37 LED Green "medium" — —
(medium) "medium" mode
mode
(if
equipped)
Suspen-
sion
In suspension Lit up in "soft"
38 mode LED Green — —
"soft" mode mode
(soft) (if
equipped)
During
operation:
When ABS is
ABS (if lit up
39 LED Orange operated. — —
equipped) During non-
operation:
turned OFF
During
operation:
When ASR is
ASR (if lit up
40 LED Orange operated.
equipped) During non-
operation:
turned OFF
During
When electric
operation:
intake air heater
Preheat- lit up
41 LED Red for preheating — —
ing During non-
engine is
operation:
Pilot operated.
turned OFF
Auto-
matic When auto- When ready
retarder matic retarder is to be
42 LED Green — —
being ready to be oper- operated:
ready (if ated. lit up
equipped)
Auto-
matic Back-
retarder ground When automatic Display of set * Zero is displayed
43 LCD retarder switch is — — when the set speed
set speed color:
turned ON. speed (*)
(if gray is cancelled.
equipped)
Auto-
matic During
When automatic
retarder operation:
retarder switch is
unit lit up
44 LED Green turned ON and — —
display During non-
the unit km/h is
(km/h) operation:
selected.
(if turned OFF
equipped)
auto-
During
matic When automatic
operation:
retarder retarder switch is
lit up
45 display LED Green turned on and — —
During non-
unit the unit MPH is
operation:
(MPH) (if selected.
turned OFF
equipped)
HD325-7, HD405-7 11
Self-diagnostic function when starting switch is

operated
1. When the starting switch is turned to the ON

position before starting the engine, the system
check is carried out for 3 seconds.
2. If the starting switch is turned to the START
position before 3 seconds have passed with the
starting switch at the ON position, everything
will go to the normal operating condition. How-
ever, even if everything goes to the normal
operating condition, the indicator gauges and
meters will not work until 3 seconds have
passed after the starting switch is turned to the
ON position.
Check function of central warning lamp, alarm

buzzer, monitor lamps, and meters
To check the normal display function of the

machine monitor, press the machine monitor check
switch to check the actuation. For details of the
actuation, see "Machine monitor normal display
functions when machine monitor check switch is
operated".
12 HD325-7, HD405-7
Service mode functions 2) ID input procedure

(1) Press switches </> to increase or
Outline decrees the value at the cursor posi-
To make it easier to carry out troubleshooting of the tion. Use these switches to select a
controllers on the network (including the machine desired value and then press switch
monitor itself), a service mode function is pro- U.
vided. To initialize sensors, operation settings, and (2) Repeat the above operation (1) for
the like, enter into the service mode of the machine four digits. The electrical equipment
monitor. system failure history screen is dis-
played.
How to operate the machine monitor a When an incorrect value is
1. Enter into the service mode entered, press the t switch and
then enter the correct data start-
1) Operation method
ing from the highest digit.
(1) Turn on the starting switch of the vehi-
a You can return to the service
cle to power ON the machine monitor.
meter screen or alert screen by
(2) While service meter screen or alert
pressing the t switch when the
screen is being displayed on the char-
cursor is located at the highest
acter display of the machine monitor,
digit.
press machine monitor mode selector
a If any switch operation is not
switch 1 (t) and machine monitor
done for 60 seconds or more dur-
mode selector switch 2 (<) at the same
ing input of an ID. The screen
time for more than 5 seconds continu-
will be returned to the service
ously, to enter into service ID input
meter screen or alert screen.
screen. The service ID input screen is
then displayed.
To enter into the service mode, input
"6491" as ID.
Machine monitor mode selector switches 1, 2
Supplementary explanation:
You can return to the service meter
screen or alert screen by turning OFF
the starting switch on the service
mode and then turn ON the starting
switch.
Service ID input screen
HD325-7, HD405-7 13
2. Service Mode Menu
a On the service mode menu, the screen can be changed by pressing switches </>. Use these switches
to select the desired operation menu screen.
a While the following display screen (selection screen) is being displayed, the screen can be changed to
the menu screen/operation screen of each function by pressing switch U.
a While the following display screen (selection screen) is being displayed, the screen can be changed to
the service meter screen of each function by pressing switch t.
Operation menu screen (character display)

1) Electrical equipment system failure history screen 2) Machine system failure history screen
** indicates the number of currently memorized ** indicates the number of currently memorized
failure histories. failure histories.
(Up to max. 20 failure histories can be memo- (Up to max. 20 failure histories can be memo-
rized.) rized.)
Outline Outline
Use this function to check the electrical system fail- Use this function to check the machine system fail-
ure history of respective controllers being memo- ure history of respective controllers being memo-
rized by the machine monitor. Regarding the error rized by the machine monitor. Regarding the error
code being used in the electric equipment system code being used in the machine system failure his-
failure history, refer to the Chapter "Troubleshoot- tory, refer to the Chapter "Troubleshooting".
ing". When the failure is repaired and after check-
ing and confirming that normal operation has been
restored, delete the failure history.
14 HD325-7, HD405-7
3) Real-time monitor function screen 5) No injection cranking function screen
Outline Outline
Use this function to check the inputting and output- Use this function to lubricate an engine without
ting signals being recognized by respective control- starting the engine to drive a vehicle after a long-
lers on the network. term storage.
Regarding the engine start method using this func-
4) Engine reduced cylinder function screen tion, refer to the Section "No injection cranking
operation of engine" in the chapter "Testing and
adjusting"
6) Adjusting function screen
Outline
Use this function to cut off the supply of fuel
sprayed from the fuel injector to each of the cylin-
ders in order to determine the cylinder where there
is defective combustion. Outline
Regarding the inspection method using this func- Use this function to correct installation errors of
tion, refer to the Section "Reduced cylinder mode sensors, solenoid valves, and compensate produc-
operation of engine" in the chapter "Inspection and tion tolerances of parts and components. Use this
Adjustment" function to change control characteristic data in
response to user's request.
Regarding the adjusting method using this function,
refer to the Section "Adjustment using monitor" in
the chapter "Testing and adjusting"
HD325-7, HD405-7 15
7) Maintenance monitor function screen 10) Option selection function screen
Outline Outline
This function is being explained in the section "Fil- Use this function to indicate the installation status of
ter and oil changing time indication on the character the optional equipment and to change the settings.
display" in the Chapter "Operation" in the Operation Use this function when optional equipment is
and Maintenance Manual. Use this function to installed or removed.
change filter and oil replacement interval and stop Regarding the setting change method using this
function. function, refer to the Section "Adjustment using
monitor" in the chapter "Inspection and Adjustment"
8) Operation information display function screen
11) Model selection function screen
Outline
Use this function to display fuel consumption aIndicates the currently selected model.
amount per operation hour. Outline
Use this function to input and select machine
9) Engine mode fixing function screen
model.
12) Initialize function screen
Outline
The engine mode controlled automatically accord-
ing to the load on the machine, etc. is fixed forcibly. Outline
This function is used to check the performance in This function operates on factory setting mode.
each engine mode. Since this function is for factory use only, do not
touch it.
16 HD325-7, HD405-7
Electrical equipment system failure history function

1) Selection of [Electrical equipment system failure history], [Electrical equipment system failure history
all clear selection]
The failure history is displayed in order of occurrence with the new failure first.
A current failure is displayed prior to the restored ones.
Pressing the > switch displays the next older failure.
Pressing the < switch displays the next newer failure.
After the oldest failure in the memory was displayed, a screen is displayed allowing to [Electrical
equipment system failure history all clear selection] of the relevant controller.
Pressing the t switch changes the screen to the [Electrical equipment system failure history selec-
tion] screen on the first layer.
Pressing the U switch change the screen to the [Electrical equipment system failure history individual
clear] or [Electrical equipment system failure history all clear].
2) Electrical equipment system failure history selection (first layer)

Pressing the > switch changes the screen to the [Initialize function] screen.
Pressing the < switch changes the screen to the [Machine system failure history] screen.
Pressing the t switch changes the screen to the ordinary or alert screen.
Pressing the U switch changes the screen to the [Electrical equipment system failure history] screen.
HD325-7, HD405-7 17
3) Selection of [Electrical equipment system failure history], [Electrical equipment system failure history
all clear selection] (second layer)
A current failure is displayed prior the restored ones.
Pressing the > switch displays next newer failure.
Pressing the < switch displays the next older failure.
After the oldest failure in memory was displayed, a screen is displayed allowing to select clearing the
entire failure history of electrical system of the relevant controller.
Pressing the t switch changes the screen to the [Electrical equipment system failure history selec-
tion] screen on the first layer.
Pressing the U switch changes the screen to the [Electrical equipment system failure history clear]
screen.
a If the history consisted of one failure, pressing the switch dies not change the screen to the [Electrical
equipment system failure history all clear] clearing (but change the screen to the [Electrical equipment
system failure history individual clear]).
4) Selection of [Electrical equipment system failure history individual clear], [Electrical equipment sys-
tem failure history all clear] (the third layer)
Select YES or NO with < or > switch.
Cursor (_) blinks on the selected item. Pressing the t switch changes the display as follows, with the
history reset if YES was selected, or not if NO was selected:
i) If NO (cancel) was selected, the display retunes to the [Electrical equipment system failure his-
tory] screen of the relevant failure (i.e., the screen before entering the [Electrical equipment sys-
tem failure history individual clear] or [Electrical equipment system failure history all clear]
screen).
ii) If YES (clear) was selected, the display return to the [Electrical equipment system failure history]
screen of a failure next to the relevant failure. If the failure history to be shown exists, the screen
return to the [Electrical equipment system failure history selection] screen.
By default, the cursor is on NO (no reset) to prevent resetting by error.
A current failure cannot cleared. If it was selected, a peep sounds for one second to notify that the
operation is cancelled.
18 HD325-7, HD405-7
Machine system failure history function

1) Display of machine system failure history
Pressing the > switch displays the next newer failure.
After the oldest failure in memory was displayed, a screen is displayed allowing clearing the entire
failure history of electrical system of the relevant controller.
Pressing the t switch changes the screen to the [Machine system failure history selection] screen.
2) Machine system failure history selection (first layer)

Pressing the > switch changes the screen to the [Real-time monitor function selection] screen.
Pressing the < switch changes the screen to the [Electrical equipment system failure history function
selection] screen.
Pressing the t switch changes the screen to the ordinary or alert screen.
Pressing the U switch changes the screen to the [Machine system failure history] screen.
HD325-7, HD405-7 19
3) Machine system failure history (second layer)

The failure history is displayed in the order of occurrence with the newest failure first.
The failure history is displayed in the order of occurrence with the newest failure first.
Pressing the > switch displays the next newer failure.
Pressing the t switch changes the screen to the [Machine system failure history] screen.
20 HD325-7, HD405-7
Real-time monitoring function

The real-time monitor shows real-time the information which the controller mounted on the vehicle has.
This function is used for checking and adjustment, diagnosis of failures of the machine and other purposes.
The real-time monitor shows the items and their data, classified by the controllers which have information.
It shows them in two ways: the ordinary display, and the 2-item display where two data items are shown
simultaneously.
Operation
1. Press the t switch and < switch for more than 5 seconds to go to the [ID Input] screen.
2. Input ID with the < and > switch, and press the U switch to go to the screen for service persons.
3. Press the < and > switch to display the [Real-time monitor selection] screen, then press the U switch to
fix the screen.
HD325-7, HD405-7 21
4. Press U switch, and the [Monitor information display/selection] screen appears. Press the < and >
switch to display the [Transmission controller information display/selection] screen, [Engine controller
information display/selection] screen, [Retarder controller information display/selection] screen, [ABS
controller information display/selection] screen (if equipped) and [2 item display function selection]
screen in order.
5. Pressing the U switch, while each selection screen is shown, displays the [1-item display] screen or the
[Select information on 2-item display] screen.
***: Shows items.

%%%%%: Shows data and unit (SI system)
$$$$: Shows ID.
In the case of 1-item display, pressing the < and > switch changes the items shown in turn, displaying the
information each controller has.
22 HD325-7, HD405-7
How to input an ID
After the screen was changed from another, “00000” is shown.
Enter a number 0-9 in the cursor position.
The cursor is at the highest digit first. Each time the < or > switch was pressed, the number changes by 1
within a range 0-9.
If the desired number was entered, press the U switch.
The cursor moves to the second highest digit. Repeat the procedures mentioned above until the last num-
ber is filled in the lowest digit.
If the lowest digit was entered, press the U switch, and the screen changes to that for displaying/selecting
the second item. Alternately, pressing the t switch returns the screen to that for displaying/selecting 2
items.
In the case of 2-item display, enter the IDs of the information to be displayed, and the 2 items are shown
simultaneously. The IDs shown are the same as those on the 1-item display screen.
6. In the case of 1-item display, pressing the < and > switch changes the items shown in turn, displaying the
information each controller has.
HD325-7, HD405-7 23
List of real-time monitoring display contents
The conditions of the input and output signals of the controller can be checked with the real-time monitoring
function of the monitor.
The following table shows the items related to the machine monitor and displayed with the real-time monitor-
ing function in the normal state.
No. Item ID No. Display of item Displayed data
1 Software No. 20200 VERSION Software No. is displayed.
2 Application ver. No. 20221 VERSION (APP) Application ver. No. is displayed.
3 Data ver. No. 20222 VERSION (DATA) Data ver. No. is displayed.
4 Rheostat 30300 RHEOSTAT Rheostat voltage is displayed.
5 Rotary switch 1 – 3 30800 SW1, SW2, SW3 –
6 DIP switch 5-1, 2 30900 SW5-1, SW5-2 SW5-1: Selection of SI or non-SI specifi-
cation
SW5-2: Unused
7 DIP switch 5-3, 4 30901 SW5-3, SW5-4 –
8 DIP switch 6-1, 2 30202 SW6-1, SW6-2 –
9 DIP switch 6-3, 4 30903 SW6-3, SW6-4 –
10 D-IN--0------7 40900 D-IN--0------7 Input signal is displayed.
11 D-IN--8------15 40901 D-IN--8------15 Input signal is displayed.
24 HD325-7, HD405-7
Contents of display in normal state Remarks
As per software No.
As per application version No.
As per data version No.
0 – 30 V
– Unused
SW5-1:
For 7831-46-7000*, normally OFF
For 7831-46-8000*, normally ON
SW5-2: Unused
– Unused
– Unused
– Unused
1 0000000 (Headlight = ON) D-IN-0: High beam

0 1 000000 (Switch = ON) D-IN-1: Machine monitor check switch
00 1 00000 (AISS switch = ON) D-IN-2: AISS switch
00000 1 00 (Switch = ON) D-IN-5: ABS system switch (if equipped)
If not equipped: 0
000000 1 0 (Switch = ON) D-IN-6: Passing switch
0000000 1 (Switch = Economy) D-IN-7: Engine mode switch
1 0000000 (Normally 1) D-IN-8: Connector check

0 0 000000 (Monitor mode switch (t) = ON) D-IN-9: Machine monitor mode switch (t)
00 1 00000 (Monitor mode switch (>) = ON) D-IN-10: Machine monitor mode switch (>)
000 1 0000 (Monitor mode switch (<) = ON) D-IN-11: Machine monitor mode switch (<)
0000 1 000 (Winker (Right) = ON) D-IN-12: Winker (Right)
00000 1 00 (Winker (Left) = ON) D-IN-13: Winker (Left)
000000 1 0 (Monitor mode switch (U) = ON) D-IN-14: Machine monitor mode switch (U)
0000000 0 (Unused) D-IN-15: Unused
HD325-7, HD405-7 25
No. Item ID No. Display of item Displayed data
12 D-IN-16-----23 40902 D-IN-16-----23 State of input signal is displayed.
15 D-OUT-0--3 40925 D-OUT-0--3 State of output signal is displayed.
26 HD325-7, HD405-7
Contents of display in normal state Remarks
0 0000000 (Switch = ON) D-IN-16: ARSC system switch (Upper) (If equipped)
If not equipped: 0
0 1 000000 (Switch = ON) D-IN-17: ARSC system switch (Lower) (If equipped)
If not equipped: 0
00 1 00000 (Switch = ON) D-IN-18: ABS system switch (Upper) (If equipped)
If not equipped: 0
000 1 0000 (Switch = ON) D-IN-19: ABS system switch (Lower) (If equipped)
If not equipped: 0
0000 1 000 (Switch = ON) D-IN-20: ASR system switch (Upper) (If equipped)
If not equipped: 0
00000 0 00 (Unused) D-IN-21: ASR system switch (Lower) (If equipped)
If not equipped: 0
000000 1 0 (Switch = ON) D-IN-22: Front brake cut-off switch
If not equipped: 0
1 0000000 (Headlight = ON) D-IN-24: Night lighting recognition

0 1 000000 (Seat belt = Installed) D-IN-25: Seat belt
00 1 00000 (Unused) D-IN-26: Unused

00 0 00000 (Normally 0) D-IN-34: Connector check
0000000 0 (Reservation for service, OP7 = OPEN) D-IN-39: Reservation for service
1 000 (Headlight Hi/Lo selector switch = ON) D-OUT-0: Headlight Hi/Lo selector switch
0 1 00 (Buzzer = ON) D-OUT-1: Buzzer
00 0 0 (Unused) D-OUT-2: Unused
000 0 (Unused) D-OUT-3: Unused
HD325-7, HD405-7 27
Engine reduced cylinder function
Regarding the inspection method using this func-

tion, refer to the Section "Reduced cylinder mode
operation of engine" in the chapter "Testing and
adjusting"
This section will describe the operation method
only.
1. Press the t switch and < switch for more than

five seconds to go to the [ID Input] screen.
2. Input ID with the < and > switch, and press the
U switch to go to the screen for service per-
sons.
3. Press the < and > switch to display the [Reduced

cylinder mode selection] screen, then press the
U switch to fix the screen.
28 HD325-7, HD405-7
4. How to operate the engine reduced cylinder function

1) Each time the > switch is pressed (to select the cylinder to be reduced with a command), the cursor
moves one step to the right.
Each time the < switch is pressed (to select the cylinder to be reduced with a command), the cursor
moves one step to the left.
Pressing the U switch issues the command to reduced the cylinder selected. Each time it is pressed,
the command toggles between reduced and cancel.
Pressing the t switch returns the screen to that of [Select the reduced cylinder mode], and any cut-
out command which has been issued from monitor is cancelled.
Example of operation: The command is issued to stop the third cylinder.
HD325-7, HD405-7 29
No injection cranking function screen

Regarding the engine start method using this function, refer to the Section "No injection cranking operation
of engine" in the chapter "Testing and adjusting"
This section will describe the operation method only.
30 HD325-7, HD405-7
Adjusting function
Regarding the adjusting method using this function,
refer to the Section "Adjustment using monitor" in
the chapter "Testing and adjusting"
This section will describe the operation method
only.
01: TM TRIGGER Transmission Initial learning re-

set
a Refer to "Rest of Initial learning for Transmis-
sion and Learning Operation" in the chapter
"Testing and adjusting"
02: ECMV TUNING ECMV compensation

a Refer to "Transmission ECMV Current Adjust-
ment" in the chapter "Testing and adjusting".
HD325-7, HD405-7 31
Maintenance Monitor Function

1. Maintenance monitor selection display (first layer)
Regarding the screen, which the current screen
turns to when the <, >, or t switch is pressed,
refer to "Second Layer Transition Diagram" in
the Section "Service Person Function".
When the U switch is pressed, the current

screen turns to the [Maintenance item No. 1]
screen.
32 HD325-7, HD405-7
2. Maintenance item selection

1) Each time the > switch is pressed, the item 2) Each time the < switch is pressed, the item
No. of the displayed screen changes from No. of the displayed screen changes from
No. 1 in the ascending order. the largest number in the descending order.
a When the item No. of the displayed screen a When the item No. of the displayed screen
is the largest, pressing the > switch chang- is No. 1, pressing the < switch changes the
es the screen to the "Default value is set" screen to the "All timer stop/all item valid"
screen. screen.
a. Maintenance interval time change (4) The cursor moves to the second highest digit.
Repeat the procedures mentioned in (2) and (3)
until the last number is filled in the lowest digit.
(5) After the lowest digit is entered, press the U
switch.
a If the entered value represents the interval time
which can be set, the screen changes to the
confirmation screen.
a If the entered value represents the interval time
which cannot be set, the time doe not change.
(6) The cursor is returned to the highest digit.
a The interval time can be set up to 50 h.
(7) If a wrong number is entered, unless the cursor
is positioned at the highest digit, press the t
switch to bring the cursor to the highest digit,
and do the procedures from the beginning
again.
a At this time, the entered values remain un-
changed.
(8) When the cursor is positioned at the highest dig-
it, pressing the t switch changes the screen to
the higher layer.
q Press the < or > switch to select YES/NO.
q The cursor (_) blinks on the selected item
When YES is selected, pressing the t switch
accepts the change. When NO is selected,
pressing the t switch cancels the change, and
goes to the "Maintenance item selection"
How to enter interval time screen.
(1) Enter a number from 0 to 9 in the cursor position. a The cursor is positioned at NO by default to pre-
(2) The cursor is positioned at the highest digit first. vent from mistakenly carrying out the reset op-
Each time the > or < switch is pressed, the num- eration.
ber is changed in the INC/DEC order by 1 within
a range 0 to 9. q When the interval time is changed, the remain-
(3) If the desired number is entered, press the U ing time on the timer is as follows.
switch to apply it. [Set interval time – time elapsed from the previous
operation]
HD325-7, HD405-7 33
b. Item specific timer stop/item specific valid 3. Default individual setting

selection
q Press the < or > switch to select YES/NO.

q When "Item specific timer" is currently operat- q The cursor (_) blinks on the selected item.
ing, "ON o OFF" is displayed on the lower When YES is selected, pressing the t switch
panel. accepts the change. When NO is selected,
q When "Item specific timer" is currently stop- pressing the t switch cancels the change, and
ping, "OFF o ON" is displayed on the lower goes to the "Maintenance monitor selection"
panel. screen.
a The timer function should be valid by default a The cursor is positioned at NO by default to pre-
with [ON] displayed. vent from mistakenly carrying out the reset op-
q Setting "Item specific timer" to stop state, eration.
[OFF] is displayed on the higher panel. q For each maintenance item, the timer should
q Setting "Item specific timer" to operation state, be set to stop/stop release.
[ON] is displayed on the higher panel. q Set the timer to stop/ release from stop for
q Press the < or > switch to select YES/NO. each of the maintenance items.
q The cursor (_) blinks on the selected item. q When the timer is made enables after it was
When YES is selected, pressing the t switch stopped, the interval time set to the timer
accepts the change. When NO is selected, before the timer was disabled is restored.
pressing the t switch cancels the change, and a The number of reset times is not incremented
goes to the "Maintenance item selection" but remains the same.
screen. a Set each valid/invalid state to valid.
a The cursor is positioned at NO by default to pre-
vent from mistakenly carrying out the reset op-
eration.
q Set the timer to stop/ release from stop for
each of the maintenance items.
q When the timer is made enabled after it was
stopped, the interval time set to the timer
before the timer was disabled is restored.
q The remaining time on the timer is reset.
a The number of reset times is not incremented
but remains the same.
34 HD325-7, HD405-7
4. "All items timer stop/all items valid selection"
*1. Press the U switch to change the screen to the "All items timer stop" screen.
*2. In the case that "All item timer stop" is selected
*3. When all item stop is carried out:
The timer functions for all items are disabled, and the screen returns to the "Maintenance monitor se-
lection" screen.
When the specific item is carried out, the setting is made to disable the function.
When cancel is carried out:
The operation is cancelled and the screen returns to the "Maintenance monitor selection" screen.
*4. When "All item valid" is selected
*5. Press the < or > switch to select YES/NO.
The cursor (_) blinks on the selected item
a The cursor is positioned at NO (not change) by default to prevent from mistakenly carrying out the
reset operation.
*6. When all item valid is carried out:
Regardless of whether specific item is valid or invalid, the interval time set to the timer before the timer
was disabled is effective for all items.
The remaining time on the timer is reset.
Meanwhile, the number of reset times is not incremented but remains the same.
The screen returns to the "Maintenance monitor selection" screen.
Setting is made valid for each item.
When cancel is carried out:
The operation is cancelled and the screen returns to the "Maintenance monitor selection" screen.
HD325-7, HD405-7 35
5. Maintenance monitor item
English message
No. Item Interval [h] ID number
[11 one-byte characters]
1 Pre fuel filter 500 P FUEL FILT 41
2 Engine oil 500 ENG OIL 01
3 Engine oil filter 500 ENG FILT 02
4 Transmission oil filter 500 TM FILT 13
5 Fuel filter 1,000 FUEL FILT 03
6 Corrosion resistor 1,000 CORR RES 06
Torque converter, transmission and
7 1,000 TC/TM/BK OIL 24
rear brake cooling oil
8 Brake oil filter 1,000 BK OIL FILT 14
9 Brake cooling oil filter 1,000 BK C FILT 16
10 Steering, hoist oil filter 2,000 HYD FILT 04
11 Differential case oil 2,000 DIFF OIL 11
12 Final drive oil 2,000 FNL OIL 08
13 Steering, hoist oil 4,000 HYD OIL 10
36 HD325-7, HD405-7
Operation information display function

Outline
q The fuel consumption value is calculated based on the target injection quantity information supplied
from the engine controller.
q The fuel consumption value can be used merely as a reference value because the actual fuel consump-
tion is not measured.
*1 *3
Upper column Upper column
q Displays fuel consumption (L/km or L/mile) for q Displays accumulated fuel consumption (L)
every 1 km (or mile) since the previous reset since the previous reset
q Calculation is made based on the above fuel q Counting will stop when the upper limit
consumption and the travel distance 9999999.9 is reached.
q Counting will stop when the upper limit Lower column
99999.9 is reached. q Displays elapsed time (h) since the previous
Lower column reset
q Displays average fuel consumption (L/h) since q Counting will stop when the upper limit
the previous reset 9999999.9 is reached.
q Counting will stop when the upper limit 99999.9 *1 – *3
is reached. q Calculation is made only when engine is oper-
*2 ating and optional equipment is provided.
Upper column *4
q Displays accumulated fuel consumption (L) q Press the U switch to delete data in the
since the previous reset screen (*1), (*2), (*3) and return to the screen
q Counting will stop when the upper limit of the previous layer.
9999999.9 is reached. q Press the t switch to return to the screen of
Lower column the previous layer without resetting the current
q Displays travel distance (km or mile) since the screen.
previous reset a Reset the data when "Initializing the monitor
q Counting will stop when the upper limit panel" and when "Turning the optional func-
9999999.9 is reached. tions OFF", in addition to the above resetting
operation.
HD325-7, HD405-7 37
Obtaining fuel consumption level [L] Procedures with the monitor panel:
q The monitor panel calculates the accumulated q Default value: 0.0%
fuel consumption (L) based on the instanta- q Specify the setting value to compensate the
neous fuel consumption [L/h] supplied from the accumulated fuel consumption (L) in the range
engine controller. of [– 50.0 to + 50.0]
q The accumulated fuel consumption (L) is com-
pensated using the fuel adjusting function
[FUEL ADJUST] on the service mode.
q The instantaneous fuel consumption [L/h] sup-
plied from the engine controller is compen-
sated in accordance with the table shown
below.
[Compensated value in accordance with the table]

= [Instantaneous fuel consumption supplied from
engine controller] x [compensation value (a)]
Model Compensation value (a)
HD325-7, HD405-7 1
HD465-7E0, HD605-7E0 1
HD785-7 1
*5
Setting of gain compensation value
1) In order to change the screen, display the cur-
rent setting value and place the cursor on the
symbol (+ or –).
2) While the cursor is being positioned at the sym-
bol, repeat '+' or '–', each time the > or < switch
is pressed.
3) Press the U switch to confirm the symbol. o
The cursor moves to the highest digit.
4) The cursor is positioned at the highest digit first.
Each time the > or < switch is pressed, the num-
ber is changed in the INC/DEC order by 1 within
a range 0 to 9 (the highest digit is 0 to 2).
5) If the desired number is entered, press the U
switch to apply it.
6) The cursor moves to the lower digit. Repeat the
procedure mentioned in 4).
7) The cursor moves to the lowest digit. Press the
U switch. (When the number is confirmed, the
screen returns to that of the previous layer.)
8) While the number is being entered, pressing the
t switch makes the number remain unchanged
and the cursor returns to the position of the sym-
bol. Pressing the t switch again change the
screen to the previous screen.
9) When the number is not within the range from
– 50.0 to + 50.0 while the lowest digit is con-
firmed, the number remains unchanged and
the cursor returns to the position of the symbol,
as is the case for pressing the t switch.
38 HD325-7, HD405-7
Engine mode fixing function
Outline
q This function is used to check the engine per-
formance. (High idle speed and torque con-
verter stall speed)
q There are 4 engine modes (A, B, C, and D). If
a mode is selected by the following operation,
it is transmitted to the transmission controller.
Then, transmission controller orders the
engine controller to operate in that mode.
q While this screen is displayed, run the engine
at high idle or stall the torque converter and
check the engine speed in each case.
q If this screen changes to another, the engine
mode fixing function is reset.
q For the Standard values of the engine in A, B,
C, and D, see the Standard value table.
a Before using this function, check the following.
q The parking brake is turned ON.
q No errors are made.
HD325-7, HD405-7 39
Option selecting function

a Regarding the setting method using this func-
tion, refer to the Section "Adjustment using
monitor" in the chapter "Testing and adjusting".
Model setting function

a Regarding the setting method using this func-
tion, refer to the Section "Adjustment using
monitor" in the chapter "Testing and adjusting".
40 HD325-7, HD405-7
HD325-7, HD405-7 41
Table of signals for each monitor connector
Machine monitor
No. Specification
CN PIN I/0 A/D
1 CN1 1 – – –
2 CN1 2 – – –
3 CN1 3 – – –
4 CN1 4 – – NSW power supply (+24 V)
5 CN1 5 – – NSW power supply (+24 V)
6 CN1 6 – – SW power supply (+24 V)
7 CN1 7 – – SW power supply (+24 V)
8 CN1 8 – – –
9 CN1 9 – – GND
10 CN1 10 – – GND
11 CN1 11 0 D D_OUT_3, (Sync 200 mA)
12 CN1 12 0 D D_OUT_2, (Sync 200 mA)
13 CN1 13 0 D D_OUT_1, (Sync 200 mA)
14 CN1 14 0 D D_OUT_0, (Sync 200 mA)
15 CN1 15 – – Sensor power output (+24 V, 100 mA)
16 CN1 16 – – Sensor power output (+5 V, 100 mA)
17 CN1 17 – – GND
18 CN1 18 – – GND
19 CN1 19 – – GND
20 CN1 20 – – GND
21 CN2A 1 I D D_IN_0, (+24 V, 5 mA, PULL DOWN)
27 *1 CN2A 7 I D D_IN_12, (NSW+24 V, 5 mA, PULL DOWN)
28 *1 CN2A 8 I D D_IN_14, (NSW+24 V, 5 mA, PULL DOWN)
*1: NSW +24 V input port is active even if the setting is made to KEY OFF when power is supplied directly
from battery.
42 HD325-7, HD405-7
Signal and model

Model name
Remarks
Signal name HD325-7 HD465-7E0
HD785-7
HD405-7 HD605-7E0
– – – – (–) : NON CONNECT
– – – – OPEN (RESERVED)
– – – – OPEN (RESERVED)
BAT DIRECT +24 V Q Q Q Directly from battery +24 V
BAT DIRECT +24 V Q Q Q Directly from battery +24 V
POWER SUPPLY +24 V Q Q Q Key switch +24 V (ACC)
POWER SUPPLY +24 V Q Q Q Key switch +24 V (ACC)
GND (for power supply) Q Q Q +24 V POWER CONNECT
GND (for power supply) Q Q Q +24 V POWER CONNECT
BUZZER OUTPUT Q Q Q Warning buzzer (Max. 200 mA sync)
HEAD LIGHT H/L SWITCHING Q Q Q
HI BEAM Q Q Q
AISS SW Q Q Q
EXHAUST SW2 – – Q Exhaust brake switch lower side
PASSING SW Q Q Q
CONNECTER CHECK Q Q Q Used to detect improper connector, connection
MODE SW2-1 > Q Q Q Mode SW2 upper side
RIGHT TURN Q Q Q
MODE SW1-1 U Q Q Q Mode SW1 upper side
HD325-7, HD405-7 43
Machine monitor
No. Specification
CN PIN I/0 A/D
29 CN2A 9 – – GND
30 CN2A 10 I D D_IN_1 (+24 V, 5 mA, PULL DOWN)
31 CN2A 11 I D D_IN_3 (+24 V, 5 MA, PULL DOWN)
36 *1 CN2A 16 I D D_IN_13 (NSW+24 V, 5 MA, PULL DOWN)
37 *1 CN2A 17 I D D_IN_15 (NSW+24 V, 5 MA, PULL DOWN)
38 CN2A 18 I A D_IN_0 (0 – 30 V)
39 CN2B 1 I D D_IN_16 (+24 V, 5 MA, PULL UP)
43 CN2B 5 I D D_IN_24 (+24 V, 5 MA, PULL DOWN)
44 CN2B 6 – – GND
49 CN2B 11 I D D_IN_25 (+24 V, 5 MA, PULL DOWN)
50 CN2B 12 I A A_IN_1 (0 – 30 V)
54 *2 CN3A 4 I D D_IN_32 (GND, 5 MA, PULL UP)
*1: NSW +24 V input port is active even if the setting is made to KEY OFF when power is supplied directly
from battery.
*2: Setting is made to PULL UP.
44 HD325-7, HD405-7
Signal and model

Model name
Remarks
HD785-7
HD405-7 HD605-7E0
SENSOR GND Q Q Q
CHECK SW Q Q Q
EXHAUST BRAKE SW1 – – Q Exhaust brake switch upper side
ABS CHECK SW Q Q Q
ENGINE MODE SW Q Q Q
MODE SW1-2 t Q Q Q Mode SW1 lower side
MODE SW1-2 < Q Q Q Mode SW1 lower side
LEFT TURN Q Q Q
ARSC SYSTEM SW1 Q Q Q ARSC system switch (upper)
ABS SYSTEM SW1 Q Q Q ABS system switch (upper)
ASR SYSTEM SW1 Q Q Q ASR system switch (upper)
FRONT BRAKE CUT OFF Q Q – (–) : NON CONNECT

Head Light SW recognition for Night Lighting
NIGHT LIGHTING SW +24 V Q Q Q function
SENSOR GND Q Q Q
ARSC SYSTEM SW2 Q Q Q ARSC system switch (lower)
ABS SYSTEM SW2 Q Q Q ABS system switch (lower)
ASR SYSTEM SW2 Q Q Q ASR system switch (lower)
SEAT BELT Q Q Q
PANEL DIMMER SWITCH Q Q Q

CONNECTOR CHECK 2 (–) : NON CONNECT,
(OPEN) Q Q Q Used to detect improper connector connection
HD325-7, HD405-7 45
Machine monitor
No. Specification
CN PIN I/0 A/D
57 *2 CN3A 7 I D D_IN_38 (GND, 5 mA, PULL UP)
58 CN3A 8 I P P_IN_0 (0.5 Vp-p)
59 CN3A 9 – – GND
62 CN3A 12 I D –
67 CN3A 17 I P P_IN_0 (0.5 Vp-p)
68 CN3A 18 – – NC
69 CN3B 1 I A A_IN_2 (High resistance input)
71 CN3B 3 I A A_IN_6 (Low resistance input)
72 CN3B 4 I A A_IN_8 (0 – 5 V)
73 CN3B 5 I A A_IN_10 (0 – 5 V)
74 CN3B 6 – – GND
77 CN3B 9 I A A_IN_7 (0 – 5 V)
78 CN3B 10 I A A_IN_9 (0 – 5 V)
79 CN3B 11 – – GND
80 CN3B 12 – – NC
81 CN4 1 – – S_NET (+)
82 CN4 2 – – S_NET (+)
83 CN4 3 – – CAN (+)
84 CN4 4 – – S_NET (–)
*2: Setting is made to PULL UP.
46 HD325-7, HD405-7
Signal and model

Model name
Remarks
HD785-7
HD405-7 HD605-7E0
OP7 Q Q Q For service mode
CAN (+) Q Q Q
HD325-7, HD405-7 47
Machine monitor
No. Specification
CN PIN I/0 A/D
85 CN4 5 – – S_NET (–)
86 CN4 6 – – GND
87 CN4 7 – – GND
88 CN4 8 – – CAN (–)
89 CN4 9 – – NC
90 CN4 10 – – NC
91 CN4 11 – – NC
92 CN4 12 – – NC
93 CN5 1 – – NC
94 CN5 2 – – RA232C_1_RTS
95 CN5 3 – – RA232C_1_RD
96 CN5 4 – – RA232C_2_RD
97 CN5 5 – – RA232C_2_RTS
98 CN5 6 – – NC
99 CN5 7 – – NC
100 CN5 8 – – RA232C_1_CTS
101 CN5 9 – – RA232C_1_TX
102 CN5 10 – – RA232C_1_SG
103 CN5 11 – – RA232C_2_SG
104 CN5 12 – – RA232C_2_TX
105 CN5 13 – – RA232C_2_CTS
106 CN5 14 – – NC
107 CN6 1 – – –
108 CN6 2 – – –
109 CN6 3 – – –
110 CN6 1 – – NC
111 CN6 5 – – –
112 CN6 6 – – NC
113 CN6 7 – – –
114 CN6 8 – – GND
48 HD325-7, HD405-7
Signal and model

Model name
Remarks
HD785-7
HD405-7 HD605-7E0
– Q Q Q (–) : NON CONNECT
CAN SHIELD GND Q Q Q
CAN (–) Q Q Q
– Q Q Q
– Q Q Q
– Q Q Q
Q Q Q
Q Q Q (–) : NON CONNECT
CAN (+) Q Q Q (–) : NON CONNECT
– Q Q Q
HD325-7, HD405-7 49
a Switch input on monitor panel board
No. SW Position I/0 A/D Specification
1 SW1 0 I D
2 SW1 1 I D
3 SW1 2 I D
4 SW1 3 I D
5 SW1 4 I D
6 SW1 5 I D
7 SW1 6 I D
8 SW1 7 I D
Rotary switch (16 positions)
9 SW1 8 I D
10 SW1 9 I D
11 SW1 A I D
12 SW1 B I D
13 SW1 C I D
14 SW1 D I D
15 SW1 E I D
16 SW1 F I D
17 SW2 0 I D
18 SW2 1 I D
19 SW2 2 I D
20 SW2 3 I D
21 SW2 4 I D
22 SW2 5 I D
23 SW2 6 I D
24 SW2 7 I D
25 SW2 8 I D
26 SW2 9 I D
27 SW2 A I D
28 SW2 B I D
29 SW2 C I D
30 SW2 D I D
31 SW2 E I D
32 SW2 F I D
50 HD325-7, HD405-7
Model name
Signal name HD325-7 HD465-7 Remarks
HD785-7
HD405-7 HD605-7
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
HD325-7, HD405-7 51
No. SW Position I/0 A/D Specification
33 SW3 0 I D
34 SW3 1 I D
35 SW3 2 I D
36 SW3 3 I D
37 SW3 4 I D
38 SW3 5 I D
39 SW3 6 I D
40 SW3 7 I D
41 SW3 8 I D
42 SW3 9 I D
43 SW3 A I D
44 SW3 B I D
45 SW3 C I D
46 SW3 D I D
47 SW3 E I D
48 SW3 F I D
49 SW5 1 I D
50 SW5 2 I D Dip switch (2 positions)
51 SW5 3 I D
52 SW5 4 I D
53 SW6 1 I D
54 SW6 2 I D
Dip switch (2 positions)
55 SW6 3 I D
56 SW6 4 I D
52 HD325-7, HD405-7
Model name
Signal name HD325-7 HD465-7 Remarks
HD785-7
HD405-7 HD605-7
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
ON: SI specification
– – –
OFF: Non-SI specification
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
– – – –
HD325-7, HD405-7 53

© 2007 KOMATSU
All Rights Reserved
54 HD325-7, HD405-7
SEN00757-02
DUMP TRUCK
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up

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
HD325-7, HD405-7 1
Automatic shift control system 1

1.Electrical circuit diagram
2 HD325-7, HD405-7
HD325-7, HD405-7 3
Outline RTCDB2(Machine monitor, retarder controller, and

q The transmission controller receives the shift the other) (Updated every 100 msec)
position signal of the gearshift lever, accelera- No. Item
tion signal of the accelerator pedal, speed sig-
1 Gear speed
nal of the transmission, and signals of various
2 Shift lever position
switches and sensors, the transmission con-
3 Lock-up operation state
troller automatically sets the transmission in
the most suitable gear speed. 4 Torque converter state
q The transmission controller controls the torque 5 Emergency escape state
converter lockup system and the brake to pre- 6 Operating state of overrun prevention brake
vent overrun, as well as the transmission. 7 Model setting abnormality state
Each of the clutch packs of the transmission 8 Option setting abnormality state
and the torque converter lockup clutch pack 9 Neutral safety alarm command
has the electronically controlled modulation 10 Overrun alarm command
valves to control the clutches independently. 11 –
Those valves control the initial pressure, build- 12 –
up rate, and torque-off time of each clutch
13 Alternator R terminal state
according to the condition of the machine to
14 key switch C terminal state
reduce the gearshift shocks, prevent gearshift
15 Emergency steering operation
hunting, and improve the durability of the
clutch. 16 Tipping alarm command
q Upon receiving the signals of the switches and 17 Fuel level
sensors to drive the display, cautions, and pilot 18 Control state of grid heater
lamps of the machine monitor, the transmis- 19 Engine coolant temperature
sion controller sends them to the network. 20 Engine speed
21 Momentary fuel consumption
Data items transmitted from transmission con- 22 Body seating state
troller to network 23 Float caution command
24 Auto suspension mode
RTCDB1(Machine monitor, retarder controller, and 25 Retarder brake signal state
the other) (Updated every 10 msec) 26 Parking brake signal state
No. Item 27 –
1 Output shaft speed Tail lamp operation (secondary brake operation
28
recognition)
2 –
29 ARSC operation (ready lamp)
3 Brake command(Rear wheel)
30 ASR command (operation ON/OFF)
4 –
31 ABS operation condition
Retarder controller model setting abnormality
RTCDB1(Dedicated to engine controller) 32
condition
(Updated every 10 msec) Retarder controller option setting abnormality
33
condition
No. Item
Accumulator oil temperature drop state
1 Throttle correction value 34
(front,rear)
2 Throttle lower limit
35 ARSC overheat alarm
3 Throttle upper limit
36 ABS controller model setting abnormality state
4 2nd method throttle
37 ABS controller option setting abnormality state
5 HIS line / brake point speed
38 ARSC setting travel speed
6 Torque curve select (engine mode)
39 –
7 ABS reference type
40 Retarder oil temperature (rear)
8 Droop switch
41 Body positioner signal
9 ABS droop trim
RTCDB2(Dedicated to engine controller)

(Updated every 100 msec)
No. Item
1 Automatic warm-up cancel flag
4 HD325-7, HD405-7
Data item transmitted from the transmission RPC-k (irregularly updated)

controller to the network No. Item
1 Model selection information
RTCDB1 (Updated every 10 msec) Option selection information
No. Item [Option item]
a. Maximum gear speed setting
1 Engine speed
b. Maximum gear speed setting for the body-up
2 Accelerator opening state
3 Seat unoccupied judgment c. Exhaust brake equipped / not equipped
2
4 Reverse not-permitted command d. Correction amount of tire size
5 – e. ELVIS function Installed/Not installed
6 Retarder switch (rear) state f. Tipping alarm function Installed/Not installed
g. ABS function Installed/Not installed
7 Foot brake (service brake) state
h. Parking brake interlock provided / not pro-
vided
RTCDB2 (Updated every 100 msec) Adjustment mode information
(Adjustment mode information)
No. Item
3 a. Trigger correction amount learning value reset
1 Service meter b. Auto IP mode command
2 Engine mode switch c. Manual IP mode command
3 –
4 –
5 AISS inhibit switch
6 Reverse travel speed selector switch
7 Accelerator sensor abnormality condition
8 Engine coolant temperature
9 Control state of grid heater
10 Momentary fuel consumption
11 Parking brake operation
12 Retarder brake operation
13 Body seating state
14 Hoist lever condition
Tail lamp output (secondary brake operation
15
recognition)
16 Float caution
17 ASR command (operation ON/OFF)
18 ARSC operation (ready lamp)
19 ARSC setting travel speed
20 ARSC overheat alarm
21 –
22 –
23 Retarder oil temperature (rear)
24 Auto suspension mode
Retarder controller option setting abnormality
25
state
Retarder controller model setting abnormality
26
state
27 Body position sensor
28 ABS operation state
ABS controller option setting abnormality
29
state
ABS controller model setting abnormality
30
state
HD325-7, HD405-7 5
Transmission controller 1
Outline
q The transmission controller controls the trans- 8. The self-diagnostic function is installed for
mission system. each of the input and output systems.
It has the following features and functions. 9. The self-diagnostic function is displayed on
1. The gear shifting patter is set in the power the monitor.
mode or economy mode. 10. If a trouble is detected, its contents are sent
2. In the braking mode, the brake is used and to the network.
the gear shifting point is heightened to in- 11. It uses the machine monitor to display if the
crease the brake cooling pump speed. Ac- failure is still existing.
cordingly, the retarder cooling effect is 12. It provides an escape function for use when
increased and the engine is used as a brake there is a failure in the electrical system.
efficiently.
3. It controls the brake through the retarder
controller for the torque converter lockup
solenoid valve and overrun prevention.
4. To reduce the gear shift shocks, the throttle
correction command is output to the engine
controller to adjust the engine speed during
gear shifting operation.
5. Speed sensors are installed to 3 places of
the transmission input shaft, intermediate
shaft and output shaft to sense slip of the
transmission clutch and protect the trans-
mission when the hydraulic system has a
trouble.
6. It connects to the network and shares vari-
ous data with other controllers.
7. It receives the model selection data (what
model it is mounted on) through the net-
work.
6 HD325-7, HD405-7
Input and output signal
ATC1
Pin Input/output Pin Input/output
Signal name Signal name
No. signal No. signal
1 Torque converter oil pressure Input 13 Accumulator oil pressure sensor (front) Input
2 – – 14 –
3 Transmission oil temperature Input 15 Alternator R terminal Input
4 – – 16 Sensor power supply Output
5 Emergency escape switch Input 17 Transmission filter clogging switch 1 Input
6 Shift lever position N Input 18 – –
7 Accumulator oil pressure sensor (rear) Input 19 Machine inclination angle Input
8 Fuel level sensor Input 20 Steering oil temperature Input
9 Torque converter oil temperature Input 21 GND (for sensor) –
10 – – 22 Sensor power supply (5V) Output
11 – – 23 – –
12 Emergency steering operation Input 24 Start Input
ATC2
1 – – 21 –
2 – – 22 Network Low Imput/output
3 – – 23 –
4 – – 24 –
5 Shift lever position 5 Input 25 Shift lever position D Input
6 Shift lever position L Input 26 Shift lever position 3 Input
7 – – 27 Coolant level Input
8 – – 28 – –
GND (for input shaft rotation, output shaft
9 – – 29 Input
rotation)
10 – – 30 Transmission output shaft rotation Output
11 – – 31 –
12 – – 32 Network High Input/output
13 – – 33 – –
14 – – 34 – –
15 Shift lever position 6 Input 35 Shift lever position R Input
16 Shift lever position 2 Input 36 Shift lever position 4 Input
17 Air cleaner clogging switch Input 37 – –
18 – – 38 – –
19 – – 39 GND (intermediate shaft speed) Input
20 Transmission intermediate shaft speed Input 40 Transmission input shaft speed Input
ATC3
1 Power supply 24V Input 21 GND Input
2 Proportional solenoid power supply 24 V Input 22 Proportional solenoid power supply 24 V Input
3 ECMV High, 1st, 4th (-) Output 23 ECMV Rev, 2nd, lock-up (-) Output
4 – – 24 KEY switch ACC Input
5 ECMV 2nd (+) Output 25 ECMV Rev (+) Output
6 ECMV Low (+) Output 26 ECMV High (+) Output
7 – – 27 – –
Torque converter oil pressure sensor power
8 Output 28 – –
supply (24V)
9 Fill switch 2nd Input 29 Fill switch Rev Input
10 Fill switch Low Input 30 Fill switch High Input
11 Power supply 24V Input 31 GND Input
12 Proportional solenoid power supply 24 V Input 32 GND Input
13 ECMV output Low, 3rd (-) Output 33 GND Input
14 KEY switch ACC Input 34 – –
15 ECMV 3rd (+) Output 35 ECMV lock-up (+) Output
16 ECMV 4th (+) Output 36 ECMV 1st (+) Output
17 – – 37 – –
18 – – 38 – –
19 Fill switch 3rd Input 39 – –
20 Fill switch 4th Input 40 Fill switch 1st Input
HD325-7, HD405-7 7
Gearshift lever position and automatic gearshifting range

q The relationship between each gearshift position and the automatic gearshifting range is as shown in
the table below.
Gearshifting characteristics Braking mode:

q Shifting the transmission up and down is car- The shift-down point and the shift-up point are both
ried out according to the shift map saved in the raised, the engine speed is maintained at a higher
controller memory. level, and the amount of cooling oil for the retarder
There are five types of shift map, depending on is ensured to provide greater effect when the engine
the condition of the input signals. is used as a brake.
The settings for each mode are as shown in
the table below. Coasting mode:
The shift-down point and the shift-up point become
Mode Set conditions close to each other to decrease the occurrences of
Braking mode Brake signal ON
unnecessarily shifting transmission.
When the following conditions are fulfilled Partial delay:

Coasting
1. Brake signal OFF
mode
2. Accelerator idle Unnecessary gearshift operations caused by the
change of the mode are reduced.
When following conditions are satisfied
1. Within certain time after brake signal is turned
Partial delay OFF Power mode:
2. Accelerator pedal is not in idle position or full The power mode uses the power of the machine to
position
the maximum to provide the maximum payload.
When the following conditions are fulfilled However, when the machine is unloaded or has only
1. Certain time after brake signal is turned OFF a light load (high acceleration), an acceleration sen-
Power mode
2. Accelerator pedal depressed
3. Power mode selector switch is at power sitive type variable shifting point is used. This de-
tects the acceleration of the machine and shifts the
When the following conditions are fulfilled
Economy 1. Certain time after brake signal is turned OFF
transmission up sooner to provide better accelera-
mode 2. Accelerator pedal depressed tion and to reduce the fuel consumption, noise, and
3. Power mode selector switch is at economy transmission shock.
Economy mode:
When the machine is being used under light load,
such as when traveling unloaded or on flat ground,
the shift-up point and shift-down point are both low-
ered, the engine speed is maintained at a lower
level, and the fuel consumption, noise, and trans-
mission shock are reduced. In this mode, the maxi-
mum engine output is limited.
8 HD325-7, HD405-7
Automatic gearshifting graph

q The shift-up/shift-down points, the torque converter lock-up ON/OFF points, and the automatic braking
(for overrun prevention) ON/OFF points of each mode are as shown in the figure below.
Note:
1. Power mode q If the travel speed lowers below 1 km/h or the
q The optimum shift-up point is selected between foot brake is not applied or the lock-up is kept
2,100 and 1,750 rpm according to the accelerat- turned on for a long period, the lockup is
ing condition of the machine and gear speed. turned off and a gear speed proper for the
q The optimum shift-down point is selected travel speed is selected.
between 1,200 and 1,400 rpm according to the 4. Lockup
accelerator pedal position and gear speed. q The point to turn ON the torque converter
2. Economy mode lockup is set properly in the range from 1,250
q The optimum shift-up point is selected between to 1,475 rpm according to the torque converter
2,100 and 1,750 rpm according to the accelerat- inlet speed (engine speed) and outlet speed
ing condition of the machine and gear speed. (transmission input shaft speed) and accelera-
q The optimum shift-down point is selected tor pedal position.
between 1,200 and 1,400 rpm according to the q The lockup-off point is 1,100 rpm.
accelerator pedal position and gear speed. q When the machine moves off downhill with the
accelerator pedal released, lockup is not
3. Braking mode
engaged until the accelerator pedal is
q While the foot brake is operated, if the travel
depressed or the foot brake is applied.
speed lowers below about 18 km/h at the 4th
gear speed, about 13 km/h at 3rd gear speed,
or 10 km/h at the 2nd gear speed, the current
gear speed (F4, F3, or F2) is maintained.
Accordingly, if the operator drives the machine
down a slope with the foot brake applied and
the engine speed is kept low by the gear speed
maintaining function, the cooling oil becomes
insufficient and the brake tends to overheat.
HD325-7, HD405-7 9
Gear shift lever positions and method of shifting 4) Gear shift lever position N
1) Gearshift lever position D At the neutral position, none of the transmis-
When shifting up (in power mode) sion clutches are actuated.
I) When the gearshift lever is set at position D,
the transmission is set to F2 torque converter Shift hold function
range. q If the hold switch on the gearshift lever is
II) When the accelerator pedal is depressed, the pushed once, the current gear speed is held. If
engine speed rises and accelerates. When the the hold switch is pressed once again or the
transmission input shaft speed reaches 1,250 – gearshift lever is operated, the gear speed can
1,475 rpm, the lock-up clutch is engaged, so be changed. If the travel speed lowers exces-
the torque converter is directly engaged and sively while the gear speed is held, the gear is
the transmission is set to direct travel. shifted down. When the travel speed rises
III) As the engine speed rises further and reaches again, however, the original gear speed is
1,750 – 2,100 rpm, the transmission shifts up to held.
F3.
While the transmission is shifting up, the Time when gear cannot be shifted
engine speed is also lowered (a command is No-shift time
output to the engine controller) in order to q In the automatic shift range, no-shift time is
reduce the shock when shifting gear. secured during each gear shifting operation to
IV) Immediately after shifting up, the engine speed prevent a malfunction caused by transient
momentarily goes down, but as the machine change of the speed at the gear shifting opera-
accelerates, it rises again and the transmission tion. The gear is not shifted in this no-shift time.
shifts up to F4 to F7 in the same way as in III) q The no-shift time is controlled finely for each
above. gear shift pattern by the all-range electronic
modulation system.
When shifting down (in power mode)
I) When the load increases and the engine speed The no-shift time for each gear shift pattern is
drops to 1,200 – 1,400 rpm, the transmission roughly shown below.
shifts down one speed.
(For example, when traveling in F7, the trans-
mission shifts down to F6.)
While the transmission is shifting down, the
engine speed is also raised (a command is out-
put to the engine controller) in order to reduce
the shock when shifting gear.
II) As the engine speed goes down further and the
transmission shifts down to F2, the torque con-
verter lock-up clutch is disengaged and the
transmission enters the torque converter drive.
a The set speed and operating condition in the

above explanation are subject to change, de-
pending on the travel condition. For details, see
the automatic gear shifting graph.
2) Gear shift lever positions 6, 5, 4, 3, 2, L

The method of shifting automatically from F1 to
(F6, F5, F4, F3, F2) is the same as for "gear
shift lever position D" above.
3) Gear shift lever position R
There is the gear shift lever position for travel-
ing in reverse.
The safety functions related to travel in reverse
are the directional inhibitor and reverse safety.
If the operation is not correct, gearshifting is
restricted.
10 HD325-7, HD405-7
Safety functions 4) Power train overrun prevention rear brake func-

1) Down-shift inhibitor function tion
If gearshift lever is operated D o 6 - L, 6 o 5 - If the engine speed rises to more than 2,350
L, 5 o 4 - L, 4 o 3 - L, 3 o 1 - L, 2 o L rpm, the central warning lamp flashes and the
For example, when traveling in D (F7), even if alarm buzzer sounds.
the gearshift lever is operated to 5, the trans- If the engine speed rises to more than 2,600
mission does not shift directly F7 o F5. It shifts rpm, the rear brake is automatically actuated.
down F7 o F6 o F5 according to the travel (To prevent overrun of engine, torque con-
speed. verter, and transmission, to improve durability
(Even if the operator makes a mistake in opera- and reliability)
tion of the gearshift lever, the transmission If a symptom of overrun is detected, the rear
does not skip a gear speed. This is to prevent brake is actuated automatically to prevent over-
overrunning of the engine.) run even if the engine speed is below the
2) Neutral safety function above value.
This circuit prevents the engine from starting if 5) REVERSE safety
the gearshift lever is not at the N position, even The machine will not travel in reverse if the
if the starting switch is turned to the START dump control lever is not at FLOAT and the
position. dump body is not completely lowered.
(This is a safety circuit to prevent the machine (Turnover prevention function)
from moving unexpectedly when the engine is 6) Speed range limit function when dump body is
started.) raised
3) Directional inhibit function After dumping the load, if the body is not com-
When traveling in reverse at a speed of more pletely lowered, shifting up is limited.
than 4.0 km/h, even if the gearshift lever is If the gearshift lever is at D, the machine starts
operated to D or positions 6 to L, the transmis- in F2. If the former is at positions 6 to L, the lat-
sion will not be shifted immediately to travel for- ter starts in F1. The gear is not shifted up until
ward. The engine speed is lowered to reduce the body is completely lowered.
the travel speed, and when the travel speed
goes below 4.0 km/h, the transmission is Self-diagnostic function
shifted to FORWARD. q The controller carries out self-diagnosis of the
(To prevent overload on power train, to improve system and displays abnormalities.
durability and reliability) q The details of the self-diagnosis are displayed
on a monitor.
When traveling forward at a speed of more q If any abnormality is detected by the self-diag-
than 4.0 km/h, even if the gearshift lever is nosis function, the abnormality data is trans-
operated to position R, the transmission will not mitted to the network and is displayed as an
be shifted immediately to travel in reverse. The action code on the machine monitor. The
speed range is shifted to N and the engine transmission system caution, warning lamp, or
speed is lowered to reduce the travel speed. alarm buzzer may also be actuated.
When the travel speed goes below 4.0 km/h,
the transmission is shifted to REVERSE.
When starting the engine, if the machine is

already traveling forward or in reverse at a
speed of more than 4.0 km/h, even if the gear-
shift lever is operated to a position R, the
machine will not move and the transmission will
be held at N.
When the travel speed goes below 4.0 km/h, it
is permitted to move the machine off.
(To prevent overload on power train, to improve
durability and reliability)
HD325-7, HD405-7 11
Transmission controller list of real-time monitoring display contents

With a real-time monitor function of a machine monitor, I can confirm a state of a controller input and
output signal.
Real-time monitoring display items related to transmission controller and contents displayed in normal
state are as follows.
No. Item ID number Displayed spec Data contents
1 Software part number 20201 VERSION Mass production software part number is output
2 Application version 20223 VERSION (APP) Software version No. is output (Soft logic part ver-
sion No.)
3 Data version 20224 VERSION (DATA) Software version No. is output (Soft logic part ver-
sion No.)
4 Transmission input shaft speed 31200 T/M SPEED:IN Input shaft speed is output
5 Transmission intermediate shaft 31300 T/M SPEED:MID Intermediate shaft speed is output
speed
6 Transmission output shaft speed 31400 T/M SPEED:OUT Output shaft speed is output
7 Fuel level 04201 FUEL SENSOR Resistance-converted value of fuel level sensor
(A_IN_5) is output
8 Fuel level 04201 FUEL SENSOR Input voltage of fuel level sensor (A_IN_5) is out-
put
9 Transmission differential speed 31402 T/M DIFF OUT Differential speed is output
10 Alternator R 04301 ALTERNATOR R Alternator R terminal input state (A_IN_0) is output
11 Torque converter oil temperature 30100 T/C OIL TEMP Torque converter oil temperature (A_IN_1) is out-
put
12 Torque converter oil temperature 30101 T/C OIL TEMP Torque converter oil temperature (A_IN_1) voltage
is output
13 Transmission oil temperature 32500 T/M OIL TEMP Transmission oil temperature is output
14 Transmission oil temperature 32501 T/M OIL TEMP Transmission oil temperature voltage is output
15 Steering oil temperature 32701 STRG OIL TEMP Steering oil temperature (A_IN_3) of oil
temperature value is output
16 Steering oil temperature 32702 STRG OIL TEMP Steering oil temperature (A_IN_3) of search
voltage value is output
17 Torque converter oil pressure 32600 T/C OIL PRESS Torque converter oil pressure (A_IN_10) is output
18 Torque converter oil pressure 32605 T/C OIL PRESS Torque converter oil pressure (A_IN_10) of input
voltage is output
19 Accumulator oil pressure (front) 35500 ACC OIL PRE F Pressure-converted value of front accumulator oil
pressure (A_IN_8) is output
20 Accumulator oil pressure (rear) 35501 ACC OIL PRE R Pressure-converted value of rear accumulator oil
pressure (A_IN_9) is output
21 Accumulator oil pressure (front) 35504 ACC OIL PRE F Voltage sensed by front accumulator oil pressure
(A_IN_8) is output
22 Accumulator oil pressure (rear) 35505 ACC OIL PRE R Voltage sensed by rear accumulator oil pressure
(A_IN_9) is output
23 Solenoid output (H) 31600 ECMV H DIR ECMV output command current to HIGH clutch is
output
24 Solenoid output (L) 31601 ECMV L DIR ECMV output command current to LOW clutch is
output
25 Solenoid output (1st) 31602 ECMV 1 DIR ECMV output command current to 1st clutch is
output
12 HD325-7, HD405-7
Data range Remarks

Depending upon software part number
Depending upon software version No.
x1 [min-1] (0 – 32767 [min-1])

---- [Other than above]
x1 [min-1] (0 – 32767 [min-1])
x1 [min-1] (0 – 32767 [min-1])
x1 [z] (0 – 250 [z])
x.001 [V] (0 – 5 [V])
x1 [min-1] (0 – 32767 [min-1])
0:OFF
1:ON
x1 [°C] (0 – 150 [°C])
x1 [mV] (0.00 – 5.00 [V])
4.72 V = 0 °C
4.33 V = 30 °C
3.55 V = 60 °C
2.20V = 100 °C
1.61 V = 120 °C
x1 [°C] (0 – 150 [°C])
x1 [mV] (0.00 – 5.00 [V])
4.72 V = 0 °C
4.33 V = 30 °C
3.55 V = 60 °C
2.20 V = 100 °C
1.61 V = 120 °C
x1 [°C] (0 – 150 [°C])
x1 [mV] (0.00 – 5.00 [V])
4.72 V = 0°C
4.33 V = 30°C
3.55 V = 60°C
2.20 V = 100°C
1.61 V = 120°C
x1 [MPa] (0.00 – 5.00 [MPa])
x1 [mV] (0.00 – 5.00 [V])
x1 [MPa] (0.00 – 5.00 [MPa])
x1 [MPa] (0.00 – 5.00 [MPa])
x1 [mV] (0.00 – 5.00 [V])
x1 [mV] (0.00 – 5.00 [V])
x1 [mA] (0 – 1000 [mA])
x1 [mA] (0 – 1000 [mA])
x1 [mA] (0 – 1000 [mA])
HD325-7, HD405-7 13

26 Solenoid output (2nd) 31603 ECMV 2 DIR ECMV output command current to 2nd clutch is
output
ECMV output command current to 3rd clutch is
27 Solenoid output (3rd) 31604 ECMV 3 DIR
output
ECMV output command current to 4th clutch is
28 Solenoid output (4th) 31605 ECMV 4 DIR
output
ECMV output command current to REV clutch is
29 Solenoid output (R) 31606 ECMV R DIR
output
ECMV output command current to lockup clutch is
30 Solenoid output (Lockup) 31609 ECMV LU DIR
output
Angle sensor input (A_IN_7) angle conversion
31 Angle sensor 32900 ANGLE SENSOR
value is output
Angle sensor input (A_IN_7) voltage is output
32 Angle sensor 32903 ANGLE SENSOR
Brake output (front wheel) direction Brake command amount of brake (retarded) con-
33 33807 BK OUTP DIR F
value troller
Brake output (rear wheel) direction Brake command amount of brake (retarded) con-
34 value 33806 BK OUTP DIR R troller
Throttle modified value to be sent to engine con-
35 Throttle modified value 36000 THROTTLE MOD
troller is output
36 Low clutch trigger modification value 38900 TRIGGER MOD L Low clutch trigger modification value is output (all
oil temperature mode)
37 High clutch trigger modification value 38901 TRIGGER MOD H High clutch trigger modification value is output (all
38 1st clutch trigger modification value 38902 TRIGGER MOD 1 1st clutch trigger modification value is output (all
14 HD325-7, HD405-7
Data range Remarks

x1 [mA] (0 – 1000 [mA])
x1 [mA] (0 – 1000 [mA])
x1 [mA] (0 – 1000 [mA])
x1 [mA] (0 – 1000 [mA])
x1 [mA] (0 – 1000 [mA])
x1 [° ] (-25.0 – 25.0 [° ])
x1 [mV] (0.00 – 5.00 [V])
x1 [%] (0 – +100.0 [%])
x1 [%] (0 – +100.0 [%])
x1 [%] (-100.0 – +100.0 [%])
Hexadecimal numbers show below
Display of 8 characters
AABBCCDD
AA: Low temperature correction value [x10msec]
BB: Medium temperature correction value [x10msec]
CC: Normal temperature correction value [x10msec]
DD: High temperature correction value [x10msec]
00000000 – FFFFFFFF [00000000 – FFFFFFFF]

(Each range: -1.28 (80) – +1.27 (7F) [sec])
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
AABBCCDD

(Each range: -1.28 (80) – +1.27 (7F) [sec])
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
AABBCCDD

(Each range: -1.28 (80) – +1.27 (7F) [sec])
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
HD325-7, HD405-7 15

39 2nd clutch trigger modification value 38903 TRIGGER MOD 2 2nd clutch trigger modification value is output (all
40 3rd clutch trigger modification value 38904 TRIGGER MOD 3 3rd clutch trigger modification value is output
(all oil temperature mode)
41 4th clutch trigger modification value 38905 TRIGGER MOD 4 4th clutch trigger modification value is output
(all oil temperature mode)
42 Revolution clutch trigger modification 38906 TRIGGER MOD R Revolution clutch trigger modification value is out-
value put (all oil temperature mode)
43 Clutch FILL switch 38919 FILL HL1234R Every each clutch of FILL SW recognition condi-
tion is output
[H,L,1,2,3,4,R]
16 HD325-7, HD405-7
Data range Remarks

AABBCCDD

(Each range: -1.28 (80) – +1.27 (7F) [sec])
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
AABBCCDD

(Each range: -1.28 (80) – +1.27 (7F) [sec])
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
AABBCCDD

(Each range: -1.28 (80) – +1.27 (7F) [sec])
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
AABBCCDD

(Each range: -1.28 (80) – +1.27 (7F) [sec])
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
[1 (ON), 0 (OFF)] by data to support right under HLR1234R attend H: H Fill switch recognition [1:ON, 0:OFF]
and display L: L Fill switch recognition [1:ON, 0:OFF]
1: One Fill switch recognition [1:ON, 0:OFF]
Example 2: Two Fill switch recognition [1:ON, 0:OFF]
011000: F1 time 3: Three Fill switch recognition [1:ON, 0:OFF]
001001: R2 time 4: FOUR Fill SW recognition [1:ON, 0:OFF]
000000: N time R: R Fill switch recognition [1:ON, 0:OFF]
100010: F4 time
HD325-7, HD405-7 17

44 Trigger initial learning flag 38920 TRIG HL1234R Trigger time initial learning flag state for each
clutch is output
[H, L, R, 1, 2, 3]
8 characters are displayed in following order

[HLR123]
H: H flag [1:ON, 0:OFF]
L: L flag [1:ON, 0:OFF]
R: R flag [1:ON, 0:OFF]
1: One flag [1:ON, 0:OFF]
2: Two flag [1:ON, 0:OFF]
3: Three flag [1:ON, 0:OFF]
45 Fill time (L) 41800 FILL TIME L LOW clutch fill time is output
(Last gear shifting condition)
x10 [msec] (0 – 2.55 [sec], No fill :0)
46 Fill time (H) 41801 FILL TIME H High clutch fill time is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
47 Fill time (1) 41802 FILL TIME 1 1st clutch fill time is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
48 Fill time (2) 41803 FILL TIME 2 2nd clutch fill time is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
49 Fill time (3) 41804 FILL TIME 3 3rd clutch fill time is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
50 Fill time (4) 41805 FILL TIME 4 4th clutch fill time is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
51 Fill time (R) 41806 FILL TIME R Revolution clutch fill time is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
52 Throttle lower limit value output 44201 THROT LIMIT LO Throttle lower limit output sent to engine controller
x0.1 [%] (0 – +100.0 [%])
53 Throttle higher limit value output 44200 THROT LIMIT HI Throttle higher limit output sent to engine controller
x0.1 [%] (0 – +100.0 [%])
54 Input signal D_IN_0-7 40905 D-IN--0------7 Input signal condition is output
55 Input signal D_IN_8-15 40906 D-IN--8-----15 Input signal condition is output
56 Input signal D_IN_16-23 40907 D-IN-16-----23 Input signal condition is output
57 Input signal D_IN_24-31 40908 D-IN-24-----31 Input signal condition is output
58 Input signal D_IN_32 40942 D-IN-32 Input signal condition is output

59 Output signal D_OUT_0-7 40949 D-OUT-0------7 ON/OFF output signal D_OUT_0-7 condition.
Display 0 at the time of power supply output setting.
60 Output signal D_OUT_8-15 40950 D-OUT-8-----15 Supports SOL_OUT_8, 9, 10A, 10B, 11A, 11B,
SIG_OUT_0, SIG_OUT_1.
61 Output signal D_OUT_16-23 40951 D-OUT-16----23 Supports SIG_OUT_2, 3, HSW_OUT_0, 1,
BATT_RY_OUT. Not used D_OUT_21 to 23.
18 HD325-7, HD405-7
Data range Remarks

Display a learning flag ON/OFF state of a clutch to fall under right
under HLR1234R in [1 or 0]
HLR1234R
1111111 (All clutches have been learned)
HLR1234R
0000000 (No clutch have been learned)
x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x0.1 [%] (0 – +100.0 [%])

x0.1 [%] (0 – +100.0 [%])
*0******: Transmission oil filter clogging D_IN_1: Transmission oil filter switch 1
****1***: Cranking D_IN_3: Emergency escape switch
******0*: Emergency steering not operated D_IN_4: C terminal signal
******1*: Emergency steering operated D_IN_6: Emergency steering relay
*******1: Shift lever N D_IN_7: Shift lever N
1*******: L fill D_IN_8: Fill signal L
*1******: 4th fill D_IN_9: Fill signal 4th
**1*****: H fill D_IN_10: Fill signal H
***1****: 1st fill D_IN_11: Fill signal 1st
****1***: 2nd fill D_IN_12: Fill signal 2nd
*****1**: 3rd fill D_IN_13: Fill signal 3rd
******1*: R fill D_IN_14: Fill signal R
Example
10010000: F1 time
00010010: R1 time
00000000: N time
11000000: F6 time
10000000: Shift lever R D_IN_16: Shift range R
01000000: Shift lever D D_IN_17: Shift range D
00100000: Shift lever 6 D_IN_18: Shift range 6
00000001: Shift lever L D_IN_23: Shift range L
*0******: Lowering of coolant level D_IN_25: Coolant level
**0*****: Clogging of air cleaner D_IN_26: Air cleaner switch
***0****: Operation of main pressure variable valve D_IN_27: Main pressure variable valve pressure switch
****0***: Operation of main oil flow selector valve D_IN_28: Main oil flow selector valve pressure switch
*****0**: Operation of lubricating oil flow variable valve D_IN_29: Lubricating oil flow variable valve pressure switch
* Not used
* Not used
* Not used
* Not used
HD325-7, HD405-7 19
Auto emergency steering system 1
1. Timer Outline
2. Battery If the engine should stop when the machie is travel-
3. Steering oil pressure switch ing, or there is any abnormality in the hydraulic
4. Emergency steering motor pump and the oil pressure of steering circuit
5. Emergency steering pump become lower than specified valve, the emergency
6. Demand valve system automatically actuates an electric pump to
ensure the hydraulic pressure for the steering,
thereby making it possible to use the steering.
This system can also be operated manually.
20 HD325-7, HD405-7
Timer
Outline
This timer is a delay timer used to prevent a mal-
function of the emergency steering system.
After the coil is energized for the set time of the
timer, the relay contact is changed.
HD325-7, HD405-7 21
Retarder control system 1
22 HD325-7, HD405-7
Retarder controller
Outline according to the travel conditions and load con-

The retarder controller has the following functions. ditions such as the load weight, turning, brak-
1. Retarder control ing, etc. sent from various sensors to set the
The proportional solenoid valve is controlled damping force of the front suspension to 1 of 3
according to the operating angle of the retarder levels of SOFT, MEDIUM, and HARD.
control lever and actuates the retarder. 6. ASR Control (if equipped)
2. Overrun prevention and retarder control when The retarder controller detects slips of the right
there is transmission abuse and left drive wheels from their speed and
The retarder controller controls the proportional steering angle and controls the ASR propor-
solenoid valve to operate the retarder accord- tional solenoid valve to maintain the speed dif-
ing to the command of the transmission control- ference between both wheels constant.
ler. The wheel slipping at higher speed is braked
and the brake torque is transmitted to the wheel
3. Hoist control rotating at lower speed to improve the travel
The retarder controller controls the hoist EPC performance.
valve (proportional solenoid valve) and hoist
selector valve (ON/OFF valve) according to the 7. Transmission of network data
position of the dump control lever and actuates 1) The retarder controller transmits the infor-
the dump body. mation of operation of the retarder, float
caution, and operation of the parking
4. Automatic retarder speed control (ARSC)
brake to the machine monitor.
(if equipped)
2) The retarder controller receives informa-
The retarder controller controls the proportional
tion of overrun prevention, retarder com-
solenoid valve to control the retarder braking
mand when there is abuse, etc. from the
force and keep the downhill travel speed at the
transmission controller.
speed set with the automatic retarder travel
speed set switch. 3) The retarder controller transmits informa-
tion of reverse inhibition, etc. to the trans-
5. Automatic Suspension Control (if equipped) mission controller.
The retarder controller changes the signals for
the automatic suspension solenoid valve
HD325-7, HD405-7 23
Input and output signal
BRC1
Pin No. Signal name Imput/output signal Pin No. Signal name Imput/output signal
1 SUS press sensor (RL) Input 13 ARSC set SW Input
2 Strg potentio Input 14 Retard lever Input
3 Retard oil temp (R) Input 15 Alternator R Input
4 GND (SIG) – 16 Sens PWR Output
5 Retard SW (rear) Input 17 Service brake press SW Input
6 Brake system filter Input 18 Validation SW2 Input
7 SUS press sensor (RR) Input 19 Hoist lever (main) Input
8 Body position sensor Input 20 Hoist lever (SUB) Input
9 – Input 21 GND (Analog GND) –
10 GND (SIG) – 22 Pot PWR Output
11 – Input 23 – Input
12 Memory clear SW Input 24 Validation SW1 Input
BRC2
1 – Output 21 S_NET Input/Output
2 Strg hoist filter SW Input 22 CAN0 L Input/Output
3 Strg hoist lever SW Input 23 CAN1 L Input/Output
4 232C RxD Input 24 *FEW SW Input
5 Brake wear SW (RL) Input 25 – Input
6 – Input 26 – Input
7 ENG oil level SW Input 27 – Input
8 – Output 28 TM & Brake oil level SW Input
9 Body float signal Output 29 GND (pulse GND) –
10 Wheel speed (RR) Input 30 T/M output shaft speed Input
11 – Output 31 GND (S_NET GND) –
12 Can SH – 32 CAN0_H Input/Output
13 Eng oil filter Input 33 CAN1_H Input/Output
14 232C TxD Output 34 GND (232C_GND) –
15 – Input 35 Key SW C (Engine start) Input
16 – Input 36 Brake wear SW (RR) Input
17 Retard cooling filter Input 37 Steering speed Input
18 Stop lamp relay Output 38 Battery liquid level SW Input
19 – Output 39 GND (pulse GND) –
20 Wheel speed (RL) Input 40 – Input
BRC3
1 VB (controller PWR) Input 21 GND (controller GND) Input
2 VIS (solenoid PWR) Input 22 VIS (solenoid PWR) Input
SOL_COM SOL_COM
3 Input 23 Input
(solenoid common GND) (solenoid common GND)
4 – Output 24 Key SIG Input
5 Hoist EPC valve Output 25 – Output
6 – Output 26 ASR valve (RL) Output
7 Auto SUS SOL1 Output 27 Lever kick out sol Output
8 +24 V for sensor Output 28 F/B cut valve Output
9 Parking brake press SW Input 29 – Input
10 ASR press SW (RL) Input 30 Shut off valve SW Input
11 VB (controller PWR) Input 31 GND (controller GND) Input
12 VIS (solenoid PWR) Input 32 GND (controller GND) Input
SOL_COM (solenoid com- 33 GND (controller GND) Input
13 Input
mon GND) 34 Reserve –
14 Key SIG Input 35 – Output
15 ASR shut off valve Output 36 ASR valve (RR) Output
16 Retard valve R Output 37 Auto SUS SOL2 Output
17 Hoist change valve Output 38 – Output
18 BCV relay Output 39 Secondary brake SW Input
19 – Input 40 ASR check SW Input
20 ASR press SW (RR) Input
24 HD325-7, HD405-7
HD325-7, HD405-7 25
Retarder controller list of real-time monitoring display contens

The input and output signal states of the retarder controller can be checked with the real-time monitoring
function of the machine monitor.
Real-time monitoring display items related to retarder controller and contents displayed in normal state are
as follows.
1 Part No. of software 20214 VERSION Mass production software part number is output
2 Application version 20231 VERSION(APP) Software version No. is output (soft logic part ver-
sion No.)
3 Data version 20232 VERSION(DATA) Software version No. is output (soft data part ver-
sion No.)
4 ARSC set switch 37701 ARSC SET SP SW A_IN_8
5 Transmission output shaft speed 31403 T/M SPEED:OUT PLS_IN1

Transmission output shaft speed is output
6 Wheel speed (left) 39705 WHEEL SPEED L PLS_IN2
Wheel speed is output.
7 Wheel speed (right) 39704 WHEEL SPEED R PLS_IN3
Wheel speed is output.
8 Retarder cooling oil temperature 30211 BRAKE OIL T R Converted temperature of retarder oil temperature
(rear) sensor (rear) (A_IN_2) is output.
9 Retarder cooling oil temperature 30212 BRAKE OIL T R A_IN_2
(rear)
10 Brake output (front wheel) 33700 BK OUTP DIR F SOL_OUT6
11 Brake output (rear wheel) 33806 BK OUTP DIR R SOL_OUT7
12 Retarder lever 33900 RETARD LEVER A_IN_4
13 Body positioner 34602 BODY POSITION A_IN_5
14 Dum lever (hoist lever) potentiometer 34304 DUMP LEVER 1 A_IN_3

1
15 Dump lever (hoist lever) potentiome- 34305 DUMP LEVER 2 A_IN_7
ter 2
16 Hoist EPC output 45600 HOIST EPC DIR SOL_OUT10A
17 Seating control command (Hi) 45102 S CNT DIR H
18 Seating control command (Lo) 45103 S CNT DIR L
Seating condition calibration value

19 45201 S CAL A
( )
Cylinder stopper calibration value
20 45301 S CAL B
( )
21 Seating control time (Hi) 45402 S CNT TIME H
22 Seating control time (Lo) 45403 S CNT TIME L

SOL_OUT10B
23 Shutoff valve output 45700 SHUT OFF VALVE
Converted angle of steering angle sensor
24 Steering position sensor 35402 STRG ANGLE
(A_IN_6) is output.
A_IN_6
25 Steering position sensor 35400 STRG ANGLE
26 PLS_IN0
Steering speed 35403 STRG ANGLE SPEED
Steering speed is output.
Converted pressure of suspension pressure sen-
27 Suspension pressure (left) 32814 SUS PRESS (L) sor (A_IN_10) is output.
Suspension pressure (left) 32815 SUS PRESS (L) A_IN_10

28
Suspension pressure (right) 32816 SUS PRESS (R) Converted pressure of suspension pressure sen-
29 sor (A_IN_9) is output.
26 HD325-7, HD405-7
Data range Remarks

Depending upon software part number
0.00 – 5.00 [V]

---- [ARSC setting OFF or other than above]
0 – 32767 [rpm]
---- [ARSC option setting OFF or other than above]
0 – 32767 [rpm]
0 – 32767 [rpm]
0 – 160 [°C]
0.00 – 5.00 [V]
0 – 1000 [mA] [command value]
0.00 – 5.00 [V]
0.00 – 5.00 [V]
0.00 – 5.00 [V]
0.00 – 5.00 [V]
0.00 – 5.00 [V]
0.00 – 5.00 [V]
0.0 – 10.00 [s]
Down to 2 decimal places are displayed.
0.0 – 10.00 [s]
ON [1]
Unit is not displayed.
OFF [0]
-180.0 – +180.0 [°]
0.00 – 5.00 [V]
0.0 – 99.99 [rad/s]
0.00 – 20.10 [MPa]
---- [Automatic suspension option setting OFF and ARSC option
setting OFF, or other than above]
0.00 – 5.00 [V]
0.00 – 20.10 [MPa]
HD325-7, HD405-7 27

Suspension pressure (right) 32817 SUS PRESS (R) (A_IN_9)
30
Judgment of empty/loaded truck 39400 EMPTY OR LOAD Judgment of empty/loaded truck is output.
31
ASR output (L) command 39601 ASR OUTP DIR L Output command value to ASR (L) solenoid is out-
32
put.
33 ASR output (R) command 39603 ASR OUTP DIR R Output command value to ASR (R) solenoid is
output.
34 Input signal D_IN_0--7 40932 D-IN--0-----7 Input signal stats of D_IN_0 – D_IN_7 are output
as they are.
35 Input signal D_IN_8--15 40933 D-IN--8-----15 Input signal stats of D_IN_8 – D_IN_15 are output
as they are.
Input signal stats of D_IN_16 – D_IN_23 are out-

put as they are.
36 Input signal D_IN_16-23 40934 D-IN-16-----23

put as they are.

put as they are.
D_OUT_0 – 7 refer to SOL_OUT_0 – 7 of CR710.
39 Output signal D_OUT_0-7 40955 D-OUT-0-----7
D_OUT_8 – 15 refer to SOL_OUT_8, 9, 10A, 10B,

11A, 11B, SIG_OUT_0 and SIG_OUT_1 of
40 Output signal D_OUT_8-15 40956 D-OUT-8-----15 CR710.
41 Output signal D_OUT_16-23 40957 D-OUT-16-----23 D_OUT_16 – 23 refer to SIG_OUT_2, 3,

HSW_OUT_0, 1 and BATT_RY_OUT of CR710.
D_OUT_21, 22 and 23 are not used.
28 HD325-7, HD405-7
Data range Remarks

0.00 – 5.00 [V]
LOAD [1]
EMPTY [0] Unit is not displayed.
Command value 0 – 1020 [mA] [00 – FF]
Command value 0 – 1020 [mA] [00 – FF]
01010101 ["1.0" is displayed under corresponding display (num-
ber)]
Input signal ON [1], Unit is not displayed.
Input signal OFF [0],
"0" is displayed on unused part.
01010101 ["1.0" is displayed under corresponding display (num- Unit is not displayed.
ber)]
Input signal ON [1],
ber)]
ber)]
ber)]
ber)]
ber)]
ber)]
HD325-7, HD405-7 29
Rerarder control function

Retarder control system diagram
Retarder lever control

q The operating angle of the retarder lever is
detected by the potentiometer and a current
corresponding to this is output to the propor-
tional solenoid valve to actuate the retarder.
Overrun prevention and retarder control when

there is transmission abuse
q The retarder controller controls the propor-
tional solenoid valve to operate the retarder
according to the command of the transmission
controller.
30 HD325-7, HD405-7
Relationship between retarder lever potentiometer and output to proportional solenoid valve
A: To improve the initial response of the propor-

tional solenoid reducing valve, the output (trig-
ger output) is set to a high value.
B: To operate the hydraulic equipment smoothly in
the low pressure range, the output is set to a
high value.
C: In the range where the retarder is normally
used, the output is proportional to the operating
angle of the retarder lever.
D: To release the hydraulic pressure smoothly in
the low pressure range, the output is set to a
low value.
HD325-7, HD405-7 31
Hoist control function

Hoist control system diagram
1. Hoist control function 3. Body seating speed control

When the engine is running, the EPC valve When the body is lowered to near the seat, the
(proportional solenoid valve) and selector open area of the EPC valve is reduced to con-
valve are controlled according to the operation trol the lowering speed of the body and reduce
of the dump control lever and operate the the seating shock.
dump body.
2. Lever positioner function

The dump control lever has four positions:
RAISE, HOLD, FLOAT, and LOWER.
If the dump control lever is operated to the
RAISE position, the dump body is raised, and
when the top of the dump body reaches the set
position of the body position sensor, the lever
is returned to the HOLD position.
If the lever is kept at the RAISE position, the
RAISE output continues to be given.
32 HD325-7, HD405-7
4. Control when starting switch is turned to 4) While running the engine at low idle, raise
ON, OFF, or START the body and float it at the maximum
Starting switch at ON: height, and then lower it to the seat.
The output is set to HOLD, regardless of the Repeat this operation 10 times.
position of the lever. 5) While running the engine at high idle,
If the engine is not started, even if the hoist raise the body and float it at the maximum
lever is operated, the condition remains at height, and then lower it to the seat.
HOLD. Repeat this operation 10 times.
Starting switch at OFF:
The hoist valve is closed and the dump body is
held in position regardless of the position of the
lever.
Engine started:
Immediately after the engine is started, the out-
put is set to HOLD, regardless of the position
of the lever.
After the lever is moved to the HOLD position,
it becomes possible to carry out normal opera-
tions.
5. Reverse inhibit function

The retarder controller judges if it is permissi-
ble to travel in reverse or not, and transmits the
result of the judgment through the network to
the transmission controller.
"FLOAT OUTPUT" or "SEATED" and "LEVER
NOT RAISED" o Reverse travel permitted
"NOT FLOAT OUTPUT" and "NOT SEATED"
o r " L E V E R R A I S E D " a n d " S E AT E D " o
Reverse travel prohibited
6. Calibration function
To absorb any inherent error in the dump body
potentiometer, calibration is carried out to rec-
ognize the dump body seating and the body
cylinder stopper condition.
After adjusting the installation of the body

potentiometer or after replacing the retarder
controller, carry out calibration in the following
order.
Order of dump control calibration (hydraulic oil
temperature: 80 – 90°C)
1) While the body is seated completely, run
the engine and set the lever to HOLD and
then to FLOAT, and check that the float
caution lamp goes off.
2) Raise the body and keep the lever in the
RAISE position until the cylinder touches
the stopper. After the cylinder touches the
stopper, keep the lever in the RAISE posi-
tion for at least 5 seconds.
3) Lower the body to the seat, and then keep
the lever at the FLOAT position for at least
5 seconds.
HD325-7, HD405-7 33
Dump control lever 1
34 HD325-7, HD405-7
1. Lever
2. Rod
3. Spring
4. Spring
5. Retainer
6. Body
7. Body
8. Bushing
9. Solenoid
10. Nut
11. Rod
12. Detent spring
13. Retainer
14. Ball
15. Seat
16. Potentiometer
17. Lever
18. Rod
19. Rod
20. Detent spring
HD325-7, HD405-7 35
Function
q If lever (1) is operated, rod (18) moves up and
down to rotate potentiometer (16) according to
the operation stroke of the lever.
q The operation angle (stroke) of the control
lever is sensed with the potentiometer and it is
output in the form of signal voltage to the con-
troller.
q One potentiometer is installed to output 2
opposite signal voltages shown in "Output volt-
age characteristics".
Operation
1. When dump control lever is set in "FLOAT"
position
q If rod (2) on the LOWER side is pushed and
moved down with lever (1), ball (14) touches
projection (a) of rod (11) on the stroke. (Before
start of mechanical detent)
q If rods (2) and (11) are pushed further, ball (14)
pushes up retainer (13) held on detent spring
(12) and escapes out to go over projection (a)
of rod (11).
q At this time, rod (18) on the opposite side is
pushed up by spring (4) and ball (14) is moved
to the small diameter side of projection (b) of
rod (19) by retainer (13) held on detent spring
(20).
q Even if the operator releases the lever, rod (18)
is held by projection (b) of rod (19) and ball
pressing force, and consequently the lever is
held in the "FLOAT" position.
36 HD325-7, HD405-7
2. When dump control lever is returned from 4. When dump control lever is set in "RAISE"
"FLOAT" position position
q To return lever (1) from the "FLOAT" position, q If rod (18) on the RAISE side is pushed and
push it down with a force larger than the hold- moved down with lever (1), ball (14) touches
ing force of rod (19), detent spring (20), projection (a) of rod (19) on the stroke. (Before
retainer (13) and ball (14). start of electric detent)
q If rods (18) and (19) are pushed further, ball
3. When dump control lever is set in "LOWER" (14) pushes up retainer (13) held on detent
position spring (20) and escapes out to go over projec-
q If lever (1) is leaned further from the "FLOAT" tion (a) of rod (19).
position, it is set in the "LOWER" position. q At this time, rod (2) on the opposite side is
q Rod (18) is pushed up by spring (4) according pushed up by spring (4).
to the operation stroke of lever (1). q If rod (2) is pushed up while current is flowing
q Since lever (17) and rod (19) installed to the in solenoid (9), nut (10) is attracted by bushing
turning shaft of potentiometer (16) are con- (8).
nected to each other, potentiometer (16) out- q As a result, rod (2) is kept pushed up. Accord-
puts voltages according to the vertical stroke of ingly, even if the operator releases the lever,
the rod. the lever is held in the "RAISE" position.
5. When dump control lever is returned from

"RAISE" position
q To return lever (1) from the "RAISE" position,
push it down with a force larger than the attrac-
tion of the solenoid. It is also returned to the
"HOLD" position when the solenoid power sup-
ply is turned "OFF" and the "RAISE" operation
is reset.
HD325-7, HD405-7 37
Auto suspension system 1
1. Dump control lever Outline

2. Retarder controller The front suspension mode (damper force) is auto-
3. Suspension cylinder matically switched according to the travel condition
4. Solenoid valve and load condition to give a more comfortable ride
5. Hydraulic cylinder to the operator and to improve the travel stability.
a For details of the internal mechanism of the
suspension, see suspention
38 HD325-7, HD405-7
Automatic suspension mode selection control

q With the front suspension, the mode (damping
force) is automatically changed according to
the travel conditions and load conditions to
ensure a comfortable ride and to improve the
travel stability of the machine. The control pat-
terns and functions of the modes (damping
force) are as shown in the table below.
S:Soft
M:Medium
H:Heard
Set mode
Control pattern Function Contents of control Empty Loaded
S M H S M H
Distinguishing To set damping force Internal pressure of front suspen-
empty/loaded according to load on sion cylinder is measured and
machine compared with standard value
Anti-roll To prevent the chas- This detects the travel speed
sis from rolling when and steering angle, and
turning at high speed switches the mode according to (When
turning)
certain conditions.
(Not controlled when traveling
empty)
(See fig. 1)
Anti-dive To prevent nose-div- The damping force is made
ing when braking stronger when the brakes are
(Brake (Brake (Brake (Brake
applied. OFF) ON) OFF) ON)
Anti-lift To prevent the front The damping force is made
from lifting up when stronger when the dump body
dumping control lever is at any position (Float) (Other (Float) (Other
than than
except FLOAT. Float) Flot)
High speed To improve stability Detects travel speed and
stability when traveling at selects damping force. (No con-
high speed trol when traveling empty)
(See fig. 2)
Fig. 1 Fig. 2
HD325-7, HD405-7 39
Auto suspention solenoid valve
2. Solenoid q The automatic suspension solenoid valve is
installed in the circuit between the hydraulic
A: To hydraulic cylinder head pump and the suspension cylinder. The valve
B: To hydraulic cylinder bottom switches oil pressure of the hydraulic cylinder
P: From pump which is installed to the front suspension,
T: To transmission oil pan according to signal from the retarder controller.
Two solenoid valves are combined to select
three modes of Soft, Medium and Hard.
40 HD325-7, HD405-7
HD325-7, HD405-7 41

© 2007 KOMATSU
All Rights Reserved
42 HD325-7, HD405-7
SEN00863-02
DUMP TRUCK
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up

Payload meter (card type) ........................................................................................................................... 2
HD325-7, HD405-7 1
Payload meter (card type) 1

Structure of system
1. Shift lever neutral detection switch (relay) Outline

2. Body FLOAT signal (reterder controller) q A dump truck is supported by 4 suspension
3. Clinometer cylinders. By measuring the total of the loads
4. Pressure sensor (for front left) on each cylinder, it is possible to know the
5. Pressure sensor (for front right) weight on the springs of the dump truck.
6. Pressure sensor (for rear left) The measurement of the load weight is
7. Pressure sensor (for rear right) obtained by calculating the difference between
8. Suspension cylinder the weight when empty and the weight when
9. Payload meter full.
10. Lamp drive relay Payload meter displays the load weight cal-
11. External display lamp culated as above on the monitor screen and
12. Battery displays the load level on the external display
13. Fuse (for external display lamp) lamps.
14. Fuse (for controller) The load weight, distance, time, time when
15. Memory card engine was turned ON/OFF, time of occur-
16. Travel signal sensor rence/cancellation of abnormalities or warn-
17. RS232C output (PC cable communication) ings, and other data of each transportation
socket cycle are automatically saved in memory.
18. Battery charge signal (alternator terminal R) These data can be later transmitted to a PC or
written in a memory card.
It also has an estimation display function:
when loading the next load, the new total load
weight is estimated and the appropriate lamp
flashes. This prevents overloading.
2 HD325-7, HD405-7
Block diagram of payload meter
q If a machine equipped with the VHMS control-

ler has the payload meter (built in the VHMS)
optionally, the payload meter II (card type) can-
not be mounted.
q When the payload meter II (card type) is
installed for the first time, replaced, or removed
on a machine having the VHMS controller, per-
form "setting with VHMS initializing manual
(tool)".
For the setting procedure, see Testing and
adjusting.
HD325-7, HD405-7 3
Principle of calculation a This figure show the rear suspension.

1. Outline
A dump truck is supported by 4 suspension
cylinders. By measuring the total of the loads
on each cylinder, it is possible to know the load
weight on the springs of the dump truck.
The measurement of the load weight is
obtained by calculating the difference between
the weight when empty and the weight when
full.
The load on each cylinder can be calculated
from the internal pressure and sectional area
of the suspension cylinder.
[Load on suspension cylinder]
W = PB SB – PT (SB – ST)
Where
W = Load on suspension cylinder
PB = Bottom pressure
PT = Top pressure
SB = Sectional area of cylinder
ST = Sectional area of rod
Because of the structure of the suspension cyl-

inder,
PB PT
Therefore, the load can be calculated as fol-
lows.
W = PBST
4 HD325-7, HD405-7
2. Measurement of weight when empty 5. Detecting distance and travel speed

(Calibration) The travel speed and distance are detected
Drive the empty dump truck at a speed of from the travel signal sensor on the truck.
about 10 km/h for about 30 seconds, and then a Travel signal sensor:
measure the average load and use it as the Transmission output speed sensor
weight when empty.
The reason why the weight is measured while
the dump truck is traveling is that the sliding
resistance of the suspension cylinders must be
averaged by extracting and retracting the cylin-
ders by changing the condition of the dump
truck.
The measured weight when empty is saved as
a calibration data in the memory in the control-
ler.
3. Measurement of mass when full

Load the dump truck and measure the weight
at that time. When loading for this purpose,
set the gearshift lever in the "N" position and
set the dump control lever in the "FLOAT" posi-
tion on a ground where the longitudinal inclina-
tion of the dump truck is ± 5°.
4. Correction on slope
If the dump truck is loaded on a slope, the
measured weight is different from the weight
measured on a level ground. To solve this
problem, the longitudinal inclination of the
dump truck is measured and the measured
weight is corrected according to the inclination
angle. (Correction range of inclination angle
: ± 5°)
HD325-7, HD405-7 5
Features of each device

1. Payload meter
Payload meter receives signals from the
pressure sensors, clinometer, body float sen-
sor, gearshift lever (neutral sensor switch on
Payload meter ), etc., calculates the load
weight with the microcomputer in it, displays
the calculation result on the panel, and indi-
cates the load level on the external indicator
lamps.
1) Name of each part of payload meter

1. Display
2. Communication "receiving" lamp
(Rx busy)
3. Communication "transmitting" lamp
(Tx busy)
4. Memory card access lamp
(CARD busy)
5. Mode switch (MODE)
6. Calibration/clear switch (CAL/CLR)
7. Total/shift switch (TOTAL/SFT)
8. Light/increment switch (LIGHT/INC)
9. Memory card (if equipped)
10. Cover
a Communication "transmitting" lamp
(3) also lights up when the communi-
cation cable is not connected to a PC
or when there is defective connection.
a When not inserting or removing mem-
ory card (9), keep cover (10) closed.
6 HD325-7, HD405-7
Left side
q Switches on left side
No. Name Type Remarks
1. Load weight compensation Rotary control –20% – +20%

trimmer (Counterclockwise) (Clockwise)
2. Speed compensation switch 0 – F rotary selector switch 0 : 107% –7 : 100% – F : 92%
3. Distance compensation switch 0 – F rotary selector switch 0 : 107% –7 : 100% – F : 92%
4. Model selector switch 0 – F rotary selector switch According to model selector code table
Up : Not used
5. Memory card use switch 2-stage selector switch Down : Used (Kept in lower position)
Up : Not used
6. Clinometer use switch 2-stage selector switch Down : Used (Kept in lower position)
7. Weight unit setting switch 2-stage selector switch Up: t (Metric ton), Down: US ton (Short ton)
Up : Permitted
8. Switch forcible prohibition setting 2-stage selector switch Down : Prohibited
switch According to Permitted/prohibited setting
table for switches
Turn CLOCKWISE to DECREASE volume
B. Buzzer volume adjustment Rotatory control Turn COUNTERCLOCKWISE to INCREASE
volume
a The switches are adjusted before the machine
is shipped. Only No. 7 and No. B can be
adjusted. For this reason, do not touch any
other switch.
HD325-7, HD405-7 7
q Table of model selector code
No. of model selector switches Model
2 HD465-7E0 Small-tire
3 HD325-7 Large-tire
7 HD465-7E0 Large-tire
8 HD405-7 Large-tire
A HD605-7E0 Large-tire
q Permitted/prohibited setting table for switches
Left side switch No. 8
Upper (permitted) Lower (prohibited)
Upper
Left (1) (2)
(memory card not used)
side
switch
No. 5 Lower
(3) (4)
(memory card used)
(1) Left side switch No. 5 (upper), No. 8 (upper)

All switches can be operated.
(2) Left side switch No. 5 (upper), No. 8 (lower)
Calibration, data all clear, time, date setting
operations only are possible.
(3) Left side switch No. 5 (lower), No. 8 (upper)
All switches can be operated.
(4) Left side switch No. 5 (lower), No. 8 (lower)
Calibration, data all clear, card dump, time,
date setting operations only are possible.
8 HD325-7, HD405-7
2) Basic operation of payload meter

Payload meter has the following basic functions.
a If the engine is started during the flow for this display, even there are items left to display, the
display will switch after several seconds to ) Normal operation display.
HD325-7, HD405-7 9
Normal operation display
Shift lever Dump lever

Condition of machine Payload meter display External display lamps
position position
Stopped N FLOAT Weight display (*1) Weight display

Empty
Traveling Except N FLOAT Time display OFF
During load- Weight display and esti-

Stopped N FLOAT Weight display
ing, before mated display
reaching 50%
of correct
Traveling Except N FLOAT Weight display OFF
weight
During load- Weight display and esti-

Stopped N FLOAT Weight display
ing, after mated display
reaching 50%
of correct Travel distance displayed
Traveling Except N FLOAT in units of m from 0 – 160 OFF
weight
m (each 5 m)
Traveling Except N FLOAT after completion, changes OFF

to time display
Loaded
Stopped N FLOAT Weight display Weight display
FLOATo Integrated weight display

When dumping (*2) N RAISE o LOWER OFF
o FLOAT (*3)
Abnormality, warning (Error code displayed in See Operation and Main-

detected
— — order of priority) tenance Manual
(*1)When load is less than 5% of correct mass, display shows 0 t.

(*2)For details of conditions taken as dumping, see V) contents of memory (1).
(*3)The integrated weight display is shown in units of 100 t. (Rounded to the nearest 100)
II) Measuring empty weight (calibration)

The weight of the machine when empty is
measured and this is used as the calibration
data.
These data are retained even when the power
is turned OFF.
III) Normal operation display (for details, see the
Operation and Maintenance Manual)
See the Normal operation display.
IV) External display lamp drive
(estimated display)
The chart on the right shows the weight display
level for the external display lamps during the
normal operation display.
The estimated display shows the estimation of
the total weight when one more loads are
added. The applicable lamp flashes to prevent
overload.
10 HD325-7, HD405-7
V) Content of memory (for details, see Operation and Maintenance Manual)

1) Cycle data
a The period between one dumping operation and the next dumping operation is taken as one cycle
and the data in that period are recorded.
a The cycle data are recorded when the dumping conditions are fulfilled (see below).
a The maximum limit for cycle data in memory is 2900 cycles.
Item Unit Range
Engine operation number Integer 1-65535

Month Month 1-12
Day Day 1-31
Time Hour Hour Displayed as 0-23 Displays value and set value at time of
Time Minute Minute 0-59 dumping
Machine ID Integer 0-200
Open ID Integer 0-200
Load weight t (Metric ton) or 0-6553.5
US ton (Short ton)
Empty travel time min 0-6553.5
Empty travel distance km 0-25.5
Empty max. travel speed km/h 0-99
Empty average travel speed km/h 0-99
Empty stopped time min 0-6553.5
Loading stopped time min 0-6553.5
Loaded travel time min 0-6553.5
Loaded travel distance km 0-25.5
Loaded max. travel speed km/h 0-99
Loaded average travel km/h 0-99
speed
Loaded stopped time min 0-6553.5
Dumping time min 0-25.5 Displays set value at time of dumping
Limit speed km/h 0-99
Warning items/cycle
Analog spare 1
MAX electric potential V 0-4.0
MIN electric potential V 0-4.0
Average electric potential V 0-4.0
Data processing on PC
Analog spare 2
Data inside cycle are handled
MAX electric potential V 0-4.0
separately as "spare signal input data".
MIN electric potential V 0-4.0
Average electric potential V 0-4.0
Digital spare 1
Lo frequency Times 0-255
Digital spare 2
Lo frequency Times 0-255
HD325-7, HD405-7 11
2) Engine ON/OFF data

a Recorded each time the engine was stopped and started.
a The maximum limit in memory for engine ON/OFF data is 115 ON/OFF sets.
Item Unit Range
Engine operation number Integer 1-65535 Serial number of operation of engine
Year (right 2 digits) Year 0-99

Month Month 1-12
Day Day 1-31 Shows when engine was switched ON
Time Hour Hour Displayed as 0-23
Time Minute Minute 0-59
Month Month 1-12
Day Day 1-31 Shows when engine was switched OFF
Integrated load weight t (Metric ton) or 0-9999000 Intergrated value between engine ON and
US ton (Short ton) engine OFF
Total number of cycles Times 0-9999
3) Abnormality and warning data

a Recorded each time a payload meter abnormality or warning is generated or cancelled.
a The maximum limit in memory for abnormality or warning data is 230 generated/cancelled sets.
Item Unit Range
Engine operation number when According to 5

error code was generated Integer 0-65535
Frequency of generation Times 1-255
after engine is switched ON

Month Month 1-12
Shows when error code was generated
Day Day 1-31
Time Hour Hour (0 – 23) Displayed as 0-23
Engine operation number Integer 0-65535
when cancelled

Month Month 1-12
Shows when error code was cancelled
Day Day 1-31
Time Hour Hour (0 – 23) Displayed as 0-23
12 HD325-7, HD405-7
4) Data of intergrated load weight and total number of cycles

a The integrated load weight and total number of cycles after a time are calculated and saved again
each time the dumping condition is fulfilled.
a Integration of the load weight and total number of cycles are started after they are cleared. (See
the volume of Operation.)
a The saving limit of the integrated load weight and total number of cycles is 999900.0 t (metric ton)
or US ton (short ton) and 9999 cycles.
Item Unit Range
Intergrated load weight t (Metric ton) or 0-999900.0

Shows integrated value after time when data
US ton (Short ton)
were cleared
Total number of cycles Times 0-9999

Month Month 1-12
Day Day 1-31 Shows date and time when data were cleared
5) Other data
Contents Item Unit Range
Operator check Machine ID Integer 0-200

mode set data Open ID Integer 0-200 Operator check mode set by input oper-
Limit speed km/h 0-99 ation
Option code Integer 0-11
Calibration Year (right 2 digits) Year 0-99
performance Month Month 1-12
Date and time when calibration was
data Day Day 1-31
performed
User write data Data 1 20 Characters Comments that can be written freely
Data 2 20 Characters into payload meter.
Data 3 20 Characters Note: Input and settings are possible
Data 4 20 Characters only from PC through cable communi-
cations.
(For details, see software manual.)
HD325-7, HD405-7 13
6) Calibration data
a These are saved in RAM each time calibration is performed.
a The maximum limit in memory for calibration data is 15 sets.
Item Unit Range
Year Year (right 2 digits) 00-99

Month Month 1-12
Day Day 1-31 Shows values and settings when cali-
Time Hour Hour 0-23 bration was performed
Model selection code Integer 0-F
Suspension pressure (front left) x 98 kPa 0-6553.5
Suspension pressure (front right) x 98 kPa 0-6553.5
Suspension pressure (rear left) x 98 kPa 0-6553.5
Suspension pressure (rear right) x 98 kPa 0-6553.5
Shows values before compensation fac-
Weight on spring (front) t (Metric ton) 0-6553.5
tor was calculated
Weight on spring (rear) t (Metric ton) 0-6553.5
Tilt angle x 180 rad –9.99 – +9.99
0-9.99999
Front wheel tilt compensation factor Integer
0-9.99999
Rear wheel tilt compensation factor Integer
0-9.99999
Front wheel link factor Integer
0-9.99999
Rear wheel link factor Integer
0-6553.5
Weight on spring (empty) t (Metric ton)
7) Load weight calculation data (analog data)

a These are saved in RAM when the load weight calculation data are required.
a The maximum limit in memory for load weight calculation data is 180 sets.
Item Unit Range
Year Year (right 2 digits) 00-99

Month Month 1-12
Day Day 1-31
Time Hour Hour 0-23
Suspension pressure (front left) x 98 kPa 0-6553.5
Suspension pressure (front right) x 98 kPa 0-6553.5
Suspension pressure (rear left) x 98 kPa 0-6553.5
Suspension pressure (rear right) x 98 kPa 0-6553.5
Weight on spring (front) t (Metric ton) 0-6553.5
Weight on spring (rear) t (Metric ton) 0-6553.5
Tilt angle x 180 rad –9.99 – +9.99
0-9.99999
Front wheel tilt compensation factor Integer
0-9.99999
Rear wheel tilt compensation factor Integer
0-9.99999
Front wheel link factor Integer
0-9.99999
Rear wheel link factor Integer
0-6553.5
Weight on spring (empty) t (Metric ton)
(Calibration value)
0.7500 –1.2500
Trimmer gain value Integer
0-6553.5
Load weight t (Metric ton)
0-25.5
Backup battery voltage V
The above data items 1) – 7) are retained even when the power is switched OFF.
14 HD325-7, HD405-7
VI) Forced display of integrated load weight and X) Service check mode
total number of cycles By operating the switches of payload meter ,
Forced display of existing abnormalities and it is possible to forcibly carry out display, set-
warnings ting, and correction of the following items.
By operating the TOTAL/SFT switch of payload
meter II, it is possible to carry out forcible dis- (a) Detailed calibration data display
play of these items. The display shows the date, suspension
For details, see the Operation and Mainte- pressure, etc. when the latest calibration
nance Manual. was carried out.
VII) Operator check mode (b) Detailed load weight calculation data dis-
By operating the switch of payload meter , it play (analog data)
is possible to carry out the following items. The display shows the suspension pres-
For details, see the Operation and Mainte- sure and pitch angle used when calculat-
nance Manual. ing the present load weight.
a) Memory card dump
b) Data all clear (c) Memory card dump (service area)
c) Abnormality, warning exists/cancelled, This writes all the data displayed for Items
and input signal condition display V-6) and V-7) to the memory card inserted
d) Machine ID setting in the machine.
e) Open ID setting
f) Limit speed setting a This function is available only when the
g) Option code setting No. 5 switch on the left side of the control-
h) Time and date correction ler (memory card use switches) is set for
"Use"
VIII) Dimming of display portion
It is possible to adjust the brightness of the (d) Data all clear (service area)
payload meter II display portion to 10 levels This forcibly deletes all the calibration data
with the LIGHT/INC switch. and analog data, except for the latest cali-
bration data.
IX) Downloading saved data
It is possible to download any data recorded in a Before clearing the data, if necessary
payload meter to a PC through a cable download the data to a PC or carry out (a)
(ANSI/E1A RS-232C). Card dump.
For details, see the PC software manual pro-
vided by Komatsu. (e) Input signal condition display
This displays some of the signal condi-
tions for the sensors input to payload
meter and the present recognition con-
dition of the payload meter.
(f) Forced initialization

This forcibly deletes all the data in payload
meter .
a Before carrying out this operation, check

the time and date. Always carry out the
operation with the machine unloaded. Do
not carry out the operation unless neces-
sary.
(g) Extra load weight setting when loading

The extra load can be forcibly input or cor-
rected to set the load weight when load-
ing.
Available range for setting: –9 – +9 (%)
HD325-7, HD405-7 15
(h) Load weight fixed display and cycle data

recording and load weight value setting
1) Load weight fixed display
When displaying the load weight in
the range shown in the table below, it
is possible to input and correct to set
the display for the load weight when
loading is completed (when loading at
least 50% of set load weight and trav-
eling 160 m or starting to dump), not
the real-time load weight.
Setting Range Payload fixed display
Period in which machine is Load weight when stopped in
stopped after loaded more previous cycle
TALKS not set
than 50% of set load and
(option codes 0 – 3, 10, 11 set)
driven 160 m until it starts
dumping
When there is per- Period in which machine is Load weight last displayed in
mission to start stopped after it receives start previous cycle
permission until it starts (Final radio transmission
TALKS set dumping value)
option codes
4 – 9 set Period in which machine is Load weight last displayed in
When disconnection
stopped after circuit is discon- previous cycle
of line from payload
nected until machine starts
meter is requested
dumping
2) Switching load weight fixed display in
cycle data recording
If the load weight fixed display in Item
1) above is applicable, it is possible to
input and correct the data to set the
load weight inside the cycle data in
Item V-1) to the fixed display load
weight value.
Possible set range: 00, 01, 10
Possible set value table
Display Load weight fixed display Recorded load weight value
00 Yes Load weight fixed display value
01 Yes Value when dumping load
10 No Value when dumping load
(i) Loading completion recognition travel dis-
tance setting
This is used to input and correct the values
to set the travel distance recognized as
completion of loading by payload meter .
Possible set range: 0 – 255 (m)
(j) Loading start recognition load weight set-

ting
This is used to input and correct the val-
ues to set the load weight recognized as
the start of loading by payload meter .
Model Possible set range
HD325-7
480 – 1,480 [× 1/100 t]
HD405-7
HD465-7E0
690 – 1,690 [× 1/100 t]
HD605-7E0
16 HD325-7, HD405-7
(k) Zero ton display range setting t Of the service check mode functions, the
This is used to input and correct the val- following functions can be downloaded to
ues to set the range of the zero display on a PC using the PC downloading software
the load weight display. provided by Komatsu.
Possible set range: 5 – 10 q Calibration data
[%: ratio of correct load weight] q Load weight calculation data (analog
data)
(l) External display lamp display range set- For details, see the software manual.
ting
This is used to input and correct the val- Method of operation
ues to set the lamp display load weight The service check mode is always actu-
range when displaying the load weight. ated.
Note, c) and d) are actuated on the
Possible set range: HD1200-1 when the parking brake is ON or
wh e n th e b r a k e l o c k i s O N, a nd o n
Lamp 1 (green) A : 50 – 255
machines other than the HD1200-1 when
Lamp 2 (yellow) B : A – 255 the shift lever is at the N position and
Lamp 3 (red) C : B – 255 when the dump lever is at FLOAT.
(f) is actuated only when the power is ON.
The set value is displayed as a propor-
a When the service mode is working,
tion (%) of the correct load mass.
on the HD1200-1, set the parking
brake to ON or the brake lock to ON,
and on machines other than the
HD1200-1, set the shift lever to the N
position and the dump lever to
FLOAT. If they are operated to other
positions, the payload meter will
return to the normal operation display,
but in this case, the data set and input
in the service check mode may not be
processed correctly.
HD325-7, HD405-7 17
Operation panel
Flow of each mode and function
18 HD325-7, HD405-7
(a) Operation for calibration data display
1. Set to "CHEC" display, then press CAL/CLR

switch (1) for at least 2 seconds.
Display: "CALO"
2. Every time the CAL/CLR switch (1) is pressed,

the display changes in the order shown on the From CALO flashing Remarks
right. 1
Right 2 digits of year for date
when CAL was carried out
Month and day for date when
3. If MODE switch (2) is pressed at any time dur- 2
CAL was carried out
ing the display in Steps (1). or (2)., the display Hour and minute for date
3
will return to "CHEC". (End) when CAL was carried out
Model selection switch (decimal
4 value) when CAL was carried out
5 x 98kPa P'FL (Front left) Suspension
pressure less than
6 x 98kPa P'FR (Front right) 100 x 98 kPa: XX.X
7 x 98kPa P'RL (Rear left) More than 100 x 98 kPa:
XXX.X
8 x 98kPa P'RR (Rear right)
Weight on front axle
t Less than 100 t:
9 2
(= 4 D F (P'FL+P'RL)) XX.X
Weight on rear axle More than 100 t:
t XXX.X
10 2
(= 4 D F (P'RL+P'RR))
Appears when value is
Angle of tilt when CAL was negative
11 x O
180 rad carried out
(–) X.XX
12 Front axle tilt coefficient
13 Rear axle tilt coefficient

X.XXX
14 Front axle link coefficient
15 Rear axle link coefficient

Weight on spring calculated Same number of digits as
16 9. and 10.
by CAL
17 CALO flashes
Returns to 1. and
repeats sequence
All displayed values are rounded to the value given.
HD325-7, HD405-7 19
(b) Operation for payload calculation data (analog data) display
1. Set to "CHEC" display, then press LIGHT/INC

switch (1) for at least 2 seconds.
Display: "ALLO" (when data in memory is
less than 170 cycles)
"A.FUL" (when data in memory is
more than 170 cycles)
A.FUL (when data in memory is
more than 180 cycles)
2. Every time the LIGHT/INC switch (1) is pressed, From ALLO flashing or A.FUL
Remarks
the display changes in the order shown on the flashing
right. 1 Hour, minute

2 x 98kPa P'FL (Front left) Suspension
pressure less than
3. If MODE switch (2) is pressed at any time dur- 3 x 98kPa P'FR (Front right) 100 x 98 kPa: XX.X
ing the display in Steps (1). or (2)., the display 4 x 98kPa P'RL (Rear left) More than 100 x 98 kPa:
XXX.X
will return to "CHEC". (End) 5 x 98kPa P'RR (Rear right)
Weight on front axle Suspension
t
6 2 pressure less than
(= 4 D F (P'FL+P'RL))
100 x 98 kPa: XX.X
Weight on rear axle More than 100 x 98 kPa:
t
7 2 XXX.X
(= 4 D F (P'RL+P'RR))
Appears when value is
negative
8 x 180 rad Angle of tilt O
(–) X.XX
9 Front axle tilt coefficient
10 Rear axle tilt coefficient X.XXX

11 Front axle link coefficient
12 Rear axle link coefficient
Calibrated empty weight on
13 t Same as 7. and 8.
spring
14 — GT o Gain trimmer
15 t Present load weight Same as 7. and 8.
16 V Backup battery
X.X
Voltage
17 ALLO flashing
Returns to (1) and
repeats sequence
All displayed values are rounded to

the value given.
20 HD325-7, HD405-7
(c) Operation for memory card dump (service area) (d) Operation for data all clear (service area)
1. Set to "CHEC" display, then press TOTAL/SFT 1. Set to "CHEC" display, then press LIGHT/INC
switch (1) switch (1) and CAL/CLR switch (2) at the same
Display: "Cd : dP" time for at least 2 seconds.
Display: "A : CLE"
2. Press TOTAL/SFT switch (1) again.
The main display will go out and memory card 2. Press CAL/CLR switch (2).
access lamp (3) will light up. The display will become "A.CLE" (lighted up),
When the memory card dump operation is and when the data all clear operation is com-
completed, the display will return automatically pleted, the display will return automatically to
to the "CHEC" display. (End) the "CHEC" display. (End)
If it is desired to stop the memory card dump If it is desired to stop the data all clear opera-
operation when the display is "Cd : dP", press tion when the display is "A : CLE", press
MODE switch (2), and the display will return to MODE switch (3), and the display will return to
"CHEC" without performing the memory card "CHEC" without performing the data all clear
dump operation. operation.
The memory card dump function can be used a Before clearing the data, download the
only when the No. 5 switch (memory card use necessary data to a PC or carry out the
switch) on the left side of the controller is set to card dump operation in Item (c).
"Use".
HD325-7, HD405-7 21
(e) Operation for input signal condition display
(2-d) Battery charge signal condition

Display: C4:XX (lights up for 3 seconds)
Engine running: C4 : oo
Engine stopped: C4 : — —
O
(2-e) Analog spare input 1 signal condition
X.X .... Input signal (V)
O
(2-f) Analog spare input 2 signal condition
X.X .... Same as C5
O
(2-g) Digital spare input 1 signal condition
1. Set to "CHEC" display, then press TOTAL/SFT
switch (1) and CAL/CLR switch (2) at the same
time for at least 2 seconds.
Hi:C7 : oo
Display: S : CHE
Lo: C7 : — —
O
2. Every time CAL/CLR switch (1) is pressed, the
(2-h) Digital spare input 2 signal condition
display changes in the order shown below.
Display: C8 : XX (lights up for 3 seconds)
X.X .... Same as C7
(2-a) Parking brake and brake lock switch signal
O
condition [HD1200-1]
(2-i) Travel speed display
Display: C9 : XX
X.X .... Travel speed (km/h)
Either one ON:CL : oo
O
Both OFF:CL : — —
(2-j) Travel distance display
O
(2-a’) Shift lever position signal condition
Travel distance with machine in present
[except HD1200-1]
condition (empty or loaded) for that cycle
Display: C1: XX (lights up for 3 seconds)
XXXX .... (m)
"N":CL : oo
Except "N":CL : — —
* If the value goes above 9999m, the display
O
starts again from 0.
(2-b) Dump lever position signal condition
O
Go to next page
FLOAT:C2 : oo
Except FLOAT:C2 : — —
O
(2-c) Engine oil pressure signal condition
Engine running:C3 : oo
Engine stopped:C3 : — —
O
22 HD325-7, HD405-7
( f ) Operation for performing forced initialization
From previous page

O
(2-k) Payload meter present recognition display
Counter display
Empty stopped .............03.01

Empty traveling.............01.02
Loading.........................06.03
Loaded traveling...........02.04
Loaded stopped............04.05
1. Set to "CHEC" display, then press CAL/CLR
Dumping .......................05.06
switche (1), TOTAL/SFT switch (2) and LIGHT/
INC switch (3) at the same time for at least 2
Invariable May change
according to seconds.
N signal when
O dumping
Display: " : "
(2-l) Machine condition time display shown below
2. Press CAL/CLR switch (1) for at least 2 sec-
Every time CAL/CLR switch (1) is pressed,
onds.
the display advances one place in order from
a) to f). The display becomes : (lighted up)
(2 seconds),
and when all the data is completely cleared, it
a) Empty traveling S1 :
automatically displays "F.CAL". (End)
b) Empty stopped S2 :
c) Loaded traveling S3 : If it is desired to stop the forced initialization
d) Loaded stopped S4 : operation when the display is " : ",
e) Dumping S5 : press MODE switch (4), and the display will
f) Loading S6 : return to "CHEC" without performing the forced
initialization operation.
* The value for

the present
machine recog-
nition condition
increases in
"minutes" in
real time.
3. If MODE switch (3) is pressed at any time dur-

ing the display in steps (1) or (2), the display
will return to "CHEC". (END)
HD325-7, HD405-7 23
(g) Operation for setting extra load weight when load- (h) Operation for setting load weight fixed display
ing and cycle data record value
1. Set to "CHEC" display, then press TOTAL/SFT 1. Set to UP : "XX" display, then press CAL/CLR
switch (1) and LIGHT/INC switch (2) at the switch (4)
same time for at least 2 seconds. Display: PL : "XX" (present set value)
Display: S.5EL
If it is necessary to correct the setting, press
2. Press CAL/CLR switch (3). LIGHT/INC switch (2) and correct.
Display UP : "XX" present set value:for + : " X"
When the correction operation is completed,
for – : "– X"
press MODE switch (1) at any time to return to
If it is necessary to correct the setting, press
the "CHEC" display. (End)
LIGHT/INC switch (2) and correct.
3. When the correction operation from Step1. is

completed, press MODE switch (4) at any time
to return to the "CHEC" display. (End)
24 HD325-7, HD405-7
( i ) Operation for setting loading completion recog- ( j ) Operation for setting loading start recognition
nition travel distance load mass
1. Set to PL : "XX" display, then press CAL/CLR 1. Set to O.SEL display, then press CAL/CLR
switch (4) switch (4)
Display: O.SEL Display: P.SEL
2. Press TOTAL/SFT switch (3). 2. Press TOTAL/SFT switch (3).

Display: XX"X" Display: XX"X"X
If it is necessary to correct the setting If it is necessary to correct the setting
for the units, press LIGHT/INC switch for the tens, press LIGHT/INC switch
(2) and correct. (2) and correct.
3. Press CAL/CLR switch (4). 3. Press CAL/CLR switch (4).

Display: X"X"X Display: X"X"XX
If it is necessary to correct the setting If it is necessary to correct the setting
for the tens, press LIGHT/INC switch for the hundreds, press LIGHT/INC
switch (2) and correct.
(2) and correct.
4. Press CAL/CLR switch (4) again.
4. Press CAL/CLR switch (4) again. Display: "X"XXX
Display: "X"XX If it is necessary to correct the setting
If it is necessary to correct the setting for the thousands, press LIGHT/INC
switch (2) and correct.
for the hundreds, press LIGHT/INC
switch (2) and correct. 5. If CAL/CLR switch (4) is pressed again, the dis-
play will return to Step (3), so it is possible to
correct again.
5. If CAL/CLR switch (4) is pressed again, the dis-
play will return to XX"X", so it is possible to cor- 6. When the correction operation from Step 1. is
rect the units again. completed, press MODE switch (1) at any time
6. When the correction operation from Step 1. is
completed, press MODE switch (1) at any time If it is impossible to set the input values even
to return to the "CHEC" display after displaying when MODE switch (1) is pressed, it returns to
O.XXX (input value). (End) Step1.
If it is impossible to set the input values even
when MODE switch (1) is pressed, it displays
O.XXX (input value) and returns to Step 2..
HD325-7, HD405-7 25
(k) Operation for setting 0 ton display range
1. Set to P.SEL display, then press

CAL/CLR switch (4)
Display: H.SEL
2. Press TOTAL/SFT switch (3).

Display: – – "XX" (present value)
If it is necessary to correct the set-
ting, press LIGHT/INC switch (2) and
correct.

26 HD325-7, HD405-7
( l ) Operation for setting display range of external

display lamps
Display: E."XXX"
(present value of lamp 5)
If it is necessary to correct the dis-
play range for lamp 5, press LIGHT/
INC switch (2) and correct.

If it is impossible to set the input values even

when MODE switch (1) is pressed, it displays
1. Set to H.SEL display, then press CAL/CLR d.FAL and returns to Step2.
switch (4)
Display: E.SEL
2. Press TOTAL/SFT switch (3).

Display: A."XXX"
play range for lamp 1, press
LIGHT/INC switch (2) and correct.
3. Press CAL/CLR switch (4).

Display: b."XXX"

Display: C."XXX"

Display: d."XXX"
HD325-7, HD405-7 27
5. Self-diagnostic function
The controller always observes the condition of the sensors and outputs, and if any abnormality occurs,
it displays and saves an error message.
Error message display
Order Error code display

of Contents Criterion
display Controller External lamp Cancellation Timing for display
priority display display of display
1 Dump lever at position — b-FL ON All flash When [for HD1200-1]
other than FLOAT removed When parking
(except when dumping) brake or brake
lock is ON
b-FL ON — When [for HD1200-1]
removed When parking
brake or brake
lock is OFF
2 Memory card — Cd flashes — When Removal
removed removed detection only
for card dump
3 Drop in backup battery Defective contact F-09 flashes — When Except during
voltage or voltage below removed loading
2.7 V
4 Cycle data memory See (*1) See (*1) — See (*1) Except during
FULL loading
Engine ON/OFF data
memory FULL
Abnormality, warning
data memory FULL
Integrated load weight,
number of cycles data
memory FULL
5 Disconnection in Output below 2 V F-18 flashes All flash When When engine is
terminal R when engine is removed running
running
6 Abnormality in sensor Output is less than F-20 flashes All flash When Any time
power source (18 V) 15 V and power removed
source voltage is
more than 20 V
7 Short circuit with Suspension pres- F-21 flashes All flash When Any time
ground, disconnection sure sensor input removed
in front left suspension signal is 0 kPa or
pressure sensor system below
8 Short circuit with F-22 flashes
ground, disconnection
in front right suspen-
sion pressure sensor
system
in rear left suspension
pressure sensor system
in rear right suspension
28 HD325-7, HD405-7
Saving abnormality,
warning data (PC soft- Remarks
ware display code)
— Display timing for other
than HD1200-1: Shift
lever position N
— Display timing for other

than HD1200-1: Shift
lever position other than
N
— Detected only when
performing card dump
Records Rated voltage: 3.6 V

(000-009)
Records
(000-011)
(000-012)
(000-013)
(000-014)
Records —
(000-018)
Records Calibration cannot be

(000-020) performed when there is
abnormality

abnormality
(000-022)
(000-023)
(000-024)
HD325-7, HD405-7 29
Order Error code display

of Content Criterion Timing for display
display Controller External lamp Cancellation
priority display display of display
11 Short circuit with Suspension pres- F-25 flashes All flash When Any time
power source in front sure sensor input removed
left suspension pres- signal is 220 x 98
sure sensor system kPa or more
power source in front
right suspension pres-
sure sensor system
power source in rear left
suspension pressure
sensor system
power source in rear
right suspension pres-
sure sensor system
15 Short circuit with Clinometer input F-31 flashes All flash When Any time
ground, disconnection signal above + 10 removed
in clinometer system
x 180 rad or more
16 Short circuit with power Clinometer input F-32 flashes
source in clinometer signal above – 10
system
x 180 rad or more
17 Calibration not per- Calibration data in F • CAL All flash When Any time
formed or abnormality in memory damaged flashes removed
RAM
18 Short circuit in external When coil is ON, F-41 flashes See When Except when load-
display lamp No. 1 relay relay coil short cir- Remarks removed ing (for external
cuits with power column display lamps, see
19 Short circuit in external F-42 flashes
source Remarks column)
display lamp No. 2 relay
23 Defective cycle data See (*2) L.bad — Start of Start of dumping -
payload (*2) flashes empty start of empty
travel travel
24 Over speed limit Travel speed is SP:SP — Set value When problem
over set speed flashes – 2km/h occurs
limit
25 Defective communica- F-71 — When —
tions or defective setting F-73 removed
of option code F-80
F-81
F-91
F-92
F-93
F-94
F-95
F-96
F-97
F-98
F-99
30 HD325-7, HD405-7
Saving abnormality,
warning data (PC soft- Remarks
ware display code)
abnormality
(000-026)
(000-027)
(000-028)
Records Applicable only when

(000-031) clinometer "use" switch
is at "use"
Calibration cannot be
abnormality
Records Load weight calculation

(000-019) stopped while problem
occurs
Records External display lamps
(000-041) actuated as follows
Applicable lamp
(000-042)
Machine stopped:
Always ON
(000-043) Machine traveling: OFF
Other lamps during load-
ing: Specified actuation
(000-044) Other than loading
Machine stopped: Flashes
Machine traveling: OFF
(000-045)
Records (000-071) —
(000-073)
(000-080)
(000-081)
(000-091)
(000-092)
(000-093)
(000-094)
(000-095)
(000-096)
(000-097)
(000-098)
(000-099)
HD325-7, HD405-7 31

© 2007 KOMATSU
All Rights Reserved
32 HD325-7, HD405-7
SEN00873-03
DUMP TRUCK
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up

Sensors, switches ........................................................................................................................................... 2
KOMTRAX terminal system (If equipped) ..................................................................................................... 16
HD325-7, HD405-7 1
Sensors, switches 1
Engine speed sensor
1. Magnet Function
2. Locknut q The engine speed sensor is installed to the
3. Wiring harness ring gear of the flywheel housing. It uses the
4. Connector rotation of the gear teeth to generate a pulse
voltage and transmits a signal to the transmis-
sion controller.
2 HD325-7, HD405-7
Accelerator sensor
HD325-7 Serial No. 7001 – 7025, 7101 – 7161
HD405-7 Serial No. 3001 – 3035, 7101 – 7157
1. Pedal
2. Connector
Outline
Accelerator signal Idle validation signal
q This is installed under the operator’s cab. The q This is installed under the operator’s cab.
accelerator pedal and accelerator sensor are When the accelerator pedal is released, signal
connected by a link. When the accelerator 2 (No. 5 pin) is connected to the ground; when
pedal is depressed, the movement is passed the accelerator pedal is depressed, signal 3
through the link and rotates the shaft of the (No. 6 pin) is connected to the ground.
potentiometer inside the accelerator sensor. The engine controller then detects the condi-
As a result, the resistance changes. A fixed tion.
voltage is impressed between the No. 1 – 3
pins of the potentiometer. A voltage signal cor-
responding to the angle of the accelerator
pedal is sent from the No. 2 pin to the engine
controller.
HD325-7, HD405-7 3
HD325-7 Serial No. 7162–

1. Pedal 3. Sensor
2. Connector
Function
• This sensor is installed on the surface of the
floor. It outputs the accelerator signal or idle val-
idation signal depending on the accelerator Output characteristics
pressing angle.
Accelerator signal
• Magnitude of the accelerator pedal displace-
ment being detected by the potentiometer in-
side the sensor is output in variable voltage from
No. 2 pin.
Idle validation signal

• The switch inside the sensor detects the accel-
erator pedal operation. As the accelerator pedal
is released, it outputs the signal being entered
to No. 5 pin from No. 4 pin. And as the acceler-
ator pedal is pressed, it outputs the signal being
entered to No. 6 pin from No. 4 pin.
4 HD325-7, HD405-7
Retarder oil temperature sensor
Steering oil temperature sensor
1. Thermistor Function
2. Plug q The retarder oil temperature sensor is installed
3. Wiring harness on the retarder pipe. It converts a temperature
4. Connector change into a change of thermistor resistance,
and transmits a signal to the transmission con-
troller. The transmission controller transmits
the signal via the network to the machine mon-
itor panel, and the machine monitor panel dis-
plays a temperature level. The temperature
level displayed on the monitor panel reaches a
predetermined position, the lamp flashes and
the warning buzzer sounds.
q The steering oil temperature sensor is installed
to the steering and hoist piping. The sensor
portion detects the temperature, and when the
oil temperature goes above the specified level,
the warning lamps lights up and the character
display shows message to warn of abnormality.
HD325-7, HD405-7 5
Coolant level sensor
1. Float Function
2. Sensor q This sensor is installed to the top of the radia-
3. Connector tor, and when the coolant level goes below the
specified level, the float goes down and the
switch goes OFF. The maintenance caution
lamp lights up and the character display shows
message to warn of abnormality.
6 HD325-7, HD405-7
Fuel level secsor
2. Float q The fuel level sensor is installed to the side
3. Arm face of the fuel tank. The float moves up and
4. Body down according to the fuel level. This movment
5. Spring of the float is transmitted by the arm and acutu-
6. Contact ates a variable resistance. This sends a signal
7. Spacer to the monitor panel to indicate the remaining
fuel level. When the display of the monitor
panel reaches a certain level, a warning lamp
flashes.
HD325-7, HD405-7 7
Air cleaner clogging sensor
1. Indicator Function
2. Spring q The air cleaner clogging sensor is installed to
3. Adapter the outward port of the air cleaner. If the air
cleaner becomes clogged and reaches the set
pressure (negative pressure), the maintenance
caution lamp lights up and character display
shows message to warn of the abnormality.
8 HD325-7, HD405-7
Body positioner sensor
1. Bearing Function
2. Brush Ass'y q The body positioner sensor is installed to the
3. Connector rear of the chassis. When the angle of the
dump body changes, the shaft rotates through
the link installed to the dump body, and the
dump body angle is detected.
HD325-7, HD405-7 9
Accumulator oil pressure sensor
1. Sensor Function
2. Connector q The accumulator oil pressure sensor is
installed to the accumulator piping on the right
side of the machine and its sensor section
senses the oil pressure. If the oil pressure low-
ers below the set level, the warning lamp lights
up and the message is indicated on the char-
acter display of the monitor panel.
10 HD325-7, HD405-7
Steering oil pressure switch (for auto emergency steering system)
1. Piston Function
2. Body q The steering oil pressure switch is installed to
3. Switch the steering and hoist piping. While the engine
4. Connector is running, if the steering circuit oil pressure
lowers below the set level, the steering oil
pressure switch operates the electric pump to
secure the oil pressure for steering.
HD325-7, HD405-7 11
Steering angle sensor (for auto suspension system)
1. Body Principle of operation:

2. Tube Magnetic contactless proximity switch
3. Connector Form of output:
Turning ON when object of sensing approaches.
Function
q A round disc with teeth like a comb is installed
to the steering column. As this disc passes
through the slit in the sensor, the sensor out-
puts a pulse signal. The suspension controller
can obtain the steering speed from the number
of pulses per time.
12 HD325-7, HD405-7
Suspension oil pressure sensor
1. Sensor Function
2. Tube q The suspension oil pressure switch is installed
3. Connector to the suspension cylinder. If the pressure
supplied through the pressure inlet is applied
to the diaphragm of the pressure sensor sec-
tion, the diaphragm is deflected and deformed.
A bridge consisting of strain gauges is installed
on the opposite side of the diaphragm. If the
diaphragm is deflected, the resistance of the
strain gauges changes. A constant voltage is
applied to the strain gauges and the change of
the resistance of the strain gauges is sent as a
change of voltage to the amplifier. The ampli-
fier amplifies the change of the voltage and
outputs it to the controller.
HD325-7, HD405-7 13
Pressure sensor (for payload meter )
1. Sensor
2. Tube
3. Connector
The pressure sensor is installed at the bottom end The output characteristics of the sensor are as
of the suspension cylinder and acts to measure the shown in the diagram.
pressure at the cylinder bottom. Voltage between pin (1) (GND) and pin (3) (output)
of each pressure sensor connector or voltage of
output (pins (4), (5), (6), (7)) of each sensor when
pin (3) of payload meter controller connector
(PM6) is grounded.
When replacing pressure sensor (1), leave the

valve (2) installed to the suspension and remove
only pressure sensor (1).
When removing or installing pressure sensor (1),
be careful not to let valve (2) rotate.
When removing pressure sensor (1), the action of
valve core (3) prevents the suspension pressure
from going down.
14 HD325-7, HD405-7
Clinometer (for payload meter ) Lamp drive relay (for payload meter )
To carry out compensation on slopes, the clinome- The external display lamps are driven by a signal
ter measures the tilt angle of the chassis in the from the payload meter.
front-to-rear direction.
The output characteristics of the clinometer are as

shown in the diagram.
Voltage between clinometer connector pin 1 (GND)
and pin 2 (output) or voltage of output (pin (8)) of
clinometer when pin (3) of payload meter controller
connector (PM6 pole) is grounded
HD325-7, HD405-7 15
KOMTRAX terminal system (If equipped) 1
q The KOMTRAX terminal transmits various

kinds of machine information wirelessly. Per-
sons to operate the KOMTRAX can refer to the
information at office to provide various kinds of
services for customers.
a To provide the services, you need to make

an arrangement for starting the
KOMTRAX terminal service separately.
Information transmittable from KOMTRAX ter-

minal system includes the following.
1. Travel history
2. Service meter
3. Position information
4. Error history
and others.
16 HD325-7, HD405-7
KOMTRAX communication modem

TC200
1. DRC connector (40 poles) connecting part Outline

2. (Not connected) q The KOMTRAX terminal can obtain various
3. GPS antenna connector connecting part kinds of machine information from network sig-
4. Orbcomm antenna connecting part nals or input signals in the machine, and trans-
mit the information via the communication
antenna. The terminal is equipped with a CPU
(central processing unit), and has wireless
communication and GPS functions as well.
q The terminal is provided with a LED lamp and
a 7-segment display lamp as a display unit.
The display unit is used for inspection and
maintenance.
HD325-7, HD405-7 17
Input and output signals

• DRC connector
Pin No. Signal name Input/output Pin No. Signal name Input/output
1 232C (OCH) control signal Input 21 Inspection mode Input
2 232C (OCH) control signal Output 22 Inspection mode Input
3 232C (OCH) control signal Input 23 232C (OCH) control signal Input
4 232C (OCH) receiving Input 24 (If equipped) Input
5 232C (OCH) transmitting Output 25 (If equipped) Input
6 CAN shield GND — 26 (If equipped) Input
7 CAN signal (L) Input/output 27 C terminal input (Hi side) Input
8 CAN signal (H) Input/output 28 R terminal input Input
9 S-NET shield GND — 29 EXGND —
10 S-NET signal Input/output 30 (If equipped) Output
11 232C (OCH) shield GND — 31 (If equipped) (5V MAX) Input
12 Writing signal Input 32 (If equipped) (5V MAX) Input
13. 232C (ICH) receiving Input 33 232C (OCH) control signal Input
14. 232C (ICH) transmitting Output 34 (If equipped) Input
15. 232C (OCH) control signal Output 35 (If equipped) Output
16. (If equipped) Input 36 ACC Input Input
17. (If equipped) Input 37 Power supply GND (if equipped) —
18. (If equipped) Output 38 Power supply GND (if equipped) —
19. (If equipped) Output 39 Permanent power supply (12V/24V) Input
20. Relay output Output 40 Permanent power supply (12V/24V) Input
*: Never connect to NC or malfunctions or failure will occur. *: Never connect to NC or malfunctions or failure will occur.
18 HD325-7, HD405-7
HD325-7, HD405-7 19

© 2008 KOMATSU
All Rights Reserved
20 HD325-7, HD405-7
SEN01181-02
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up
20 Standard value table

Standard service value table
Standard value table for engine ...................................................................................................................... 2
Standard value table for machine ................................................................................................................... 4
HD325-7, HD405-7 1
SEN01181-02 20 Standard value table
Standard value table for engine 1

HD325-7
Machine model
HD405-7
Engine SAA6D140E-5
Cate- Standard value Service limit
Item Measurement conditions Unit
gory for new machine value
P mode 2,300 ± 25 2,300 ± 25
Max. speed at no load rpm
E mode 2,150 ± 25 2,150 ± 25
Performance
Speed
P mode 965 ± 50 965 ± 50
Min. speed at no load rpm
E mode 725 ± 25 725 ± 25
Necessary At 0°C (without starting aid) rpm Min. 110 —
speed for
starting At –20°C (with starting aid) rpm Min. 85 —
Air intake kPa Max. 3.73 7.47
Whole speed range
resistance {mmH2O} {Max. 380} {762}
Air boost kPa Min. 183 156
At rated output
pressure {mmHg} {Min. 1,370} {1,170}
Exhaust kPa Min. 163 139
At rated output
pressure {mmHg} {Min. 1,220} {1,040}
Air intake and exhaust system
Exhaust
Whole speed range (20°C ) °C Max. 650 700
temperature
%
Max. 25 35
At sudden acceleration (Low → High) (Bosch
{Max. 2.5} (3.5)
index)
Exhaust gas
Bosch
color At rated output Max. 1.5 2.5
index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 —
Valve clearance
Exhaust valve mm 0.57 —
EGR valve and Min. 1.18 Min. 1.18
At low idle
bypass valve MPa {Min. 12.0} {Min. 12.0}
drive oil {kg/cm2} Min. 1.43 Min. 1.43
pressure At high idle
{Min. 14.6} {Min. 14.6}
Compression Engine oil temperature: 40 – 60°C MPa Min. 4.1 2.8
pressure Engine speed: 200 – 250 rpm {kg/cm2} {Min. 42} {29}
Body
Blow-by At rated output kPa Max. 2.94 3.92

pressure Engine coolant temperature: Min. 70°C {mmH2O} {Max. 300} {400}
At rated output SAE0W30E0S MPa Min. 0.34 0.21
Engine oil temperature: Min. 80°C SAE5W40E0S {kg/cm2} {Min. 3.5} {2.1}
Lubrication system
Engine oil
SAE10W30DH
pressure At low idle MPa Min. 0.10 0.08
SAE15W40DH
Engine oil temperature: Min. 80°C SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Engine oil
Whole speed range (Inside of oil pan) °C 90 – 110 120
temperature
Ratio to fuel consumption at continuous rated
Oil consumption % Max. 0.15 0.3
output
2 HD325-7, HD405-7
HD325-7
Machine model
HD405-7
Engine SAA6D140E-5
Cate- Standard value Service limit
Item Measurement conditions Unit
gory for new machine value
Function of
kPa
radiator Cracking pressure (Differential pressure) — —
{kg/cm2}
Cooling system
pressure valve
Fan speed At rated speed rpm 1,020 ± 30 1,020 ± 30
15 – 17 19 – 21
Fan belt tension Deflection under finger pressure of 98 N {10 kg} mm
(When new) (When retightened)
Alternator belt
Deflection under finger pressure of 98 N {10 kg} mm 13 – 16 13 – 16
tension
HD325-7, HD405-7 3
Standard value table for machine 1

Cate- Standard value for
Item Measurement conditions Unit Service limit value
gory new machine
F1 • Engine coolant temperature: 10.3 ± 5% 10.3 ± 5%

Within operating range
F2 • Transmission oil tempera- 15.8 ± 5% 15.8 ± 5%
ture: 60 – 80°C
• When empty
F3 21.3 ± 5% 21.3 ± 5%
• Travel resistance 3.3%
F4 28.7 ± 5% 28.7 ± 5%
Travel speed
km/h
(Power mode)
F5 38.5 ± 5% 38.5 ± 5%
F6 52.4 ± 10% 52.4 ± 10%
F7 70.0 ± 10% 70.0 ± 10%

Performance
R 10.6 ± 5% 10.6 ± 5%
F1 • Engine coolant temperature: 10.3 ± 5% 10.3 ± 5%

• Transmission oil tempera- 14.5 ± 5% 14.5 ± 5%
F2
ture: 60 – 80°C
• When empty
F3 19.5 ± 5% 19.5 ± 5%
• Travel resistance 3.3%
F4 26.4 ± 5% 26.4 ± 5%
Travel speed
km/h
(Economy mode)
F5 35.5 ± 5% 35.5 ± 5%
F6 48.5 ± 10% 48.5 ± 10%
F7 65.1 ± 10% 65.1 ± 10%
R 9.8 ± 5% 9.8 ± 5%
Shift up • Engine coolant temperature: 2,100 ± 50 2,100 ± 50

• Transmission oil tempera- 1,400 ± 50 1,400 ± 50
Power mode
ture: 60 – 80°C
Shift down
• Hydraulic oil temperature: 1,325 ± 35 1,325± 35
Automatic shift control
45 – 55°C (F2 o F1 only) (F2 o F1 only)

Engine speed
• "Braking mode" refers to

Shift up when the accelerator is OFF 2,000 ± 50 2,000 ± 50
or the rear brake is ON. rpm
Economy
1,300 ± 50 1,300 ± 50
mode
Shift down
1,250 ± 50 1,250 ± 50
(F2 o F1 only) (F2 o F1 only)
Shift up 2,450 ± 50 2,450 ± 50

Braking
mode
Shift down 1,550 ± 50 1,550 ± 50
4 HD325-7, HD405-7

gory new machine
F1 • F2 • Engine coolant temperature: 1,300 – 1,475 1,300 – 1,475

Set Within operating range
Auto lock-up
F3 – F7 • Transmission oil tempera- 1,250 – 1,475 1,250 – 1,475

ture: 60 – 80°C
F1 • F2 • Hydraulic oil temperature: 1,100 ± 10 1,100 ± 10
Reset 45 – 55°C
F3 – F7 • "Braking mode" refers to 1,100 ± 10 1,100 ± 10
when the accelerator is OFF
prevention
Set or the rear brake is ON. 2,600 ± 10 2,600 ± 10

Overrun
Engine speed
Reset rpm 2,350 ± 10 2,350 ± 10
Same as shift
down for auto-
Down-shift inhibitor
matic shift control
given above
• Transmission oil tempera- Power 1,930 ±
ture: 85 – 110°C 1,930 ± 100
mode 100
converter
Torque
Engine speed at torque • Hydraulic oil temperature:

converter stall 45 – 55°C
Economy 1,820 ±
• Engine coolant temperature: 1,820 ± 100
mode 100
Starting to • Operating effort at a point +10.0

29.4 - 5.0
+10.0
29.4 - 5.0
depress 150 mm from pedal fulcrum +1.0 +1.0
N {3.0 - 0.5 } {3.0 - 0.5 }
Operating effort
Accelerator
{kg} +5 +5
58.7 - 10 58.7 - 10
pedal
Fully +1 +1
{6.0 - 0.5 } {6.0 - 0.5 }
Starting to • Travel at a point 150 mm
Storoke depress from pedal fulcrum mm 45 ± 5 45 ± 5
io fully
N Max. 29.4 Max. 29.4
Operating effort • At center of lever knob
{kg} {Max. 3.0} {Max. 3.0}
R–N
Transmission shift lever
N–D
D–5
• Stroke at 216.4 mm from ful-
Storoke mm 24.5 ± 1 24.5 ± 1
crum
5–4
4–3
3–L
• Oil temperature: 60 – 70°C 0.78 ± 0.10 0.78 ± 0.10

Oil pressure at inlet port
• Engine: Full throttle {8 ± 1} {8 ± 1}
Torque converter
0.59 ± 0.10 0.59 ± 0.10

Oil pressure at outlet port
MPa {6.0 ± 1} {6.0 ± 1}
{kg/cm2} 1.91 ± 0.15 1.91 ± 0.15
Lock-up pressure
{19.5 ± 1.5} {19.5 ± 1.5}
Main relief pres- • Oil temperature: 60 – 80°C 3.43 ± 0.20 3.43 ± 0.20
High idle
sure {35 ± 2.0} {35 ± 2.0}
HD325-7, HD405-7 5

gory new machine
L, H, 3rd, • Oil temperature: 60 – 80°C 1.62 ± 0.15 1.62 ± 0.15
Control valve set pressure
Actual 4th clutch • Engine: Full throttle {16.5 ± 1.5} {16.5 ± 1.5}
machine 1st, 2nd, R Note: The pressure detected 2.94 ± 0.15 2.94 ± 0.15
clutch when using modulation {30.0 ± 1.5} {30.0 ± 1.5}
checker or fixed valve is
1.67 ± 0.20 1.67 ± 0.20
L, 4th clutch different from the mea-
{17 ± 2} {17 ± 2}
Transmission
When using surement on the actual

modulation machine. MPa 1.96 ± 0.20 1.96 ± 0.20
H, 3rd clutch
checker or {kg/cm2} {20 ± 2} {20 ± 2}
fixed valve 1st, 2nd, R 3.24 ± 0.20 3.24 ± 0.20
clutch {33 ± 2} {33 ± 2}
• Oil temperature: 60 – 80°C
(When using EO10-CD)
0.147 ± 0.05 0.147 ± 0.05
Lubricating oil pressure or
{1.5 ± 0.5} {1.5 ± 0.5}
Oil temperature: 80 – 100°C
(When Using EO30-CD)
18.00-33- • Machine unloaded
(Inflation pressure)
32PR 0.56 ± 0.01 0.56 ± 0.01

Standard tires
HD325-7
(Front and {5.75 ± 0.1} {5.75 ± 0.1}
kPa
Tires
rear tires)
{kg/cm2}
18.00-R33
0.69 ± 0.01 0.69 ± 0.01
HD405-7 (Front and {7.0 ± 0.1} {7.0 ± 0.1}
rear tires)
• When machine stopped
Operating force (empty) N 9.8 – 29.4 Max. 29.4
(Turning speed for steering (If it is impossible when the {kg} {1.0 – 3.0} {Max. 3.0}
wheel: 30 rpm) machine stopped, travel at
low speed with engine at low
idle)
Steering wheel
• Length at circumference of
steering wheel
Play mm 20 – 50 20 – 50
• Engine stopped, until tires
start to move
No. of turns • Lock o lock Turns 3.4 ± 0.4 3.4 ± 0.4
Left • Oil temperature: 60 – 80°C

Max. 4 Max. 4
o right • Engine speed: Whole range
Turning time sec.
Right • Lock o lock
Max. 4 Max. 4
o left
Steering
MPa 20.6 ± 0.98 20.6 ± 0.98

valve
Relief pressure • Engine: Full throttle

{kg/cm2} {210 ± 10} {210 ± 10}
• Demand valve relief valve
• Position of 150 mm from ful- N
+44.1
234 - 14.7
+44.1
234 - 14.7
Operating effort crum of pedal
Brake
{kg}
pedal
+4.5 +4.5
{23.9 - 1.53 } {23.9 - 1.53 }
Storoke mm 45 ± 5 45 ± 5
N 5.88 – 9.8 2.94 – 14.7

control lever
Operating effort • Position of 167 mm from ful-

Retarder
crum of lever {kg} {0.6 – 1.0} {0.3 – 1.5}

0 0
Storoke deg 78 - 2 78 - 2
6 HD325-7, HD405-7

gory new machine
• Position of 150 mm from ful- +46.6 +46.6
charge pressure brake pedal
Emergency
N 254 - 25.8 254 - 25.8

Operating effort crum of lever {kg] +4.8
{25.9 - 2.6 }
+4.8
{25.9 - 2.6 }
Storoke mm 51 ±5 51 ±5
• Oil temperature: 80°C 20.6

+0.98
0 20.6
+0.98
0
Accumulator
Cut-out pressure • At engine rated speed +10 +10

MPa {210 0 } {210 0 }
{kg/cm2} +0.49 +0.49
13.7 0 13.7 0
Cut-in pressure +5 +5
{140 0 } {140 0 }
36.5 ton • Initial speed: 32 km/h Max. 23.5 Max. 23.5
Service brake payload • Distance from starting to lose
braking distance speed to stopping
Empty Max. 17.0 Max. 17.0
• On flat, dry road surface
m
36.5 ton
Max. 31.7 Max. 31.7
Retarder brake payload
braking distance
Empty Max. 25.0 Max. 25.0
Front brake • Brake pedal is pressed to +0.76 +0.76

18.4 - 1.52 18.4 - 1.52
piston pres- stroke end.
Brakes
+7.5 +7.5
sure • Accumulator is fully charged. {187.5 - 16.5 } {187.5 - 16.5 }
Rear brake • Engine is stopped.
Brake actuating MPa 4.9 ± 0.49 4.9 ± 0.49
piston pres- • Pressure is measured at first
pressure {kg/cm2} {50 ± 5} {50 ± 5}
sure operation.
Rear brake
4.21 ± 0.29 4.21 ± 0.29
piston pres- {43 ± 3} {43 ± 3}
sure
• Carrying 36.5 ton payload
Stopping distance when emer-
• Initial speed: 32 km/h m Max. 52.1 Max. 52.1
gency brake is applied
• On flat, dry road surface
• With 36.5 ton payload
Braking capacity (sin ) • After adjusting clearance % Min. 25 Min. 25
Parking
brake
between disc and pad

• F2
Starting test rpm Min. 1,600 Min. 1,600
• Torque converter stall
+0.98 +0.98
• Engine: Full throttle MPa 20.6 20.6
valve
Hoist
0 0
Relief pressure
• Measure at end of stroke {kg/cm2} {210
+10
} {210
+10
}
0 0
when raising body
Lifting speed • Oil temperature: 45 – 55°C 10 ± 1.5 10 ± 1.5

• Engine: Full throttle sec.
Lowering speed • Use FLOAT when lowering 10 ± 1.5 10 ± 1.5
Body

• Set with No. 2 cylinder
Hydraulic drift mm Max. 85 Max. 85
extended 200 mm
• Hydraulic drift after 5 minutes
HD325-7, HD405-7 7

gory new machine
• On flat road surface
Front A 233 ± 10 233 ± 10
• When empty
Installed length mm
Suspension cylinder
Rear B 176 ± 10 176 ± 10
2.90 ± 0.49 2.90 ± 0.49

Front
{29.6 ± 5} {29.6 ± 5}
MPa
Pressure
{kg/cm2} 2.24 ± 0.49 2.24 ± 0.49
Rear
{22.9 ± 5} {22.9 ± 5}
For front
10.7 ± 0.34 10.7 ± 0.34
service
{109 ± 3.5} {109 ± 3.5}
Accumulator
brake
• Gas temperature
Nitrogen gas For rear MPa
(atmosphere temperature):
pressure service {kg/cm2}
20 ± 5 °C 6.2 ± 0.20 6.2 ± 0.20
brake and
{63 ± 2.0} {63 ± 2.0}
parking
brake
8 HD325-7, HD405-7
HD325-7, HD405-7 9

© 2007 KOMATSU
All Rights Reserved
10 HD325-7, HD405-7
SEN01182-02
DUMP TRUCK
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up
30 Testing and adjusting 1

Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting............................................................................................. 3
Testing engine speed ...................................................................................................................................... 9
Testing intake air pressure (boost pressure) ................................................................................................. 10
Testing exhaust temperature..........................................................................................................................11
Testing exhaust gas color ............................................................................................................................. 13
Adjusting valve clearance ............................................................................................................................. 14
Testing compression pressure ...................................................................................................................... 16
Testing blow-by pressure .............................................................................................................................. 18
Testing engine oil pressure ........................................................................................................................... 19
Testing EGR valve and bypass valve drive oil pressure ............................................................................... 20
Handling of fuel system devices ................................................................................................................... 21
Releasing residual pressure from fuel system .............................................................................................. 21
Testing fuel pressure..................................................................................................................................... 22
Testing fuel return rate and leakage.............................................................................................................. 23
Bleeding air from fuel circuit.......................................................................................................................... 26
HD325-7, HD405-7 1
SEN01182-02 30 Testing and adjusting
Testing the fuel circuit for leakage................................................................................................................. 28

Testing and adjusting alternator belt tension................................................................................................. 29
Testing and adjusting fan belt tension ........................................................................................................... 30
Testing and adjusting air conditioner compressor belt tension...................................................................... 31
2 HD325-7, HD405-7
Tools for testing, adjusting, and troubleshooting 1

Sym-
Q'ty
Testing/Adjusting item Part No. Part name Remarks
bol
-101 – 200 kPa
Testing air boost pressure A 799-201-2202 Boost gauge kit 1
{-760 – 1,500 Hg}
Testing exhaust tempera-
B 799-101-1502 Digital thermometer 1 -99.9 – 1,299 °C
ture
Bosch index 0 – 9 (with standard
1 799-201-9001 Handy smoke checker 1
color)
Testing exhaust gas color C
Commercially
2 Smoke meter 1
available
Commercially (Intake: 0.35 mm, Exhaust: 0.57
Adjusting valve clearance D Thickness gauge 1
available mm)
1 795-502-1590 Compression gauge 1 0 – 6.9 Mpa {0 – 70 kg/cm²}
Testing compression pres-
E 795-471-1310 Adapter 1
sure 2 For 140E-3, 5 engine
6217-71-6110 Gasket 1
1 799-201-1504 Blow-by checker 1
Testing blow-by pressure F Commercially Hose (Inside diameter:
2 1
available 25 mm, Length, 100 mm)
Pressure gauge:
Testing engine oil pressure 799-101-5002 Hydraulic tester 1 2.5, 5.9, 39.2, 58.8 MPa
1 {25, 60, 400, 600 kg/cm²}
Testing EGR valve and G Pressure gauge:
790-261-1204 Digital hydraulic tester 1
bypass valve drive oil 58.8 MPa {600 kg/cm²}
pressure Pressure gauge:
2 799-401-2320 Hydraulic tester 1
0.98 MPa {10 kg/cm²}
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 5.9, 39.2, 58.8 MPa
1 {25, 60, 400, 600 kg/cm²}
Pressure gauge:
Testing fuel pressure H 58.8 MPa {600 kg/cm²}
Pressure gauge:
0.98 MPa {10 kg/cm²}
795-471-1450 Adapter 1 8 × 1.25 mm o R1/8
3
07005-00812 Gasket 1
1 6151-51-8490 Spacer 1 Inside diameter: 14 mm
2 6206-71-1770 Joint 1 Joint diameter: 10mm
Commercially
3 Hose 1 Size x Length: ø 5 mm × 2 – 3 m
available
Testing fuel return rate and Commercially
J 4 Hose 1 Size x Length: ø 15 mm × 2 – 3 m
leakage available
Commercially
5 Stopwatch 1
available
Commercially
6 Measuring cylinder 1 Capacity: 1l
available
HD325-7, HD405-7 3
Sym-
Q'ty
bol
Pressure gauge:
1 {25, 60, 400, 600 kg/cm²}
Pressure gauge:
Testing power train oil pres- 790-261-1204 Digital hydraulic tester 1
K 58.8 MPa {600 kg/cm²}
sure
Pressure gauge:
0.98 MPa {10 kg/cm²}
799-101-5220 Nipple 1
3 M10 × P1.25
07002-11023 O-ring 1
Pressure gauge:
1 {25, 60, 400, 600 kg/cm²}
Testing brake oil pressure L Pressure gauge:
58.8 MPa {600 kg/cm²}
2 566-35-43561 Nipple 1 18 × 1.5 (female: R 2/8)
3 793-520-1805 Brake test kit 1
Testing wear of front brake
M 566-98-41410 Gauge 1 Tools carried on machine
pad
1 792-610-1000 Suspension tool 1
2 • 792-610-1130 Pump 1
3 • 792-610-1110 Hose 1
4 • 792-610-1120 Joint 1
N2 – N6: Pump assembly
5 • 07020-21732 Fitting 1 Kit No. 792-610-1100
6 • 792-610-1140 Joint 1 N7 – N13:
Testing and adjusting front
N 7 • 792-610-1250 Valve 1 Charging tool assembly
suspension cylinder Kit No. 792-610-1200
8 • 792-610-1260 Nipple 1
9 • 792-610-1480 Stem 1
10 • 792-610-1640 Joint 1
11 • 792-610-1400 Regulator 1
12 • 792-610-1430 Gauge 1 24.5 MPa {250 kg/cm²}
13 • 792-610-1440 Gauge 1 9.81 MPa {100 kg/cm²}
1 792-610-1000 Suspension tool 1
2 • 792-610-1130 Pump 1
3 • 792-610-1110 Hose 1
4 • 792-610-1120 Joint 1
O2 – O6: Pump assembly
5 • 07020-21732 Fitting 1 Kit No. 792-610-1100
6 • 792-610-1140 Joint 1 O7 – O13:
Testing and adjusting rear
O 7 • 792-610-1250 Valve 1 Charging tool assembly
suspension cylinder Kit No. 792-610-1200
8 • 792-610-1260 Nipple 1
9 • 792-610-1480 Stem 1
10 • 792-610-1640 Joint 1
11 • 792-610-1400 Regulator 1
12 • 792-610-1430 Gauge 1 24.5 MPa {250 kg/cm²}
13 • 792-610-1440 Gauge 1 9.8 MPa {100 kg/cm²}
4 HD325-7, HD405-7
Sym-
Q'ty
bol
Pressure gauge:
1 {25, 60, 400, 600 kg/cm²}
Testing and adjusting steer- Pressure gauge:
P 790-261-1204 Digital hydraulic tester 1
ing hoist circuit oil pressure 58.8 MPa {600 kg/cm²}
799-101-5220 Nipple 1
2
07002-11023 O-ring 1
Pressure gauge:
1 {25, 60, 400, 600 kg/cm²}
Testing dump EPC circuit oil Pressure gauge:

Q 790-261-1204 Digital hydraulic tester 1
pressure 58.8 MPa {600 kg/cm²}
2 799-101-5230 Nipple 1 14 × 1.5
799-401-3100 Adapter 1 Size 02
3
02896-11008 O-ring 1
Emergency body raising
R 792T-491-1110 Plug 1
tool
79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
Operating effort S
79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
1 792-610-1700 Gas charge tool 1
792-610-1310 Nipple (For Russia) GOST
792-610-1320 Nipple (For USA) CGA No. 351
Gas pressure check and fill- 792-610-1330 Nipple (For USA) ASA B-571-1965
T
ing of the accumulator 2 1 DIN 477-1963
792-610-1350 Nipple (For Germany) NEN 3268-1966
SIS-SMS 2235/2238
792-610-1360 Nipple (For UK) BS341 Part 1-1962
799-601-4100
or T-adapter Ass'y 1
799-601-4200
799-601-4130 • T-adapter 1 For Ne sensor
799-601-4330 • Socket 1 For G (Bkup) sensor
799-601-4240 • Socket 1 For Atomospheric sensor
799-601-4250 • Socket 1 For boost pressure sensor
For common rail pressure sensor
799-601-9420 • T-adapter 1 (Include 799-601-9000 and 799-
Engine related controller, 601-9200)
sensor and actuator diagno- U
799-601-4150 • T-adapter 1 For oil pressure sensor
sis
799-601-9430 • Socket 1 For supply pump PCV
799-601-9020 • T-adapter 1 For injector
799-601-4260 • T-adapter 1 For controllerl (4-pole)
For controllerl (50-pole)
799-601-4211 • T-adapter 1
(799-601-4100 only)
For controllerl (60-pole)
799-601-4220 • T-adapter 1
(799-601-4100 only)
For 60-pole
799-601-4350 • T-adapter 1
(799-601-4100 only)
HD325-7, HD405-7 5
Sym-
Q'ty
bol
799-601-9000
or
799-601-9100 T-adapter Ass'y
or
799-601-9300
Engine related controller, 799-601-9320 • T-adapter 1 For 24-pole
sensor and actuator diagno- U
799-601-9310 • Plate 1
sis
For boost temperrature sensor
795-799-5540 Socket 1
For intake-air temperrature sensor
For water temperrature sensor
795-799-5530 Socket 1 For fuel temperrature sensor
For oil temperrature sensor
799-601-2500
or
799-601-2700
or
799-601-2800
or
799-601-2900 T-adapter Ass'y 1 799-601-2900 is not supply
or
799-601-7100
or
799-601-7400
or
799-601-8000
For Econo (799-601-2700 is not
799-601-2600 • T-box 1
include)
799-601-2740 • For MIC adapter 1 For MIC-5P
799-601-4100 T-adapter Ass'y 1
799-601-4211 • For DRC adapter 1 For DRC50
799-601-9020 • For DT adapter 1 For DT2P
Sensor and actuator of
V
machine diagnosis 799-601-7000
or
799-601-7100
799-601-7400
or
799-601-8000
799-601-7020 • For X adapter 1 For X2P
For SW8P (799-601-8000 is not
799-601-7060 • For SWP adapter 1
include)
For M1P (799-601-7000 and 799-
799-601-7080 • For M adapter 1
601-7100 are not include)
799-601-7090 • For M adapter 1 For M2P
799-601-7180 • For AMP040 adapter 1 For A8P (799-601-7400 only)
6 HD325-7, HD405-7
Sym-
Q'ty
bol
For A12P (799-601-7000 and 799-
799-601-7190 • For AMP040 adapter 1
601-7100 are not include)
799-601-7330 • For S adapter 1 For S16PW (799-601-8000 only)
799-601-7320 For AMP040 adapter 1 For SW16P
799-601-7360 For relay adapter 1 For REL-5P
799-601-7370 For relay adapter 1 For REL-6P
799-601-7520 • For 070 adapter 1 For 070-12P
799-601-7540 • For 070 adapter 1 For 070-18P
799-601-7550 • For 070 adapter 1 For 070-20P
799-601-9000
799-601-9200
For DT2P (Include 799-601-9020
799-601-9020 • For DT adapter 1
and 799-601-7000)
Sensor and actuator of
V 799-601-9030 • For DT adapter 1 For DT3P
machine diagnosis
For DT4P (Include 799-601-9020
799-601-9040 • For DT adapter 1
and 799-601-7000)
799-601-9060 • For DT adapter (Gray) 1 For DT8PGR
799-601-9070 • For DT adapter (Black) 1 For DT8PB
• For DT adapter
799-601-9080 1 For DT8PG
(Green)
799-601-9110 • For DT adapter (Gray) 1 For DT12PGR
799-601-9120 • For DT adapter (Black) 1 For DT12PB
• For DT adapter
799-601-9130 1 For DT12PG
(Green)
• For DT adapter
799-601-9140 1 For DT12P
(Brown)
799-601-9350 • For DRC adapter 1 For DRC-40
799-601-9360 • For DRC adapter 1 For DRC-24
Testing coolant tempera- Digital temperature
– 799-101-1502 1 -99. 9 – 1,299 °C
ture and oil temperature gauge
Testing operation force and – 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
pedal force – 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Testing stroke and hydrau- Commercially
– Scale 1
lic drift available
Testing work equipment Commercially
– Stopwatch 1
speed available
Testing voltage and resis- Commercially
– Circuit tester 1
tance available
HD325-7, HD405-7 7
R: Plug
8 HD325-7, HD405-7
Testing engine speed 1

k Set chocks to the tires.
k Before starting measurement, check that
there is no one in the surrounding area.
a Test the engine speed under the following con-

ditions.
q Coolant temperature:
q Hydraulic oil temperature: 45 – 55 °C
q Torque converter oil temperature:
60 – 80 °C
1. Testing engine speed (low idle and high

idle)
1) Switch to the monitoring function of ser-
vice mode 1 and display the engine
speed. For details, see "Special functions
of monitor panel (EMMS)" in the Trouble-
shooting section.
a Monitoring item: ENG SPEED
2) Start the engine, set the measurement

conditions, and measure the engine
speed.
2. Testing torque converter stall speed

a See "Testing torque converter stall speed"
(mentioned later).
HD325-7, HD405-7 9
Testing intake air pressure (boost 6. Depress the accelerator pedal gradually, run
the engine at high idle and stall the torque con-
pressure) 1 verter, then measure the air supply pressure.
a Testing instruments for intake air pressure k There is danger of damage to the inter-
Symbol Part No. Part name

nal parts of the transmission, so never
operate the gear shift lever to any posi-
A 799-201-2202 Boost gauge kit tion other than the D position during
the stall operation.
k When installing and removing the testing a After completing the measurement, lower
instrument, take care not to touch a hot the engine speed to low idle, then return
part. the gearshift lever to the N position.
1. Remove the engine right side cover.
2. Remove the air boost pressure measurement

plug (1).
7. After completing the measurement, remove

the measuring instrument and set to the origi-
nal condition.
3. Install nipple [1] and hose [2] of boost gauge kit

A and connect them to gauge (A).
4. Run the engine at mid-range speed or above
to bleed the oil from inside the hose.
a Insert the connection of the hose and
pressure gauge about half way, repeat the
action to open the self-seal portion at the
hose end, and bleed the oil.
a If Pm kit (A) is available, the air bleeding
coupling (790-261-1130) in it may be
used.
a If there is oil inside the hose, the gauge
will not work, so always bleed the oil.
5. Turn the parking brake switch ON, depress the

brake pedal, then set the gear shift lever to the
D position.
k If the gearshift lever is operated to any
position other than the D position, the
machine may move off even if the
brake is being depressed, so always
measure at the D position.
10 HD325-7, HD405-7
Testing exhaust temperature 1 4. When measuring the exhaust temperature at

torque converter stall, implement below proce-
a Testing instrument for exhaust temperature dure.
Symbol Part No. Part name a To prevent the torque converter from over-
heating, use the full stall (torque converter
B 799-101-1502 Digital thermometer
stall + hydraulic relief) to stabilize the
k
exhaust temperature, then stall only the
Install and remove the testing instrument
torque converter and measure the temper-
after the exhaust manifold is cooled.
ature.
1) Start the engine and raise the temperature
1. Remove the engine right side cover.
of the coolant to the operating range.
2) Turn the parking brake switch ON, depress
2. Remove exhaust temperature measurement
the brake pedal, then set the gear shift
plug (1).
lever to the D position.
k If the gearshift lever is operated to
any position other than the D posi-
tion, the machine may move off
even if the brake is being
depressed, so always measure at
the D position.
3) Depress the accelerator pedal gradually,
run the engine at high idle and stall the
torque converter. At the same time, oper-
ate the dump lever to the LOWER position
and relieve the oil pressure (full stall).
a Continue until the exhaust tempera-
ture reaches the standard value of
3. Install sensor [1] and connect it to digital tem- 650 °C.
perature gauge B. k There is danger of damage to the
a Clamp the wiring harness of the tempera- internal parts of the transmission,
ture gauge at a suitable place to prevent it so never operate the gear shift
from touching any hot part. lever to any position other than the
D position during the stall opera-
tion.
4) When the temperature stabilizes at near
the target temperature, return the dump
lever to NEUTRAL and measure the tem-
perature with only the torque converter
stalled.
a The exhaust temperature will start to
go down from the full stall condition,
so measure the temperature when it
stabilizes.
a If the exhaust temperature does not
go down but rises, make the set tem-
perature at full stall higher.
a After completing the measurement,
lower the engine speed to low idle,
then return the gearshift lever to the N
position.
HD325-7, HD405-7 11
5) After completing measurement, remove

the measuring equipment and set to the
original condition.
5. When measuring the maximum value for the

exhaust temperature during actual operation,
do as follows.
Carry out actual work and record the maximum
exhaust temperature during operation.
a Set the temperature gauge to the PEAK
mode. The maximum temperature is auto-
matically recorded.
6. Detach the measurement tool after the mea-

surement, and make sure that the machine is
back to normal condition.
12 HD325-7, HD405-7
Testing exhaust gas color 1

a Testing instrument for exhaust gas color
1 799-201-9001 Handy smoke checker
C Commercially
2 Smoke meter
available
k When installing and removing the measur-

ing instrument, take care not to touch a hot
part.
a If an air source and a electric power source are

not available in the field, use handy smoke 2) Connect the probe hose, accelerator
checker C1. When recording official data, etc., switch outlet and air hose to the Smoke
use smoke meter C2. Meter C2.
a Raise the body and lock it by inserting the pin. a Restrict the supplied air pressure
below 1.5 MPa {15 kg/cm²}.
1. Testing with handy smoke checker C1 3) Connect the power cable to an outlet of
1) Stock a sheet of filter paper to smoke power.
checker C1. a Before connecting the cable, check
2) Insert the exhaust gas intake pipe in the that the power switch of the smoke
exhaust pipe. meter is turned OFF.
3) Start the engine and raise the temperature 4) Fit a filtering paper by loosening the suc-
of the coolant to the operating range. tion pump cap nut.
4) Let the exhaust gas stay on the filtering a Fit the filtering paper securely so that
paper by operating a handle of Handy air may not leak.
Smoke Checker C1, when the engine 5) Turn ON the power switch of smoke meter
speed is suddenly accelerated or kept at C2.
high idle.

5) Remove the filter paper and compare it of the coolant to the operating range.
with the attached scale to make a judge- 7) As increasing the engine speed rapidly or
ment. running it at high idle, press the accelera-
tor pedal of smoke meter C2 and collect
2. Testing with smoke meter C2 the exhaust gas with the filter paper.
1) Insert probe [1] of the Smoke Meter C2 8) Put the polluted filtering paper on non-pol-
into the exhaust gas pipe outlet, and fas- luted filtering paper (more than 10 sheets)
ten it to the outlet with a clip. in the filtering paper holder, and read the
indicated value.
9) Detach the measurement tool after the
measurement, and make sure that the
machine is back to normal condition.
HD325-7, HD405-7 13
Adjusting valve clearance 1 5. While No.1 cylinder is at compression top dead

center, adjust the valve clearance of q mark in
a Adjusting instrument for valve clearance the below figure according to the following pro-
Symbol Part No. Part name cedure.
Commercially
D Thickness gauge
available
1. Open the engine hood and remove the engine

right side cover and all cylinder head covers
(1).
6. To adjust the valve clearance, insert feeler

gauge D into clearance between rocker arm
(5) and cross head (6), and adjust the valve
clearance with adjustment screw (3).
a With the clearance gauge inserted, turn
the adjustment screw so that clearance
gauge can move with a light force.
2. Remove belt protection cover and loosen the
a Valve clearance
tension of the fan belt and alternator belt.
Intake valve: 0.35 mm,
a To confirm the timing mark.
Exhaust valve: 0.57 mm
3. Remove radiator under cover.
4. Rotate the crankshaft forward to bring the

stamped "1.6TOP" line (a) of the damper to
pointer (2) and set the No. 1 cylinder to the
compression top dead center.
a Rotate the crankshaft with the mounting
bolt of the crank pulley (width across flats:
24 mm), and be sure to rotate it only for-
ward to prevent the bolt from loosening.
a When No. 1 cylinder is at the top dead
center, its rocker arm can be manually
moved as much as the valve clearance.If
it cannot be moved, that means that No. 1
cylinder is not yet at the top dead center.
In that case, rotate it by one more turn.
14 HD325-7, HD405-7
7. While holding adjustment screw (3), tighten

locknut (4).
3 Locknut:
45.1 – 51.0 Nm {4.6 – 5.2 kgm}
a After tightening the locknut, check the
valve clearance again.
a It is also allowed to adjust respective cylin-

ders in the firing order by turning the crank
shaft 120° at a time.
q Firing order: 1 – 5 – 3 – 6 – 2 – 4
8. After finishing adjustment, return the removed

parts.
3 Cylinder head cover mounting bolt:
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
a Adjust the belt tension referring to "Testing
and adjusting fan belt and alternator belt
tension".
HD325-7, HD405-7 15
Testing compression pressure 1

a Testing instrument for compression pressure
1 795-502-1590 Compression gauge
E 795-471-1310 Adapter
2
6217-71-6110 Gasket
k When testing the compression pressure,

take care not to burn you rself on t he
exhaust manifold, muffler, etc. or get
caught in a rotating part.
a Measure the compression pressure after the 5. Install adaptor E2 to mounting hole of injector
engine is warmed up. and connect compression gauge E1.
(Engine oil temperature: 40 – 60 °C) a Fit the gasket to the adapter end without
fail
1. Open the engine hood and remove the engine a Fix the adapter with the injector holder.
right side cover. 3 Holder mounting bolt:
58.8 – 73.5 Nm {6.0 ± 7.5 kgm}
2. Remove cylinder head cover (1) of the cylinder a Apply a little amount of engine oil to the
to measure the compression pressure. connecting parts of the adapter and gauge
so that air will not leak easily.
6. Install rocker arm assembly (2) and adjust

valve clearance.
3 Rocker arm assembly mounting bolt:
93 – 103 Nm {9.5 – 10.5 kgm}
a For the adjustment, refer to the section,
"Adjustment of valve clearance".
3. Set cylinder to be tested at compression top

dead center and remove rocker arm assembly
(2).
a For the adjustment, refer to the section,
"Adjustment of valve clearance".
4. Disconnect fuel high-pressure tube (3) and

injector wiring harness and remove injector (4).
a Before disconnecting the fuel high-pres- 7. Referencing "Special functions of machine
sure tube, loosen all center clamps. monitor", set the no injection cranking and the
a Disconnect the terminal of the injector wir- engine speed measurement mode.
ing harness on the injector side and the k Be sure to set no injection cranking
bracket on the rocker housing side and mode. Otherwise engine may start and
pull them outside the rocker arm housing this may create a dangerous condition.
(Loosen the 2 terminal nuts alternately).
a After removing holder from injector, lead a
wire under the fuel pipe which comes out
sideways from the injector and pull up the
wire to remove injector (do not ply the
upper part of the injector to remove it).
16 HD325-7, HD405-7
8. Rotate the engine with the starting motor and

measure the compression pressure.
a Read the pressure gauge pointer when it
is stabilized.
9. After finishing testing, remove the testing tools

and return the removed parts.
a Install the injector and fuel high-pressure
tube according to the following procedure.
1) Push in injector (11) with the hand to
assemble holder (12) temporarily.
2) Tighten bolt (13) and washer (14) tempo-
rarily.
2 Spherical part of washer: Engine oil
3) Tighten sleeve nut (15) of the fuel high-
pressure tube temporarily.
4) Tighten bolt (13) permanently.
3 Bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
5) Tighten sleeve nut (15) permanently.
3 Sleeve nut: 39.2 – 49.0 Nm {4 – 5 kgm}
a Install the injector wiring harness accord-

ing to the following procedure.
1) Install the injector wiring harness to the
rocker arm housing and fix the connector
side with the plate.
2) Fix the intermediate clamp with the clip.
3) Tighten the nut on the injector side.
3 Nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm}
4) Secure the clamp and spacer with the
bolt.
3 Rocker arm assembly mounting bolt:

93 – 103 Nm {9.5 – 10.5 kgm}
a Adjust the valve clearance. For details,

see "Adjusting valve clearance".

29.4 – 34.3 Nm {3.0 – 3.5 kgm}
HD325-7, HD405-7 17
Testing blow-by pressure 1

a Testing tools for blow-by pressure
1 799-201-1504 Blow-by checker
F Commercially Hose (Inside diameter: 25
2
available mm, Length, 100 mm)
1. Connect hose F2 to the blow-by tube from

under the machine, install nozzle [1] of blow-by
checker F1, and connect blow-by gauge [2] by
hose [3].
5. Detach the measurement tool after the mea-

back to normal condition.
2. Start the engine and raise the temperature of

the coolant to the operating range.

D position.
k If the gearshift lever is operated to any
machine may move off even if the
brake is being depressed, so always
measure at the D position.
4. Depress the accelerator pedal gradually, run

verter, then measure the blow-by pressure.
k There is danger of damage to the inter-
tion other than the D position during
a After completing the measurement, lower
the engine speed to low idle, then return
the gearshift lever to the N position.
18 HD325-7, HD405-7
Testing engine oil pressure 1 6. Detach the measurement tool after the mea-
a Testing instrument for engine oil pressure back to normal condition.
799-101-5002 Hydraulic tester
1
G 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
1. Remove the engine left side cover.
2. Remove the oil pressure measurement plug

(1) on the cylinder block.
3. Install nipple [1] of hydraulic tester G1 and con-

nect hydraulic tester G2 (9.8 MPa {10 kg/cm2}
by hose [2].
4. Start the engine and raise the temperature of

the engine to the operating range.
5. Measure the engine oil pressure at low idle

and also at high idle.
HD325-7, HD405-7 19
Testing EGR valve and bypass 3. Connect hydraulic tester G2 to the nipple.
valve drive oil pressure 1
4. Start the engine and measure the oil pressure
a Testing instrument for EGR valve and bypass at low idle and high idle.
valve drive oil pressure
1
G 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
a The measuring point may be different from the

following explanation, depending on each
applicable machine.
1. Remove oil pressure pickup plug (2) from the

left side of timing gear cover (1).
2. Install nipple [1] (Component part of tool F1: 5. After finishing measurement, remove the mea-
PT 1/8) to the hole from which the oil pressure suring instruments and return the removed
pickup plug was removed. parts.
q Remove the gasket sealant remaining on the
threads of the removed plug with a wire brush
and apply new adhesive or gasket sealant to
the plug before installing.
2 Plug: LT2 or LG-4
3 Plug: 9.8 – 19.6 Nm {1.0 – 2.0 kgm}
20 HD325-7, HD405-7
Handling of fuel system devices 1 Releasing residual pressure from

a Precautions for checking and maintaining fuel fuel system 1
system. a Pressure is generated in the low-pressure cir-
The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause a Between Feed pump – Fuel filter – Fuel
trouble. supply pump
When checking and maintaining the fuel sys- High-pressure circuit:
tem, take care more than the past. If dust, etc. Between Fuel supply pump – Common rail
sticks to any part, wash that part thoroughly – Fuel injector
with clean fuel. a The pressure in both low-pressure circuit and
a Precautions for replacing fuel filter cartridge high-pressure circuit lowers to a safety level
Be sure to use the Komatsu genuine fuel filter automatically 30 seconds after the engine is
cartridge. stopped.
Since the common rail fuel injection system a Before checking the fuel system and installing
(CRI) consists of more precise parts than the and removing its parts, the residual pressure in
conventional fuel injection pump and nozzle, it the fuel system must be released completely.
employs a high-efficiency special filter to pre- Accordingly, observe the following.
k
vent foreign matter from entering it. When inspecting the fuel line or removing
If a filter other than the genuine one is used, or installing a equipment of fuel system,
the fuel system may have a trouble. Accord- wait for at least 30 seconds after the engine
ingly, never use such a filter. is stopped to release the remaining pres-
sure in the fuel system before starting oper-
ation. (There is still pressure remaining in
the circuit, so do not start operations imme-
diately after the engine is stopped.)
HD325-7, HD405-7 21
Testing fuel pressure 1 4. Run the engine at high idle or rated load
(torque converter relief) and measure the fuel
a Testing tools for fuel pressure pressure.
Symbol Part No. Part name a If the fuel pressure is in the following
range, it is normal.
1 0.15 – 0.3 MPa {1.5 – 3 kg/cm2} (high idle)
790-261-1204 Digital hydraulic tester
H 2 799-401-2320 Hydraulic tester
795-471-1450 Adapter (8 x 1.25 o R1/8)
3
07005-00812 Gasket
a Measure the fuel pressure only for the low-

pressure circuit between the feed pump-fuel fil-
ter-fuel supply pump.
k The high-pressure circuit between fuel sup-
ply pump-common rail-fuel injector is
under extremely high pressure, so it cannot
be measured.
1. Remove the engine left side cover. 5. After finishing testing, remove the testing tools
and return the removed parts.
2. Remove fuel pressure inspection plug (1).
3. Install adapter H3 and nipple[1] of hydraulic

tester H1, and connect to hydraulic tester H2.
22 HD325-7, HD405-7
Testing fuel return rate and leakage 1
a If the engine has the intake manifold equipped 1. Preparation work

with the return block on it to return the fuel 1) Remove tube (3) between common rail (1)
spilling from the injector to the fuel tank, test and supply pump (2).
the fuel return rate and fuel leakage according
2) Insert spacer J1 on supply pump (2) side
to the following procedure.
and tighten the removed joint bolt again.
a Testing tools for fuel return rate and leakage.
a Connect the return pipe to the fuel
Symbol Part No. Part name tank again, too.
1 6151-51-8490 Spacer a Be sure to fit the gaskets to both ends
of the spacer.
2 6206-71-1770 Joint
Commercially
3 Hose
available
J Commercially
4 Hose
available
Commercially
5 Stopwatch
available
Commercially
6 Measuring cylinder
available
a Prepare a receiver of about 20 l to receive the

fuel flowing out during the test.
HD325-7, HD405-7 23
3) Insert joint J2 to common rail (1) side and

tighten again the removed joint bolt.
a Be sure to fit the gaskets to both ends
of the joint.
4) Connect the inspection hose J3 to the end
of joint J2.
a Bind connecting portion with wire so
that the inspection hose should not
come off.
a Now the preparation for testing pres-
sure limiter leak amount is completed.
5) When the testing is completed, stop the

engine.
3. Testing injector return amount

a During testing injector return amount,
keep a hose end connected to pressure
limiter and insert the other end to the
receiver.
Disconnect both ends of injector return
tube.
1) Disconnect return hose (5) to the fuel tank
2. Testing pressure limiter leakage amount and connect test hose J4.
1) Adjust the route of inspection hose J3 to
remove its sag and insert the hose end
into the receiver.
2) Referencing "Measuring engine speed",
set up the condition necessary for check-
ing the engine speed.
3) Start the engine and keep it at rated load
(torque converter relief).
4) When the engine speed is stabilized,
check the leakage amount per minute with
measuring cylinder J6.
a The leakage also can be judged by
testing for twenty seconds and triples
its leakage amount.
a Bind connecting portion with wire so
a If the leakage from the pressure lim-
that the inspection hose should not
iter is in the following range, it is nor-
come off.
mal.
Engine speed Leakage
(rpm) (cc/min)
Rated speed Max. 10
24 HD325-7, HD405-7
2) Adjust the route of inspection hose J4 to

remove its sag and insert the hose end
into the receiver.
6) When the testing is completed, stop the

engine.
3) Referencing “Measuring engine speed“, 4. Operations after completion of testing

set up the condition necessary for check- If all the tests are completed, remove the
ing the engine speed. instruments and set to the original condition.
4) Start the engine and run the engine at the
rated output.
5) When the engine speed is stabilized,
check the return amount per minute with
measuring cylinder J6.
a It also can be judged by testing for
twenty seconds and triples its return
amount.
a If the supply pump is not supplying
fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the test.
a If the return rate (spill) from the injec-
tor is in the following range, it is nor-
mal.
Rated output speed Return (Spill) limit
(rpm) (cc/min)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
HD325-7, HD405-7 25
Bleeding air from fuel circuit 1 2. Install fuel pre filter (1) to filter head.
a Apply engine oil thinly over the packing on
a If fuel is used up, or if a fuel circuit part is the fuel pre-filter side.
removed or installed, bleed air from the fuel cir- a After the packing of the fuel pre-filter
cuit according to the following procedure. touches the sealing face of the filter head,
tighten the fuel pre-filter 3/4 turns.
1. Remove fuel pre-fuel filter (1) and fill it with
fuel.
a Fill the fuel filter with clean fuel and take
care that dirt will not enter it.
a Confirm the cap is installed to portion (a)
(center hole) of the fuel pre filter and add
fuel from portion (b) (peripheral holes).
a After filling the pre-fuel filter with fuel,
remove the cap from part (a).
a If clean fuel is not available, do not
remove the filter. Operate the priming
pump (4) to fill the filter with fuel.
(Refer to procedure 4 and 5 for operations
of priming pump.)
a Do not add fuel to fuel main filter exter- 3. Remove air bleed plug (3) of the fuel main filter
nally. and operate priming pump (4).
a Operate the priming pump until the fuel

flows out of the plug hole and install the
plug.
3 Air bleed plug:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
26 HD325-7, HD405-7
4. Remove air bleed plug (5) of the fuel main filter

and operate priming pump (4).
flows out of the plug hole and install the
plug.
3 Air bleed plug:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
5. Loosen air bleeder (6) of the fuel supply pump

and operate priming pump (4) 90 – 100 times.
flows out of the air bleeder and tighten the
air bleeder. Then, operate the priming
pump several times more until it becomes
heavy.
3 Air bleeder:
4.9 – 6.9 Nm {0.5 – 0.7 kgm}
6. Start the engine with the starting motor.

a The air in the high-pressure circuit is bled
automatically if the engine is cranked.
a If the engine does not start, there may be
still air in the low-pressure circuit. In this
case, repeat the above procedure from
step 3.
HD325-7, HD405-7 27
Testing the fuel circuit for 9. Inspect the fuel piping and components for fuel
leakage 1 leakage.
a Check mainly around the high-pressure
k Very high pressure is generated in the high- circuit parts coated with the color checker
pressure circuit of the fuel system. If fuel for fuel leakage.
leaks while the engine is running, it is dan- a If any fuel leakage is detected, repair it
gerous since it can catch fire. and inspect again from step 1.
After testing the fuel system or removing a If no fuel leakage is detected, check is
and installing its components, check for completed.
fuel leakage according to the following pro-
cedure.
a Clean and degrease the engine and the parts
around it in advance so that you can test it eas-
ily for fuel leakage.
1. Spray color checker (developer) over the fuel

supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2. Run the engine at a speed less than 1,000 rpm

and stop it after its rotation is stabilized.
3. Inspect the fuel piping and devices for fuel

leakage.
circuit parts coated with the color checker
for fuel leakage.
a If any fuel leakage is detected, repair it
and inspect again from step 1.
4. Run the engine at low idle.
5. Inspect the fuel piping and devices for fuel

leakage.
for fuel leakage.
6. Run the engine at high idle.
7. Inspect the fuel piping and components for fuel

leakage.
for fuel leakage.
8. Run the engine at high idle to apply load to the

engine.
a When checking while the components to
be checked are mounted on the machine,
stall the torque converter or relieve the
hydraulic pump.
28 HD325-7, HD405-7
Testing and adjusting alternator Adjusting

belt tension 1 a If the deflection is abnormal, adjust it according
Testing
1. Remove the engine right side cover. 1. Loosen bolts and nuts (1), (2), (3), and (4) in
numeric order.
2. Press the middle point of the belt between the
alternator pulley and drive pulley with the fin- 2. Rotate nut (5) to move alternator (6) and adjust
ger and measure deflection (a) of the belt. the belt tension.
a Deflection (a) when pressing force is a If nut (5) is
approx. 58.8 N {approx. 6 kg}: 13 – 16 mm q Rotated to the right, the belt tension is
lowered.
q Rotated to the left, the belt tension is
heightened.
a Check each pulley for breakage, V-groove
for wear, and V-belt for contact with the V-
groove.
a If the belt is lengthened to the adjustment
limit, cut, or cracked, replace it with new
one.
3. Tighten the nuts and bolts (4), (3), (2), and (1)
in numeric order.
a If the V-belt is replaced, adjust its tension
again after 1 operating hour.
HD325-7, HD405-7 29
Testing and adjusting fan belt tension 1
Testing
Press the center of the belt (indicated by the arrow)
between the fan pulley and crankshaft pulley with
your finger and check the deflection of the belt.
a Check the belts one by one.
a Pressing force: Approx. 98 N {Approx. 10 kg}
a Deflection: 15 – 17 mm (When new)
: 19 – 21 mm (When retightened)
Adjusting
a If the deflection is out of the standard range,
adjust it according to the following procedure.
1. Install 3 belts (1).
2. Adjust the deflection of the belts by moving
tension pulley (3) with adjustment bolt (2).
a After adjusting, check the belt tension
again.
a If any belt is replaced, adjust its tension
30 HD325-7, HD405-7
Testing and adjusting air Adjusting

conditioner compressor belt a If the deflection is abnormal, adjust it according
tension 1
Testing 1. Loosen bolts and nuts (1), (2), and (3) in
1. Open the engine compartment cover on the numeric order.
control valve side and remove the air condi-
tioner compressor belt cover. 2. Rotate nut (4) to move compressor (5) and
adjust the belt tension.
2. Press the middle point of the belt between the a If nut (4) is
air conditioner compressor pulley and drive q Rotated to the right, the belt tension is
pulley with the finger and measure deflection lowered.
(a) of the belt. q Rotated to the left, the belt tension is
a Deflection (a) when pressing force is heightened.
approx. 58.8 N {approx. 6 kg}: 10 – 15 mm a Check each pulley for breakage, V-groove
for wear, and V-belt for contact with the V-
groove.
a If the belt is lengthened to the adjustment
limit, cut, or cracked, replace it with new
one.
3. Tighten the nuts and bolts (3), (2), and (1) in

numeric order.
a If the V-belt is replaced, adjust its tension
HD325-7, HD405-7 31

© 2007 KOMATSU
All Rights Reserved
32 HD325-7, HD405-7
SEN01183-02
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up
30 Testing and adjusting

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 ........................................................................................................................... 17
Testing and adjusting parking brake performance ........................................................................................ 19
Bleeding air from brake circuit ...................................................................................................................... 20
Testing wear of rear brake disc ..................................................................................................................... 21
Testing wear of front brake pad..................................................................................................................... 22
Method for emergency release of parking brake .......................................................................................... 23
Testing and adjusting front suspension cylinder ........................................................................................... 24
Testing and adjusting inverted type rear suspension cylinder....................................................................... 29
Testing and adjusting front suspension cylinder (mode selector hydraulic cylnder) ..................................... 33
Testing and adjusting hydraulic pressure in steering, hoist circuit ................................................................ 34
Testing and adjusting dump EPC circuit oil pressure.................................................................................... 37
HD325-7, HD405-7 1
Air bleeding from steering cylinder................................................................................................................ 38

Procedure for raising body in emergency ..................................................................................................... 39
Adjusting body positioner sensor .................................................................................................................. 40
Handling of high voltage circuit of engine controller...................................................................................... 41
Adjusting transmission controller .................................................................................................................. 41
Method for emergency escape at electrical system failure ........................................................................... 42
2 HD325-7, HD405-7
Testing torque converter stall 5. When the torque converter oil temperature
goes above 90°C, run the engine immediately
speed 1 at low idle and return the gear shift lever to the
k Stop the machine on level ground, turn the N position.
parking brake switch ON, and set chocks to k Never operate the gear shift lever with
the tires. the accelerator pedal depressed. Oth-
erwise it may create a large shock and
1. Switch the machine monitor display to the may also cause to shorten the service
monitoring function of service mode 1 and dis- life of the machine.
play the following 2 items at the same time with
the monitoring function. 6. Run the engine at a medium speed, and when
a Monitoring items the torque converter oil temperature goes
[1] Code No. 01002 : Engine speed down to approx. 80 °C, run at low idle.
[2] Code No. 30100 : Torque converter oil tem- a Keep the gear shift lever at the N position.
perature
a Refer to "Special functions of machine 7. Repeat Steps 3 – 6 and equalize the oil tem-
monitor (EMMS)" for the operating perature in the torque converter and transmis-
method. sion.
8. At the same time as repeating Steps 3 and 4,

measure the stall speed when the torque con-
verter oil temperature is 80 °C.
a Measure the stall speed 2 – 3 times.
a The stall speed may vary according to the fol-

lowing conditions, so always measure the stall
speed at the time of delivery.
1) Variations according to the engine serial
number
2) Variations due to atmospheric pressure
and temperature
2. Start the engine and raise the temperature of 3) Variations due to the torque consumed by
the torque converter oil and hydraulic oil. accessories
a Torque converter oil temperature: 4) Variations due to characteristics of the
60 – 80°C torque converter
Hydraulic oil temperature: 45 – 55 °C
5) Variations due to the method of measuring
the stall
D position.
a If the gear shift lever is operated to any
machine may move off even if the brake is
being depressed, so always measure at
the D position.
4. Depress the accelerator pedal gradually, run

verter to raise the torque converter oil temper-
ature.
k There is danger of damage to the inter-

tion other than the D position during
HD325-7, HD405-7 3
Testing power train oil pressure 1
a Testing tools for power train oil pressure a Table of oil pressure measurement port
positions and gauges to use
Symbol Part number Part name
799-101-5002 Hydraulic tester Gauge
No. Measurement location (MPa{kg/cm2})
1
790-261-1204 Digital type hydraulic tester
1 Main relief pressure 5.9{60}
K 2 799-401-2320 Hydraulic gauge
2 Torque converter inlet port pressure 2.45{25}
799-101-5220 Nipple
3 3 Torque converter outlet port pressure 2.45{25}
07002-11023 O-ring
4 Torque converter lock-up clutch pressure 5.9{60}
5 Transmission Lo clutch pressure 5.9{60}
6 Transmission Hi clutch pressure 5.9{60}
7 Transmission 1st clutch pressure 5.9{60}
8 Transmission 2nd clutch pressure 5.9{60}
9 Transmission 3rd clutch pressure 5.9{60}
10 Transmission 4th clutch pressure 5.9{60}
11 Transmission R clutch pressure 5.9{60}
a The transmission lubrication pressure is repre-

sented by the torque converter outlet port pres-
sure, so there is no need to measure it.
4 HD325-7, HD405-7
k Stop the machine on a level ground, turn 4) After completing the measurement, remove
the parking brake switch PARKING, and put the measuring equipment and set to the
chocks under the tires. original condition.
k Stop the engine and wait until the oil temper-
ature lowers sufficiently before installing Items related to torque converter
and removing the testing instruments. 2. Testing torque converter inlet oil pressure
k When measuring the oil pressure while the k Raise the dump body and lock it with the
machine is traveling, secure a wide travel pin.
area and take care of the safety around the k Take care not to "get burned", since the oil
machine. temperature is high.
k When removing and installing a plug or an
Whole power train oil pressure gauge, stop the engine.
1. Testing main relief pressure 1) Referring to "Testing main relief oil pres-
k Raise the dump body and lock it with the sure", check that there is not abnormality.
pin. 2) Remove plug (2), install nipple K3, and
k Take care not to "get burned", since the oil connect oil pressure gauge [1] (2.45 MPa
temperature is high. {25 kg/cm 2 }) of hydraulic tester K1 by
k When removing and installing a plug or an hose [2].
oil pressure gauge, stop the engine.
1) Raise the transmission oil temperature.
a Oil temperature for measurement:
60 – 80°C
2) Remove plug (1), install nipple K3, and
connect oil pressure gauge [1] (5.9 MPa
{60 kg/cm 2 }) of hydraulic tester K1 by
hose [2].
3) Start the engine and measure the oil pres-

sure at high idle.
4) After completing the measurement, remove
original condition.
3) Start the engine and set the gear shift

lever in the "N", and then measure the oil
pressure at low idle and high idle.
HD325-7, HD405-7 5
3. Testing torque converter outlet oil pressure 4. Testing torque converter lock-up clutch
k Raise the dump body and lock it with the pressure
pin. k Raise the dump body, then lock with pin.
k Take care not to "get burned", since the oil 1) Remove oil pressure pickup plug (4),
temperature is high. install nipple K3, and connect hose [2] of
k When removing and installing a plug or an hydraulic tester K1.
oil pressure gauge, stop the engine.
1) Referring to "Testing main relief oil pres-
sure", check that there is not abnormality.
2) Remove plug (3), install nipple K3, and
{25 kg/cm 2 }) of hydraulic tester K1 by
hose [2].
2) Lower the dump body and set to the origi-

nal condition.
3) Connect oil pressure gauge [1] (5.9 MPa
{60 kg/cm2}) to hose [2].
of the torque converter oil to the operating
range.
5) Turn the parking brake switch TRAVEL,
depress the parking brake pedal, then set
the gearshift lever to position "L".
6) Release the brake, travel at high idle, and
measure the oil pressure when the lock-up
pilot lamp lights up.
k In F1, a maximum travel speed of
approx. 11.5 km/h is reached, so check
carefully that the surrounding area is
safe.
3) Start the engine and measure the oil pres-

sure at high idle.
original condition.

original condition.
6 HD325-7, HD405-7
Transmission related 5. Testing transmission Lo clutch pressure

a Table of gearshift lever positions, speed k Raise the dump body, then lock with pin.
ranges, and clutches actuated 1) Remove oil pressure pickup plug (5),
install nipple K3, and connect hose [2] of
Gearshift lever Clutches
Speed hydraulic tester K1.
R N D 6 5 4 3 2 L engine Lo Hi 1st 2nd 3rd 4th R
F1
F2
F3
F4
F5
F6
F7
N
R
a The mark indicates the speed ranges that

are actuated for each position of the gearshift
2) Lower the dump body and set to the origi-
lever.
nal condition.
a The mark and mark indicate the clutches
that are actuated for each travel speed.
{60 kg/cm2}) to hose [2].
a The mark indicates the speed range when 4) Start the engine and raise the temperature
measuring the oil pressure for each clutch. of the torque converter oil to the operating
range.
5) Turn the parking brake switch TRAVEL,
depress the parking brake pedal, then set
the gearshift lever to position "L".
6) Release the brake and measure the oil
pressure when traveling at high idle.
k In F1, a maximum travel speed of
approx. 11.5 km/h is reached, so check
carefully that the surrounding area is
safe.

original condition.
HD325-7, HD405-7 7
6. Testing transmission Hi clutch pressure 7. Testing transmission 1st clutch pressure

k Raise the dump body, then lock with pin. k Raise the dump body, then lock with pin.
1) Remove oil pressure pickup plug (6), 1) Remove oil pressure pickup plug (7),
install nipple K3, and connect hose [2] of install nipple K3, and connect hose [2] of
hydraulic tester K1. hydraulic tester K1.
2) Lower the dump body and set to the origi- 2) Lower the dump body and set to the origi-
nal condition. nal condition.
3) Connect oil pressure gauge [1] (5.9 MPa 3) Connect oil pressure gauge [1] (5.9 MPa
{60 kg/cm2}) to hose [2]. {60 kg/cm2}) to hose [2].
4) Start the engine and raise the temperature 4) Start the engine and raise the temperature
of the torque converter oil to the operating of the torque converter oil to the operating
range. range.
5) Turn the parking brake switch TRAVEL, 5) Turn the parking brake switch TRAVEL,
depress the parking brake pedal, then set depress the parking brake pedal, then set
the gearshift lever to position "3". the gearshift lever to position "L".
6) Release the brake, travel at high idle, and 6) Release the brake and measure the oil
measure the oil pressure when the shift pressure when traveling at high idle.
indicator shows "3". k In F1, a maximum travel speed of
k In F3, a maximum travel speed of approx. 11.5 km/h is reached, so
approx. 21.5 km/h is reached, so check carefully that the surround-
check carefully that the surrounding area is safe.
ing area is safe.

7) After completing the measurement, remove the measuring equipment and set to the
the measuring equipment and set to the original condition.
original condition.
8 HD325-7, HD405-7
8. Testing transmission 2nd clutch pressure 9. Testing transmission 3rd clutch pressure
range. range.
the gearshift lever to position "2". the gearshift lever to position "4".
6) Release the brake, travel at high idle, and 6) Release the brake, travel at high idle, and
measure the oil pressure when the shift measure the oil pressure when the shift
indicator shows "2". indicator shows "4".
k In F2, a maximum travel speed of k In F4, a maximum travel speed of
approx. 16.0 km/h is reached, so approx. 29.5 km/h is reached, so
check carefully that the surround- check carefully that the surround-
ing area is safe. ing area is safe.
7) After completing the measurement, remove 7) After completing the measurement, remove
the measuring equipment and set to the the measuring equipment and set to the
original condition. original condition.
HD325-7, HD405-7 9
10. Testing transmission 4th clutch pressure 11. Testing transmission R clutch pressure
range. range.
the gearshift lever to position "6". the gearshift lever to position "R".
6) Release the brake, travel at high idle, and 6) Release the brake and measure the oil
measure the oil pressure when the shift pressure when traveling at high idle.
indicator shows "6". k In R, a maximum travel speed of
k In F6, a maximum travel speed of approx. 12.0 km/h is reached, so
approx. 52.5 km/h is reached, so check carefully that the surround-
check carefully that the surrounding area is safe.
ing area is safe.

7) After completing the measurement, remove the measuring equipment and set to the
the measuring equipment and set to the original condition.
original condition.
10 HD325-7, HD405-7
Adjusting transmission speed sensor 1
a There are 3 speed sensors installed to the 3. Secure sensor (1) with lock nut (3).
transmission. Adjust each sensor as follows. 3 Nut: 49.0 – 68.6Nm {5 – 7 kgm}
CN3: Input shaft speed sensor
CN4: Intermediate shaft speed sensor
CN5: Output shaft speed sensor
1. Screw in until the tip of sensor (1) contacts the

face or tip of the tooth of gear (2).
a Before installing, check that the tip of the
sensor is not scratched and that there are
no iron particles sticking to the sensor tip.
2 Thread portion: Gasket sealant (LG-5)
2. Turn back sensor (3) 1/2 – 1 turn from this

position.
a After the above work, clearance (a) between
the sensor tip and gear tooth tip is 0.75 – 1.0 4. After completing the adjustment, check that the
mm. each transmission shaft speed is displayed
normally by using the monitoring function of
the machine monitor.
a For details of the method of operation, see
"Special functions of machine monitor".
HD325-7, HD405-7 11
Testing brake oil pressure 1 (Measuring with diagnostic tools)

1) While the engine is stopped, remove plug (4)
a Testing instruments for brake of oil pres- (18, P: 1.5), install nipple L2, and install nipple
sure [1] of hydraulic tester L1.
Symbol Part No. Part Name 2) Install oil pressure gauge (39.2 MPa {400 kg/
cm2}) by hose [2].
799-101-5002 Hydraulic meter
1
790-261-1204 Digital hydraulic meter
L Nipple 18 x 1.5
2 566-35-43561 (female: PT 1/8)
3 793-520-1805 Brake test kit
k Stop the machine on a level place, apply

the parking brake, and set chocks under
the tires securely.
1. Measuring ACC charge oil pressure

(Measuring with monitor)
1) Set the machine monitor in service mode
1 and display the following 2 items simul-
taneously with the monitoring function.
a Monitoring items
(1) Code No. 35500:
ACC oil pressure (Front)
(2) Code No. 35501:
ACC oil pressure (Rear)
2) Start the engine.

3) Measure the cut-in pressure at high idle.
i) Press and release the brake pedal
repeatedly to lower the oil pressure in
the accumulator.
ii) Read the lower one of the ACC oil
pressures (front or rear) when it starts
rising after it reaches the bottom
(Approx. 14.2 MPa {Approx. 145 kg/ a For the method of measurement, see
cm2}). "Measuring with monitor", 2) – 4). (Read
4) Measure the cut-out pressure at high idle. the pointer of the oil pressure gauge, how-
q Read the ACC oil pressure (front or ever.)
rear) when it stops rising at the high-
est point (Approx. 20.6 MPa {Approx.
210 kg/cm2}) after the cut-in pressure.
12 HD325-7, HD405-7
2. Rear brake actuating pressure

1) Remove air bleeder (1) and install brake
test kit L3.
2) Operate the brake pedal and retarder con-
trol lever and measure the oil pressure.
a After finishing measurement, bleed
air, referring to "Bleeding air from
brake circuit" on the page 15.
3. Front brake actuating pressure

a Check that the front brake cut-off switch is
turned OFF.
1) Remove air bleeder (3) and install brake
test kit L3.
2) Operate the brake pedal and measure the
oil pressure.
a After finishing measurement, bleed
air, referring to "Bleeding air from
brake circuit" on the page 15.
HD325-7, HD405-7 13
Testing of accumulator nitrogen

gas pressure and procedure for
charging accumulator with
nitrogen gas 1
a Testing instrument
Symbol Part No. Part name Remarks
T1 792-610-1700 Gas charge tool —
792-610-1310 Nipple GOST

(For Russia)
792-610-1320 Nipple CGA No. 351

(For USA)
Nipple
T2 792-610-1330 (For USA) ASA B-571-1965
3. Connect gas charge tool T1 to valve (4) of
DIN 477-1963 accumulator (1) according to the following pro-
792-610-1350 Nipple NEN 3268-1966 cedure.
(For Germany) SIS-SMS 2235/2238
1) Turn handle (a) of gas charge tool T1 to
792-610-1360 Nipple (For UK) BS 341 Part 1-1962
the left until it stops.
Nitrogen gas cylinder (c) must be
k
q
Put on proper personal protection items connected even when you measure
(goggles, leather gloves and protective only the gas pressure.
clothes) so that the leaking nitrogen gas q Close the valve of nitrogen gas cylin-
will not touch your skin or clothes and work der (c) and handle (b).
on the windward side as long as possible. For connection of nitrogen gas cylin-
k
q
When handling nitrogen gas in a room or der (c) and gas charge tool T1, see
another place which is not ventilated well, "Procedure for charging accumulator
ventilate the work place forcibly and observe with nitrogen gas".
the Oxygen Deficiency Prevention Rules of
2) Connect gas charge tool T1 to valve (4) of
the Labor Safety and Sanitation Law.
k
accumulator (1).
Since the accumulator is charged with
high-pressure nitrogen gas, wrong han-
dling of it can cause an explosion and
injury or death. When handling the accu-
mulator, observe the following strictly.
q Do not bring fire near the accumulator or
put the accumulator in fire.
q Do not drill, weld or gas-cut the accumulator.
q Do not give impacts to the accumulator by
hitting or rolling.
q When discarding accumulator, discharge it
of the nitrogen gas.
Testing of accumulator nitrogen gas pressure

a The nitrogen gas pressure in the accumulator
disconnected from the machine can be mea-
sured according to the following procedure, too.
1. Stop the engine and depress the brake pedal
repeatedly to lower the oil pressure in the
brake circuit to zero.
a Generally, if the brake pedal is depressed
30 times, the reaction force to the brake
pedal is lost and the oil pressure is low-
ered to zero.
2. Remove valve guard (2) and cap (3) from
accumulator (1).
14 HD325-7, HD405-7
4. Turn handle (a) of gas charge tool T1 to the left 3. Connect gas charge tool T1 and nitrogen gas
and read the gauge. cylinder (c) to valve (4) of accumulator (1)
a Since the indicated value varies with the according to the following procedure.
ambient temperature, correct it by the fol- 1) Turn handle (a) of gas charge tool T1 to
lowing formula. (The unit of each value in the left until it stops.
the formula is °C.) 2) Turn handle (b) to the left to open.
Indicated gas pressure = 3) Connect gas charge tool T1 to valve (4) of
Standard gas pressure x ((273 + t)/ accumulator (1).
(273 + 20))
4) Connect gas charge tool T1 and nitrogen
Standard gas pressure =
gas cylinder (c).
Indicated gas pressure/((273 + t)/
q There are 2 types of threads of nitro-
(273 + 20))
gen gas cylinders, W22-14 thread
t = Gas temperature at time of charge (°C)
(mail screw, type A) and W23-14
Reference: t may be assumed to be ambi-
thread (female screw, type B). When
ent temperature.
using a gas cylinder of W23-14 thread
(female screw, type B), connect the
5. If the gas pressure is too high or too low, adjust hose by using the adapter. (The
it referring to "Procedure for charging accumu- adapter is attached to gas charge tool
lator with nitrogen gas". T1.) [For Japan]
a Each time the pressure is measured, some q Use nipple T2 to connect the hose,
nitrogen gas is discharged and the pres- depending on the specification of the
sure lowers. Add nitrogen gas by the loss. nitrogen gas cylinder. [For overseas]
6. Remove gas charge tool T1 from accumulator

(1) and return the removed parts. See "Proce-
dure for charging accumulator with nitrogen
gas".
Procedure for charging accumulator with nitro-

gen gas
a The accumulator disconnected from the machine
can be charged with nitrogen gas according to
the following procedure, too.
1. Stop the engine and depress the brake pedal
repeatedly to lower the oil pressure in the
brake circuit to zero.
a Generally, if the brake pedal is depressed
30 times, the reaction force to the brake
pedal is lost and the oil pressure is low-
ered to zero.
2. Remove valve guard (2) and cap (3) from

accumulator (1).
4. Open nitrogen gas cylinder (c) slightly to dis-

charge nitrogen gas at pressure of 0.19 – 0.29
MPa {2 – 3 kg/cm²}.
5. After nitrogen gas starts flowing out of handle

(b), close handle (b).
HD325-7, HD405-7 15
6. Turn handle (a) slowly to the right to open

valve (4) of accumulator (1) gradually.
a If handle (a) is turned too much, the valve
core of the accumulator will be damaged
and gas will leak. Accordingly, operate
handle (a) carefully.
7. Open the valve of nitrogen gas cylinder (c) fur-

ther to charge the accumulator with nitrogen
gas.
8. During the work, close the valve of nitrogen

gas cylinder (c) and check the nitrogen gas
pressure in the accumulator. 13. In a week after charging the accumulator with
a Since the indicated value varies with the nitrogen gas, check that the nitrogen gas pres-
ambient temperature, correct it by the fol- sure has not lowered.
lowing formula. (The unit of each value in a Check the functions in 5 minutes after
the formula is °C.) stopping the engine. (If the engine is
Indicated gas pressure = stopped for more than 5 minutes, the
Standard gas pressure x ((273 + t)/ brake circuit pressure lowers and the func-
(273 + 20)) tions cannot be checked accurately.)
Standard gas pressure = 1) Stop the machine on a level place and set
Indicated gas pressure/((273 + t)/ the parking brake switch to the "PARK-
(273 + 20)) ING" position.
t = Gas temperature at time of charge (°C)
2) Start the engine and run it at medium
Reference: t may be assumed to be ambi-
speed for 1 minute and then stop it.
ent temperature.
3) Turn the starting switch to the ON position
and depress the brake pedal repeatedly.
9. After the accumulator is charged to the stan-
Count the number of depressing until the
dard pressure, close the valve of nitrogen gas
brake oil pressure caution lamp lights up.
cylinder (c).
q If number of depressing is less than
q If the accumulator is charged too much,
5: Accumulator gas pressure may
turn handle (b) to the left slowly with the
have lowered.
valve of nitrogen gas cylinder (c) closed to
q If number of depressing is 5 or more:
release the nitrogen gas gradually to
Accumulator gas pressure is normal.
adjust pressure.
10. Remove gas charge tool T1 from valve (4) of

accumulator (1) according to the following pro-
cedure.
1) Turn handle (a) to the left to close the
valve of the accumulator.
2) Turn handle (b) to the left to open and dis-
charge nitrogen gas remaining in gas
charge tool T1 and hoses.
3) Remove gas charge tool T1 from valve (4)
of the accumulator.
11. Apply soap water to valve (4) of the accumula-

tor to check that nitrogen gas is not leaking.
12. Install cap (3) and valve guard (2) to accumula-

tor (1).
3 Cap: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
16 HD325-7, HD405-7
Testing brake performance 1 2. Testing braking performance of retarder

brake
k Stop the machine on the level ground and 1) Start the engine and turn the parking
turn the parking brake switch PARKING. brake switch OFF.
k If the machine starts to move, it can cause a
2) Pull the retarder lever fully, then set the
serious personal injury. Should the ma-
gear shift lever to the D position.
k If the torque converter is stalled
chine start moving during the performance
test, reduce the engine speed immediately,
while the gearshift indicator is indi-
move the gear shift lever to the N position
cating "F1", the inside of the trans-
and depress the foot brake. mission may be broken.
Accordingly, when stalling the
1. Testing braking performance of foot brake torque converter, seat the body
(service brake) securely and check that the body
1) Start the engine and turn the parking pilot lamp is turned OFF, and then
brake switch OFF. set the gearshift lever in the D
2) Depress the brake pedal fully, then set the position and check that the gear-
gear shift lever to the D position. shift indicator is indicating "F2".
k If the torque converter is stalled 3) Depress the accelerator pedal gradually
while the gearshift indicator is indi- and check that the machine does not
cating "F1", the inside of the trans- move when the torque converter is stalled
mission may be broken. at the specified speed.
Accordingly, when stalling the
torque converter, seat the body
securely and check that the body
pilot lamp is turned OFF, and then
set the gearshift lever in the D
position and check that the gear-
shift indicator is indicating "F2".
3) Depress the accelerator pedal gradually
and check that the machine does not
move when the torque converter is stalled
at the specified speed.
4) After completing the testing, run the

engine at low idle and set the gear shift
lever to the "N" position.
3. Testing braking performance of parking

brake
1) Turn the parking brake switch PARKING
and start the engine.
2) Set the gear shift lever to the D position.
k If the torque converter is stalled
while the gearshift indicator is indi-
4) After completing the test, run the engine at
cating "F1", the inside of the trans-
low idle and set the gear shift lever to the mission may be broken.
"N" position. Accordingly, when stalling the
torque converter, seat the body
securely and check that the body
pilot lamp is turned OFF, and then
set the gearshift lever in the D
position and check that the gear-
shift indicator is indicating "F2".
HD325-7, HD405-7 17
3) Depress the accelerator pedal gradually

and check that the machine does not
move when the torque converter is stalled
at the specified speed.
a If the machine moves while the en-
gine speed is below the specified
speed, perform "Check of wear of
rear brake disc" described later.
4) After completing the testing, run the

engine at low idle and set the gear shift
lever to the "N" position.
18 HD325-7, HD405-7
Testing and adjusting parking

brake performance 1
1. Testing by starting machine (when unloaded)
1) Stop the machine on level ground and
apply the parking brake.
2) Place the transmission shift lever in the
"D" (F2) position.
3) Raise the engine speed gradually and
measure the engine speed when the
machine starts to move.
a When the machine starts to move,
release the accelerator pedal, and
depress the brake pedal and return
transmission shift lever to "N" at the
same time.
a If the engine speed at the point when
the machine starts to move is less
than standard value, adjust the park-
ing brake as follows.
2. Adjusting
1) Stop the machine on level ground and
release the parking brake (set to the
TRAVEL position).
2) Turn bolt (1) clock wise to bring both pads
(2) into tight contact with disc (3).
3) Turn bolt (1) back 240° ± 15° (4 clicks)
counterclockwise from this position.
a Standard clearance:
Total for both clearances: 1.8 ± 0.08
mm
a After adjusting the clearances, actua-
tion stroke (a) of the parking brake
chamber will be approx. 40 mm.
4) Replace the pads, set bolt (1) to the initial
adjustment position in Step 4) with both
pads in tight contact with the disc, then
turn bolt (1) back 360° ± 15° (6 clicks)
counterclockwise from this position.
a Standard clearance:
Total for both clearances: 1.88 ± 0.08
mm
a After adjusting the clearances, actuation
stroke (a) of the parking brake chamber
will be approx. 50 mm.
HD325-7, HD405-7 19
Bleeding air from brake circuit 1

a If any brake circuit device was removed and
installed or if the transmission and brake cool-
ing oil was replaced, bleed air from the brake
circuit according to the following procedure.
k Stop the machine on a level ground and set
chocks under the tires securely.
1. Rear brake
a Bleed air from the slack adjuster side first,
then bleed air from the wheel brake side.
1) Using a vinyl tube for bleeding air, depress

the brake pedal and loosen air bleeder
screw (1) or (2) by 3/4 turns. Keep 2. Front brake
depressing the brake pedal until bubbles a Check that the front brake cut switch is
do not come out of the bleeder any more. turned OFF.
When bubbles do not come out any more, 1) Loosen air bleeder (6) by 3/4 turns and
tighten (close) the bleeder and release the bleed air similarly to step 1) for the rear
pedal. brake.
2) Pull the retarder control lever and loosen
air bleeder screw (1) or (2) by 3/4 turns.
Keep pulling the retarder control lever until
bubbles do not come out of the bleeder
any more. When bubbles do not come out
any more, tighten (close) the bleeder and
release the retarder control lever.
3) Bleed air from bleeder (3) on the wheel

side similarly to step 1) above.
a After finishing bleeding air, tighten
(close) the bleeder and put the cap.
20 HD325-7, HD405-7
Testing wear of rear brake disc 1

k Stop the machine on level ground, turn the
parking brake switch PARKING, and put
chocks under the tires.
k Carry out the inspection when the brake oil
temperature is less than 60°C.
k When the disk comes close to the wear
limit, carry out the inspection more fre-
quently. Be sure to carry out inspection of
the retarder braking performance at the
same time.
1. Check that the brakes other than parking brake

are not being actuated.
2. Stop the engine.
3. Remove cap nut (1) of the gauge.
5. Install cap nut (1) of the gauge.

3 Cap nut: 19.6 Nm {2.0 kgm}
4. Push in the rod (2) of the gauge until it contacts

the piston and judge the amount of wear.
a With a new machine, adjust so that inner
(deeper) end (a) of groove (D) on the rod
(2) is aligned with the end face of guide
(3).
The adjustment position will move out of
alignment, so do not loosen locknut (4) of
guide (3) except when replacing the disc.
a Outer end (b) of groove (D) indicates the
wear limit for the disc. If it is inside guide
(3) totally [If it reaches the end face of
guide (3)], the disc has reached the wear
limit.
HD325-7, HD405-7 21
Testing wear of front brake pad 1

a Inspecting instruments of front brake pad
wear
Symbol Part No. Part Name
Gauge
M 566-98-41410 (Tools carried on machine)
k Stop the machine on level ground, apply

the parking brake, and put chocks under
the tires.
1. Visual check
Check visually, and if the pad has reached the
wear limit line, replace the pad.
2. Checking with gauge

1) Depress the brake pedal, keep the pad (1)
pressed against the disc (2), then insert
inspection gauge M into indicator hole (d)
of the caliper (3).
2) If the stepped part of the gauge contacts
th e mo u th o f t he h ol e , t h e pad h a s
reached the wear limit, so replace it.
e: Remaining thickness up to wear limit
a Replace the pads on the left and right sides at
the same time.
a The pad wear is not the same for both left and
right sides, so check the wear of all pads.
22 HD325-7, HD405-7
Method for emergency release of

parking brake 1
a If any problem occurs in the electrical system
or hydraulic system of the parking brake and
the parking brake is not released, it is possible
to release the brake temporarily as follows.
k If any problem occurs in the hydraulic sys-
tem, there is a strong possibility that the
wheel brake will not work properly, so after
releasing the parking brake, always tow the
machine at low speed to a safe place.
k When carrying out the operation to release
the parking brake, stop the machine on
level ground and check that the surround-
ing area is safe before starting the opera-
tion.If the parking brake must be released
o n a slo p e i n a n eme rg e n cy o r o t h e r
unavoidable situation, set chocks to the
tires securely.
1. In order to create a gap between the pad and

disc, turn the parking brake adjustment nut (1)
clockwise while pushing down the lock of the
nut.
2. Tow the machine to a safe place.

a After moving the machine, set chocks
securely to the tires.
HD325-7, HD405-7 23
Testing and adjusting front sus- 2) Before adjusting the oil level, check the
condition of the variable damper valve.
pension cylinder 1 S posision : soft mode
a Testing and adjusting instruments of front H posision : hard mode
suspension cylinder M posision : medium mode
Sym-
bol Part No. Part Name Remarks
1 792-610-1000 Suspension tool

2 •792-610-1130 Pump assembly N2 – N6
: Pump assembly
3 •792-610-1110 Hose Kit No.
4 •792-610-1120 Joint : 792-610-1100
5 •07020-21732 Fitting
6 •792-610-1140 Joint
7 •792-610-1250 Valve assembly N7 – N13
: Charging tool
N 8 •792-610-1260 Nipple assembly
9 •792-610-1480 Stem Kit No.
: 792-610-1200
10 •792-610-1640 Joint a With the truck empty, starting switch ON,
Regulator parking brake OFF, and hoist control lever
11 •792-610-1400 assembly
at the FLOAT position, check that the cyl-
24.5 MPa inder of the variable damper valve is in the
12 •792-610-1430 Gauge {250 kg/cm2} soft mode.
9.81 MPa a If the cylinder of the variable damper valve
13 •792-610-1440 Gauge {100 kg/cm2} is not in the soft mode when checking,
operate as follows to switch to the soft
a Stop the machine empty on level ground. mode.
i) Use the retarder brake (Note 1) and
1. Testing length of cylinder drive the machine several times
1) Check that the bottom of the cylinder repeatedly forward and in reverse to
cover is within the range (e) marked by set to the soft mode.
arrows for the cylinder level. Note 1: If the foot brake pedal is
used, the automatic suspen-
sion is automatically set to
the medium mode, and the
resistance of the cylinder
increases, so it takes time to
adjust.
24 HD325-7, HD405-7
2. Releasing nitrogen gas q Pressure sensor (With payload meter)

1) Set hydraulic jack [1] (50ton) under the
main frame.
2) Disconnect pressure sensor connector (2)
of valve (1), then loosen the valve (1) 2 – 3
turns.
a The pressure sensor is installed to only
the machines which are equipped with
the payload meters.
a When releasing the nitrogen gas,
there is danger that releasing the gas
from the valve core of feed valve (3)
will damage the valve core, so
remove the gas at the valve.
a When loosening the valve, loosen
only the valve itself. Do not loosen the q Oil level valve
pressure sensor or nipple.
a When the valve is loosened, and oil
and gas spurt out together, tighten the
valve slightly, and allow time for the
gas to escape slowly.
3) Operate the hydraulic jack so that dimen-
sion (a) of the cylinder is the specified
dimension for the oil level.
Dimension (a): 88 ± 3 mm
q With payload meter spec.
q Standard spec.
HD325-7, HD405-7 25
3. Adjusting of oil level 4. Filling suspension cylinder with gas

a Release the nitrogen gas before adjusting 1) Remove cap (5) from feed valve (3).
the oil level. 2) Set tool N as shown in the diagram.
1) Remove feed vavle (3), and install joint a Before installing regulator N11, blow
N6. the connector filter with nitrogen gas
2) Install fitting N5 to joint N4, then connect at 0.981 MPa {10 kg/cm2} or more to
hose N3 and volume pump N2. blow out all dirt or dust. (Dirt or dust in
3) Loosen air bleeding valve (4), then oper- the system causes failures.)
ate volume pump N2 until no more bub- 3) Open valve [2] of the gas cylinder [1], and
bles come out with the oil from air bleed check the pressure reading of gauge N12
side hole (b). (internal pressure of gas cylinder).
4) When no more bubbles come out with the a The pressure indicated must be at
oil, tighten air bleeding valve (4). least 0.981 MPa {10 kg/cm 2} higher
3 Air bleeding valve: than the pressure inside the suspen-
39.2 – 49.0 Nm {4 – 5 kgm} sion cylinder (max. pressure inside
5) Remove valve (1), then operate volume suspension cylinder: 4.31 MPa {44
pump N2 until no more bubbles come out kg/cm2}).
with the oil from the valve (1) mount. 4) Turn handle N11a of regulator N11 slowly
6) When no more bubbles come out with the clockwise, set the pressure reading of
oil, tighten the valve (1). gauge N13 to 0.981 MPa {10 kg/cm 2 }
3 Valve: 39.2 – 49.0 Nm {4 – 5 kgm} above the internal pressure of the suspen-
7) After completion of supplying the oil, sion cylinder, then operate valves N7 and
remove the volume pump, then install feed N10 to fill the suspension cylinder with
valve (3). nitrogen gas.
3 Feed valve: a Fill the left and right cylinders in the
39.2 – 49.0 Nm {4 – 5 kgm} same way.
5) When dimension (a) of the left and right
cylinders reaches the standard value, turn
handle N11a of regulator N11 counter-
clockwise to stop the flow of nitrogen gas.
a Standard dimension a: 233 ± 10 mm
6) Turn handle N10a of N10 fully back coun-
terclockwise, loosen air bleeding plug N7a
of valve N7, release the gas inside the
hose, then remove tool N.
a Be careful not lose the O-ring of the
feed valve.
26 HD325-7, HD405-7
5. Adjusting installed length of cylinder

a Carry out adjustment of the installed length
of the cylinder with the machine-empty and
on level ground.
1) To remove the sliding resistance of the
cylinder (catching of bushing or packing),
drive the machine forward approx. 15 m
and stop suddenly, then drive in reverse to
the original position and stop again sud-
denly. Repeat this cycle 3 – 4 times, and
finally, allow the machine to stop slowly
without depressing the brake. Then mea-
sure the installed length.
a Do not use the foot brake when brak-
ing the machine. Use the retarder
control lever to brake the machine,
and check that the suspension is in
the soft mode.
2) If the result of the check shows that the
installed length is too long, release nitro-
gen gas to adjust the length.
a Loosen the valve (1) slightly to release
the nitrogen gas. When doing this,
release only a small amount of gas; do
not make the cylinder move.
a If too much nitrogen gas is released
and the cylinder moves, the installed
length may be below the specified
length.
a Do not press the tip of the valve core.
If the tip of the valve core is pressed,
the valve core may be damaged.
3) After releasing nitrogen gas and adjusting
the installed length, repeat Step 1) to
check the installed length again.
4) Repeat the above Steps 1) – 3) to adjust
the cylinder to the specified length.
5) Finally, check that there is no leakage of
gas from the valve core (6), valve (1), and
piston rod gland.
a Use soapy water to check for leakage
of gas.
a If there is any leakage of gas from the
valve core, use tool [3] and remove
the valve core.
HD325-7, HD405-7 27
Note:1. Checking after changing oil and gas

After the oil and gas have been changed,
operation of the machine causes the gas
to dissolve in the new oil inside the cylin-
der until it is saturated, so the volume of
gas is reduced and the installed length of
the suspension goes below the specified
limit. Therefore, 48 hours after changing
the oil and gas, check the installed length
of the suspension and adjust the gas if the
length is not within the specified value.
2. Checking for changes in installed length
caused by variation in ambient tempera-
ture.
Depending on the ambient temperature
when the machine is working, the gas in
the suspension may expand or contract,
so the installed length will also change. In
territories where there are big differences
in temperature throughout the year,
inspect daily and adjust to keep the
installed length within the specified range.
28 HD325-7, HD405-7
Testing and adjusting inverted

type rear suspension cylinder 1
a Testing and adjusting instruments of rear
suspension cylinder
Sym-
bol Part No. Part Name Remarks
1 792-610-1000 Suspension tool

2 •792-610-1130 Pump assembly O2 – O6
: Pump assembly
3 •792-610-1110 Hose Kit No.
4 •792-610-1120 Joint : 792-610-1100
5 •07020-21732 Fitting
6 •792-610-1140 Joint 2) Disconnect pressure sensor connector (2)
of valve (1), then loosen the valve 2 – 3
7 •792-610-1250 Valve assembly O7 – O13
: Charging tool turns.
O 8 •792-610-1260 Nipple assembly a When releasing the nitrogen gas, there
9 •792-610-1480 Stem Kit No. is danger that releasing the gas from
: 792-610-1200
10 •792-610-1640 Joint the valve core of feed valve (3) will
damage the valve core, so remove the
Regulator
11 •792-610-1400 assembly gas at the valve (1).
a When loosening the valve (1), loosen
24.5 MPa
12 •792-610-1430 Gauge {250 kg/cm2} only the valve itself. Do not loosen the
pressure sensor or nipple.
k When loosening the valve (1),
9.81 MPa
13 •792-610-1440 Gauge {100 kg/cm2}
gradually loosen only valve (1)
a Stop the machine empty on level ground. itself, and do not remove the valve
until all the nitrogen gas has been
1. Testing length of cylinder released from the slit.
Check that dimension (a) of the rear suspen- k If the nitrogen gas has not all been
sion cylinder is within the specified value. released, pressure sensor (5) are
Specified value for dimension (a) : still under high pressure, so do not
176 ± 10 mm loosen them under any circum-
stances.
a When the valve (1) is loosened, and
oil and gas spurt out together, tighten
the valve slightly, and allow time for
the gas to escape slowly.
2. Releasing nitrogen gas

1) Set block [2] between the stopper and
axle housing.
a Thickness of block : 26 mm
Dimension (a) : 97 ± 3 mm
HD325-7, HD405-7 29
2) Set tool O to the feed valve supply as

shown in the diagram.
a Before installing regulator O11, blow
the filter in the connector with nitro-
gen gas at 0.981 MPa {10 kg/cm2} or
more to blow out all dirt or dust. (Dirt
or dust in the system causes failures.)
3) Open valve [2] of the gas cylinder [1], and
check the pressure reading of gauge O12
(internal pressure of gas cylinder).
a The pressure indicated must be at
least 0.981 MPa {10kg/cm 2 } higher
than the pressure inside the cylinder
(max. pressure inside cylinder: 2.74
MPa {28 kg/cm2}).
3. Adjusting oil level
4) Turn handle O11a of regulator O11 slowly
a Release the nitrogen gas before adjusting
clockwise, set the pressure reading of
the oil level. gauge O13 to 0.981 MPa {10kg/cm 2 }
1) Remove feed valve (3), and install joint above the internal pressure of the cylinder,
O6. then operate valves O7 and O10 to fill the
2) Install fitting O5 to joint O4, then connect cylinder with nitrogen gas.
hose O3 and volume pump O2. a Fill the left and right cylinders in the
3) Loosen air bleeding valve (1), then oper- same way.
ate volume pump O2 until no more bub- 5) When dimension (a) of the left and right
bles come out with the oil from air cylinders reaches the standard value, turn
bleeding valve (1). handle O11a of regulator O11 counter-
4) When no more bubbles come out with the clockwise to stop the flow of nitrogen gas.
oil, tighten air bleeding valve (1). a Standard dimension (a): 176 ± 10 mm
5) After adding oil, remove the volume pump, 6) Turn handle O10a of O10 fully back coun-
then install feed valve (3). terclockwise, loosen air bleeding plug
O7a of valve O7, release the gas inside
the hose, then remove tool O.
a Be careful not to lose the O-ring of the
feed valve.
4. Filling suspension cylinder with gas

1) Remove cap (5) from feed valve (3).
30 HD325-7, HD405-7
a If gas leaks from the valve core, remove

the valve core with tool [3].
2 Valve core: Gasket sealant
16.7 – 34.3 Nm {1.7 – 3.5 kgm}
5. Adjusting installed length of cylinder

a Carry out adjustment of the installed length
of the cylinder with the machine empty and
on level ground.
1) To remove the sliding resistance of the 6. Testing and adjusting dust cover
cylinder (catching of bushing or packing), a To protect the rear suspension from stones
drive the machine forward approx. 15 m and other objects thrown up by the tires
and stop suddenly, then drive the machine when the machine is traveling, carry out
forward approx. 15 m and stop suddenly, inspection of the cover and repair or
then drive in reverse to the original posi- replace it as necessary.
tion and stop again suddenly. Repeat this 1) Check visually that there are no cracks or
cycle 3 – 4 times, and finally, allow the breaks in cover (1).
machine to stop slowly without depressing a If the cover is damaged, replace it
the brake. Then measure the installed with a new part.
length. 2) Check that hooks (2) are not missing. (3
a Do not use the foot brake when brak- places)
ing the machine. Use the retarder a If any hooks are missing, remove all
control lever to brake, the machine, mud and dirt, then install hooks.
then check that the suspension is in
the soft mode.
2) If the result of the check shows that the
installed length is too long, release nitro-
gen gas to adjust the length.
a Loosen the valve slightly to release
the nitrogen gas. When doing this,
release only a small amount of gas;
do not make the cylinder move.
a If the nitrogen gas is so released that
the cylinder may move, the installed
length may be below the specified
length.
a Do not press the tip of the valve core.
If the tip of the valve core is pressed,
the valve core may be damaged.
3) After releasing nitrogen gas and adjusting
the installed length, repeat Step 1) to
check the installed length again.
4) Repeat the above Steps 1) – 3) to adjust
the cylinder to the specified length.
5) Finally, check that there is no leakage of
gas from the valve core (6), valve, and pis-
ton rod gland.
a Use soapy water to check for leakage
of gas.
HD325-7, HD405-7 31
3) Check that band (3) is not loose or miss-

ing.
a If the band is loose or missing, tighten
to the following torque.
3 Band:
669 ± 49 Ncm {69 ± 5 kgcm}
32 HD325-7, HD405-7
Testing and adjusting front sus-

pension cylinder (mode selector
hydraulic cylnder) 1
1. Testing
1) Check that length (a) of hydraulic cylinder
(1) is as specified under the following con-
dition.
a Condition (Mode S)
(1) Machine is empty.
(2) Starting switch is ON.
(3) Parking brake switch is ON.
(4) Work equipment control lever is
at FLOAT.
a Specified length (a): 352 ± 1 mm
2) Shift the hoist lever from the FLOAT posi-

tion to another position and check that
hydraulic cylinder length (a) is not (is
longer than) 352 ± 1 mm.
2. Adjusting
1) Remove mounting bolt (2) of hydraulic cyl-
inder (1) and disconnect hydraulic cylinder
(1).
2) Loosen locknut (3) and adjust mounting
length (a) with rod end.
a Specified length (a): 352 ± 1 mm 5) Check that the hole of bracket (5) is in the
3) Install (Return) hydraulic cylinder (1) with slit (part e) in modes S and M.
mounting bolt (2).
4) Turn the starting switch to the ON position
and shift the hoist lever from the FLOAT
position to another position and check that
length (a) of hydraulic cylinder (1) is not (is
longer than) 352 ± 1 mm.
(Reference)
q (b) in hard mode : 383 ± 1 mm
q (d) in medium mode : 414 ± 1 mm
HD325-7, HD405-7 33
Testing and adjusting hydraulic 2. Adjusting hydraulic pressure in steering

circuit
pressure in steering, hoist circuit1 If the hydraulic pressure is not within the stan-
a Special tool list dard value, adjust as follows.
q Steering oil pressure (Adjusted with demand
valve)
799-101-5002 Hydraulic tester 1) Remove cap (2) of relief valve (5), loosen
1
790-261-1204 Digital type hydraulic tester locknut (3), and rotate adjustment screw
P (4) to adjust the oil pressure.
799-101-5520 Nipple
2 a To INCREASE pressure, turn CLOCK-
07002-11023 O-ring
WISE
k
To DECREASE pressure, turn COUN-
Stop the machine on level ground, apply
the parking brake, and put chocks under TERCLOCKWISE
the tires. a One turn of the adjustment screw
k Lower the body to the frame, stop the adjusts by (2.43 MPa {24.8 kg/cm2}).
engine, then remove the cap from the
hydraulic tank and release the pressure
inside the cylinder circuit.
Steering circuit
1. Testing hydraulic pressure in steering cir-
cuit
1) Raise the hydraulic oil temperature.
a Oil temperature when measuring :
45 – 55°C
2) Remove the oil pressure pickup plug,
install nipple P2, and connect oil pressure
gauge [1] (39.2 MPa {400 kg/cm 2 }) of
hydraulic tester P1 by hose [2].
3) Operate the steering wheel fully to the left
or right, and measure the hydraulic pres-
sure when the circuit is relieved.
2) After adjusting, hold the adjustment screw

with a screwdriver to prevent it from turn-
ing, then tighten the locknut and install the
cap.
3 Cap: 0.29 – 0.39 Nm {3 – 4 kgm}
34 HD325-7, HD405-7
3. Testing steering valve supply pressure Hoist circuit

1) Heighten the hydraulic oil temperature. 1. Testing hoist circuit oil pressure
a Oil temperature for measurement: 1) Heighten the hydraulic oil temperature.
45 – 55 °C a Oil temperature for measurement:
2) Remove the left fender cover. 45 – 55 °C
3) Remove oil pressure pickup plug (6), 2) Remove the oil pressure pickup plug,
install nipple P2, and connect oil pressure install nipple P2, and connect oil pressure
gauge [1] (39.2 MPa {400 kg/cm 2 }) of gauge [1] (39.2 MPa {400 kg/cm 2 }) of
hydraulic tester P1 by hose [2]. hydraulic tester P1 by hose [2].
4) Turn the steering wheel fully to the left or 3) Operate the hoist lever to raise the body to
right to relieve the pressure and measure the maximum, relieve the pressure, and
the pressure at this time. measure the pressure while running the
engine at full throttle.
4. Measuring steering cylinder supply pres-

sure
1) Heighten the hydraulic oil temperature.
a Oil temperature for measurement:
45 – 55 °C
2) Remove oil pressure pickup plug (9) or (8)
and install nipple P2.
a Plug (9) is for the left steering and
plug (8) is for the right steering.
{400 kg/cm 2 }) of hydraulic tester P1 by
hose [2].
4) Turn the steering wheel fully to the left or
right to relieve the pressure and measure
the pressure at this time.
2. Adjusting hoist circuit oil pressure

If the hoist circuit oil pressure is out of the stan-
dard range, adjust it according to the following
procedure.
q Hoist cylinder oil pressure (Adjusted with
hoist valve)
1) Loosen locknut (2) of relief valve (4) and
rotate adjustment screw (3) to adjust the
oil pressure.
a If the adjustment screw is rotated to
the right, the oil pressure rises.
If the adjustment screw is rotated to
the left, the oil pressure lowers.
a The oil pressure rises or lowers by
4.2 MPa {42.8 kg/cm2} per turn of the
adjustment screw.
HD325-7, HD405-7 35
2) After adjusting, fix the adjustment screw

with a screwdriver and tighten the locknut.
3 Tightening torque for locknut:
29.4 – 39.2 Nm {3 – 4 kgm}
3) Referring to "Measuring steering oil pres-
sure", check that the oil pressure is in the
standard range.
3. Testing hoist cylinder oil pressure

1) Remove the oil pressure pickup plug,
install nipple P2, and connect oil pressure
gauge [1] of hydraulic tester P1 by hose
[2].
2) Measure the hoist cylinder oil pressure
similarly to the hoist circuit oil pressure.
36 HD325-7, HD405-7
Testing and adjusting dump EPC 2. Testing dump EPC output pressure
1) Disconnect EPC hose (3) or (4) to be
circuit oil pressure 1 measured.
a Measuring dump EPC circuit oil pressure (3): Dump raise side (Port PB)
(4): Dump lower side (Port PA)
1
790-261-1204 Digital hydraulic tester
Q 2 799-101-5230 Nipple (14 x 1.5)
799-401-3100 Adapter
3
02896-11008 O-ring
k Loosen the oil filler cap of the hydraulic

tank slowly to release the residual pressure
in the hydraulic tank.
Measuring
1. Testing dump EPC basic pressure
1) Remove oil pressure pickup plug (2) (M14 2) Install adapter Q3 to the hoist valve and
x 1.5) from dump EPC valve (1) on the connect the hose.
inside of the hydraulic tank (inside of the 3) Install nipple [1] of hydraulic tester Q1 to
machine). Q3 and connect oil pressure gauge [2]
(5.9 MPa {60 kg/cm2}) by hose [3].
4) Start the engine, set the dump lever in the
raise, float, or lower position, and measure
the circuit oil pressure.
2) Install nipple Q2, connect hose [2], and

{60 kg/cm2}) of hydraulic tester Q1.
3) Start the engine, set the dump lever in
neutral, and measure the oil pressure at
high idle.
HD325-7, HD405-7 37
Air bleeding from steering

cylinder 1
k Stop the machine on a level ground, apply
the parking brake, then put chocks under
the tires.
k Before operating the steering wheel, be
sure to check that there is no one around
the front tires.
a If the hydraulic cylinder was removed and

installed or its hydraulic piping was removed,
breed air from the hydraulic cylinder according
1. Start engine, run engine at low idle for 5 min-

utes.
2. Turn the steering wheel at 30 rpm (2 seconds

for one turn) to the left and right to a point
approx. 50 mm from the end of the steering
cylinder stroke.
Repeat this action ten times.
(This action is to prevent damage to the piston
seal caused by compression and combustion
of air in the steering cylinder.)
3. Turn the steering wheel at 30 rpm to the left

and right to the end of the steering cylinder
stroke.
Repeat this action four times.
4. Turn the steering wheel as quickly as possible

to the left and right to the end of the steering
cylinder stroke.
When reaching the end of the stroke at the left
and right, turn the steering wheel immediately
in the opposite direction, and carry out this
action continuously.
Repeat this action ten times in both direction.
38 HD325-7, HD405-7
Procedure for raising body in k When performing this procedure, be

sure not to go under the dump body
emergency 1 but stand on the ground.
a Tool for raising body in emergency a The dump body lowers by itself. Keep it at
safe lowering speed by adjusting the tight-
ening depth tool R.
R 792T-491-1110 Plug
5. After the dump body lowers completely, remove
a If the dump body cannot be raised because of tool R and install plug (2).
a failure in the controller or electric system, 3 Tightening torque of plug:
raise it to dump the load according to the fol- 44.1 – 53.9 Nm {4.5 – 5.5 kgm}
lowing procedure.
1. Stop the engine and remove the hydraulic tank

cap to release the residual pressure from the
hoist circuit.
2. Remove plug (1) and screw in tool R fully.

a If tool R is tightened in fully, the spool is
moved to the rising stroke end.
a Distance between end of valve and end of
spool: 103 mm
1) If the engine can be started, start the

engine under this condition, and the dump
body rises.
2) If the engine cannot be started, turn the
emergency steering switch "ON" and raise
the dump body with the hydraulic pressure
of the emergency steering pump.
a Do not operate the emergency steer-
ing pump for more than 90 seconds
continuously. If the load cannot be
dumped in 90 seconds, cool down the
steering pump, and then operate it
again.
3. Stop the engine and remove tool R and install

plug (1).
3 Tightening torque of plug:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
4. When lowering the dump body, remove plug

(2) and tighten tool R slowly.
HD325-7, HD405-7 39
Adjusting body positioner 4) Install mounting bolt (2).

5) Tighten locknut (1).
sensor 1 6) Repeat the checking procedure above to
a If the body positioner rod has been discon- check that the input voltage is within the
nected and connected again or the body posi- normal range.
tioner sensor has been removed and installed
again, inspect and adjust the body positioner
sensor as follows.
1. Checking sensor input voltage

1) Switch the machine monitor display to the
monitoring function of service mode 1 and
display the body positioner sensor input
voltage.
a Monitoring item
Code No. 34602: BODY POSITION
a For details of the method of opera-
tion, see "Special functions of ma-
chine monitor".
3. Calibration of system
k Stop the machine on a level ground
and lock the tires with chocks securely.
1) Start the engine and raise the hydraulic oil
temperature to 80 – 90 °C.
2) Lower the dump body to the lower stroke
end and relieve the pressure by lowering
operation at this position for a minimum of
5 seconds.
a Check that the body pilot lamp is not
lightedup.
3) Raise the dump body to the raise stroke
end and relieve the pressure at this posi-
2) Start the engine. tion by raising operation for a minimum of
3) Operate the dump lever and check the 5 seconds.
monitoring voltage when the dump lever is 4) While running the engine at low idle, raise
operated fully to the LOWER position and and float the dump body 10 times.
RAISE position. a Move the lever to the raising stroke
a When operated fully to LOWER: end and floating stroke end.
0.46 – 0.54 V 5) While running the engine at high idle,
a When operated fully to RAISE: raise and float the dump body 10 times.
4.00 – 4.70 V a Move the lever to the raising stroke
end and floating stroke end.
2. Adjusting link length a Repeat the operations of 3) and 4)
a If the monitoring voltage is not within the above 5 – 10 times.
normal range, adjust the length of the link 6) Run the engine at high idle and raise the
as follows. body to the stroke end. Then, keep the
1) Loosen locknut (1). engine speed at high idle and set the
2) Remove mounting bolt (2). dump control lever in the LOWER position
3) Turn rod end (3) to adjust the length of the to lower the body to the seating position.
link (4). a Repeat this operation 5 – 10 times.
a Standard installing length (a):
315 mm.
a Adjust the input voltage as follows.
q INCREASE link length to DE-
CREASE voltage
q DECREASE link length to IN-
CREASE voltage
40 HD325-7, HD405-7
Handling of high voltage circuit of Adjusting transmission

engine controller 1 controller 1
4. Disconnecting or connecting operation of the a After any of the following operations, adjust the
connector between the engine controller and transmission in order to tune the feeling of
the engine shall be performed only when the transmission and its controller.
starting switch is in the OFF position. q The transmission has been overhauled or
replaced.
5. Do not start the engine while the T adapter is q The transmission control valve has been
ins er ted or c onnec ted to the conn ector repaired or replaced.
between the engine controller and the engine q The transmission controller has been replaced.
for diagnosis. q Power train speed sensor has been repaired or
a You may turn the starting switch to the replaced.
OFF or ON position but must not turn it to q The transmission oil temperature sensor has
the START position. been repaired or replaced.
q The transmission oil filter has been clogged
abnormally and repaired.
a For the adjusting operation of the transmission,
use the service function of the machine moni-
tor.
a For the details of the operation method, see
" Sp e c i a l f u n c t i o n s o f m a c h i n e m o n i t o r
(EMMS)".
HD325-7, HD405-7 41
Method for emergency escape at electrical system failure 1

If any problem occurs in the electrical system of the engine or transmission control system, it may disable the
engine to start or the machine to move off.
If such a problem occurs, temporarily restore the engine or transmission electrical system to move the
machine to a safe place, then carry out regular troubleshooting.
1. When any problem occurs in the engine control system and the engine cannot be started
a Decide the escape method according to the following flowchart.
a Refer to "Special functions of machine monitor (EMMS)" for the method of checking the failure code.
Note: If the engine cannot be started and the machine is towed, release the parking brake temporarily refer-
ring to "Method for emergency release of parking brake", since it cannot be released by operating the
switch.
42 HD325-7, HD405-7
2. When transmission control system has a trouble and machine cannot start
a Check the failure code and select a proper escape procedure from the following table.
a For the method of checking the failure code, see "Special functions of machine monitor".
Failure Condition when Starting gear speed set with lever
Escape method Remarks
code trouble occurred position after escape operation
1500L0 Occurrence condition 2 Escape procedure 2 — Occurrence condition 1
Gear speed is kept fixed and
15G0MW Occurrence condition 2 Escape procedure 3 D – L: F2 gear is not shifted from fixed
15H0MW Occurrence condition7 Escape procedure1 D – L: F2, R: R gear after machine restarts.
If lever is set to N position,
15J0MW Occurrence condition7 Escape procedure1 D – L: F2, R: R gear is set in neutral.
15K0MW Occurrence condition7 Escape procedure3 D – L: F2, R: R
Occurrence condition 2
15L0MW Occurrence condition7 Escape procedure3 D – L: F1, R: R Gear is set in neutral sud-
15M0MW Occurrence condition7 Escape procedure3 D – L: F2, R: R denly during travel. Once
machine stops travel, gear is
15N0MW Occurrence condition7 Escape procedure3 D – L: F2, R: R kept in neutral and machine
does start when lever is
15SBL1 Occurrence condition7 Escape procedure1 R: R operated.
15SBMA Occurrence condition2 Escape procedure1 D – L: F2
Occurrence condition 3
15SCL1 Occurrence condition7 Escape procedure1 D – L: F2, R: R Gear is set in neutral sud-
denly during travel.
15SCMA Occurrence condition7 Escape procedure1 D – L: F2, R: R
15SDL1 Occurrence condition7 Escape procedure1 D – L: F2, R: R Occurrence condition 4
After engine is started, gear
15SDMA Occurrence condition7 Escape procedure1 D – L: F2, R: R is kept in neutral and
machine does not start when
15SEL1 Occurrence condition7 Escape procedure1 D – L: F1 lever is operated.
15SEMA Occurrence condition7 Escape procedure1 D – L: F2, R: R Occurrence condition 5
15SFL1 Occurrence condition7 Escape procedure1 D – L: F2 Lever responds abnormally
and does not work. If lever is
15SFMA Occurrence condition7 Escape procedure1 D – L: F1, R: R operated, gear is set in neu-
tral.
15SGL1 Occurrence condition7 Escape procedure1 D – L: F4
15SGMA Occurrence condition7 Escape procedure1 D – L: F2, R: R Occurrence condition 6
Gear speed is kept fixed and
15SHL1 Occurrence condition7 Escape procedure1 D – L: F6 gear is not shifted from fixed
gear after machine restarts.
15SHMA Occurrence condition7 Escape procedure1 D – L: F2, R: R If lever is set to N position,
gear is set in neutral but can-
15SJMA Occurrence condition1 Escape procedure1 D – L: F2, R: R not be shifted any more.
If display becomes normal, machine
DAQ0KK Occurrence condition1 Escape procedure5 can travel normally (Note 1). Occurrence condition 7
Proper clutch for travel is
If display becomes normal, machine used and gear speed is
DAQ2KK Occurrence condition1 Escape procedure4 can travel normally (Note 1). fixed. If there is not proper
clutch, gear is set in neutral.
DAQ9KQ Occurrence condition4 Escape procedure6 — If lever is set to N position,
If display becomes normal, machine gear is set in neutral.
DAQRKR Occurrence condition2 Escape procedure5
can travel normally (Note 1).
Note 1
DAQRMA Occurrence condition4 Escape procedure1 D – L: F2, R: R Even if trouble disappears,
gear is kept in neutral until
DB2RKR Occurrence condition1 Escape procedure1 D – L: F2, R: R lever is set to N position
DDTHKA Occurrence condition1 Escape procedure1 D – L: F2, R: R once.
DDTJKA Occurrence condition1 Escape procedure1 D – L: F2, R: R

DDTKKA Occurrence condition1 Escape procedure1 D – L: F1
DDTLKA Occurrence condition1 Escape procedure1 D – L: F2
DDTMKA Occurrence condition1 Escape procedure1 D – L: F4
DDTNKA Occurrence condition1 Escape procedure1 R: R
DDTPKA Occurrence condition1 Escape procedure1 D – L: F6
DF10KA Occurrence condition5 Escape procedure7 If display becomes normal, machine

If display becomes normal, machine
DF10KB Occurrence condition5 Escape procedure7
DF1KA Occurrence condition1 Escape procedure1 D – L: F2, R: R
DLF1LC Occurrence condition1 Escape procedure1 D – L: F2, R: R
DLF2KA Occurrence condition1 Escape procedure1 D – L: F2, R: R
HD325-7, HD405-7 43
Failure Condition when Starting gear speed set with lever

Escape method Remarks
code trouble occurred position after escape operation
DLF2LC Occurrence condition1 Escape procedure1 D – L: F2, R: R
DLT3KA Occurrence condition6 Escape procedure3 D – L: F2, R: R
DXH1KA Occurrence condition1 Escape procedure1 D – L: F2, R: R
DXH1KB Occurrence condition1 Escape procedure1 D – L: F2, R: R
DXH1KY Occurrence condition1 Escape procedure1 D – L: F2, R: R
DXH4KY Occurrence condition7 Escape procedure1 D – L: F1
DXH7KA Occurrence condition7 Escape procedure1 D – L: F2
DXH7KB Occurrence condition7 Escape procedure1 D – L: F2
DXH7KY Occurrence condition7 Escape procedure1 R: R
DXHHKA Occurrence condition7 Escape procedure1 D – L: F2, R: R
DXHHKB Occurrence condition7 Escape procedure1 D – L: F2, R: R
DXHHKY Occurrence condition7 Escape procedure1 D – L: F6
Escape procedure 1: a Connectors A1 and A2 are installed to

1) Stop traveling and return the gearshift lever to near the fuse box.
the "N" position. a Connect and disconnect the connectors
2) Operate the gearshift lever again and move with the starting switch at ON or with the
the machine off. engine started.
a When operating the gearshift lever, release 3) Operate the gearshift lever again and move
the accelerator pedal. the machine off.
a N o D – L or N o R a When operating the gearshift lever, release
the accelerator pedal.
Escape procedure 2: a N o D – L or N o R
Tow the machine. a The emergency escape mode is main-
a If the engine cannot be started and the machine tained until the starting switch is turned
is towed, the parking brake cannot be released OFF.
by operating the switch, so carry out the opera-
tion to release it temporarily. For details, see Escape procedure 4:
"Method for emergency release of parking Check the circuit breaker and fuse. If they are nor-
brake". mal, replace the transmission controller.
q Circuit breaker: No. 64 "FUB2" (80 A)
Escape procedure 3: q Fuse: BT2-No. 18-17 (10 A)
1) Stop traveling and return the gearshift lever to
the "N" position. Escape procedure 5:
2) Connect and disconnect emergency escape Check the circuit breaker and fuse. If they are nor-
connectors A1 (female) and A2 (male), and mal, replace the transmission controller.
switch to the emergency escape mode. q Circuit breaker: "FUA2" (30 A)
44 HD325-7, HD405-7
q Fuse: BT2-No. 18-17 (10 A)
Escape procedure 6:
Check the model selection setting. If it is normal,
see adjustment of transmission controller.
Escape procedure 7:
Check the fuse. If it is normal, replace the gearshift
lever.
q Fuse: BT3-No. 14-13 (10 A)
HD325-7, HD405-7 45

© 2007 KOMATSU
All Rights Reserved
46 HD325-7, HD405-7
SEN01184-01
DUMP TRUCK
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up

Setting and adjusting of devices ..................................................................................................................... 2
Special functions of machine monitor (EMMS) ............................................................................................. 14
HD325-7, HD405-7 1
Setting and adjusting of devices 1

Items to be set or adjusted after replacement, disassembly, assembly or additional installation of
controllers or sensors
a If any of the following devices or parts is replaced, disassembled, assembled or installed additionally,
carry out the necessary setting and adjusting.
Device/Option replaced,
disassembled,
Necessary setting/adjusting
assembled or installed
additionally
Setting of model selection (See 1-1 of this section)
Setting of option selection (See 1-2 of this section)
Setting of machine monitor (corrosion resistor) in OFF (See 1-3 of this section)
Machine monitor
Deletion of information of electrical equipment system fault history (See *2-1)
Setting of service meter (See *3-1)
Setting of reverse travel odometer (See *3-2)
Adjusting of transmission ECMV current (See *2-2)
Transmission
Resetting and execution of transmission initial learning (See *2-2)
Setting of option selection (See 1-2 of this section)
Transmission controller Adjusting of transmission ECMV current (See *2-2)
Resetting and execution of transmission initial learning (See *2-2)
Transmission ECMV Adjusting of transmission ECMV current (See *2-2)
solenoid Resetting and execution of transmission initial learning (See *2-2)
Retarder controller Setting of option selection (See 1-2 of this section)
Body positioner sensor
Adjusting of body positioner sensor (See *2-3)
Body positioner rod
KOMTRAX How to start operation of KOMTRAX terminal
ORBCOMM controller Setting of ORBCOMM
Card-type payload meter Initialization and after-replacement setting of card-type payload meter
Optional device Setting of option selection
*2-1: For the setting and adjusting procedure, see "Special functions of machine monitor (EMMS)" ([10]
Electrical equipment system fault history display function).
*2-2: For the setting and adjusting procedure, see "Special functions of machine monitor (EMMS)" ([15]
Adjusting function).
*2-3: For the setting and adjusting procedure, see "Adjusting of body positioner".
*3-1: For the setting and adjusting procedure, see Service News.
*3-2: For the setting and adjusting procedure, see Service News.
1
2 HD325-7, HD405-7
1-1. Setting of model selection 4) Displaying service menu selection screen

1. Switching to service mode After confirming all ID's of 4 digits, display
1) Confirming the screen display the service menu selection screen in the
Check that the machine monitor is in oper- service mode.
ator mode and the screen is displaying a By inputting and determining the ID
either the "service meter and integrated once, it will be effective until the start-
odometer", "action code" or "failure code". ing switch is turned OFF.
2) Displaying ID input screen
Press the following 2 switches at the same
time for longer than 5 seconds to display
the ID input screen.
q [t] switch and [<] switch
a If the switch is pressed for longer than
5 seconds, the character display sec-
tion becomes blank. After confirming
this condition, release the switch.
2. Selecting and determining service menu

1) When pressing the [>] switch or [<] switch
in the service menu selection screen, the
service menu is displayed endlessly in the
order shown in the below table, so select
the model selection function (MACHINE).
q [>]: To proceed to next service menu.
q [<]: To return to previous service menu.
a Displayed service menu:
3) Input and determination of ID
After displaying ID input screen, operate Display Function
[>], [<], [U], and [t] switch to input 4 dig- ELECTRIC FAULT
Electrical system failure history
its ID. display function
a ID: 6491 MACHINE FAULT
Mechanical system failure history
q [ > ]: Number at the cursor increases. display function
q [ < ]: Number at the cursor decreases REAL-TIME
Real-time monitoring function
q [U]: Number at the cursor is deter- MONITOR
mined CYLINDER
Reduced cylinder mode function
q [t]: Cursor moves to left end or the CUT-OUT
display returns to operator mode NO INJECTION No injection cranking function
screen. TUNING Adjusting function
a If the ID input screen is left without MAINTENANCE Filter and oil replacement time setting
switch operation for longer than 60 MONITOR function
seconds, it automatically returns to OPERATION INFO Operation information display function
the operator mode screen. FIX POWER
Engine mode fixing function
MODE
OPTIONAL
Option selection function
SELECT
MACHINE Model selection function
Initialize function
INITIALIZE
(exclusive function for factory)
HD325-7, HD405-7 3
a As for the use of the service menu, 3. Selecting and setting of model
besides model selection function, 1) When pressing the [>] switch or [<] switch
option selection function, and filter in the model selection setting screen, the
and oil replacement time setting func- model which can be set is displayed end-
tion (part of function), refer to the sec- lessly in the order shown in the below
tion of "Special function of machine table, so select the applied model.
monitor". q [>] switch: To proceed to next model
a [<] switch: To return to previous model
*
In the " " part, the model presently
set is displayed.
q
a Displayed model:
a Even if the model presently set is cor- Display Model
rect, be sure to carry out the setting
HD785 HD785-7
newly.
HD605 HD605-7E0
HD465 HD465-7E0
HD405 HD405-7
HD325 HD325-7
2) After selecting the model in the model

selecting screen, determine the model by
pressing the [U] switch.
q [U]: Determine the setting.
q [ t]: To cancel the setting
a The below figure shows the example
that HD465-7E0 has been selected.
2) After selecting the model selection func-

tion, press [U] switch for longer than 5
seconds and display the model selection
setting screen.
q [U]: Conduct the service menu.
a Press [U] switch for longer than 5
seconds, otherwise it will not change
to model selection setting screen.
a In the model selection setting screen,
display only the model to be set at the
[*] part.
4 HD325-7, HD405-7
4. Storing data in controller

1) After determining the model selection set-
ting, check that the display automatically
returned to the service menu screen and
the selected model is surely displayed.
2) Turn the starting switch OFF and keep

that condition for longer than 15 seconds.
a Unless the starting switch is turned off
for longer than 15 seconds, the new
data is not memorized in the control-
ler.
3) Turn the starting switch ON again.
a After this operation the model setting
becomes effective.
5. Carrying out option setting

If once carrying out the model selection set-
ting, all setting of option selection is reset, so
continue to carry out the setting of option
selection.
a Refer to section "1-2. Setting of option
selection".
HD325-7, HD405-7 5
1-2. Setting of option selection

a Item list of option selection function
Item Display Code Default setting Contents of selection
ARSC ARSC 02 Added (ADD) If ARSC is installed, select ADD.
ASR ASR 03 Not added (NO ADD) If ASR is installed, select ADD.
ABS ABS 04 Not added (NO ADD) If ABS is installed, select ADD.
Auto-suspension AUTO SUS 05 Added (ADD) If auto-suspension is installed, select ADD.
— — 09 E1 Selecting operation is prohibited (Fixed to E1).
— — 10 Not added (NO ADD) Selecting operation is prohibited (Fixed to NO ADD).
Set speed compensation value quantity for tire size.
HD325-7 : 0 %
HD405-7 : – 1 %
Tire size com-
TIER SIZE 12 0% • If speedometer reading is not correct, adjust it with
pensation
this item.
• If setting is increased by 1%, reading is increased
by 1% at 0%.
If inclinometer (machine lateral inclination sensor) is
Inclinometer INCLINOMET 13 Added (ADD)
installed, select ADD.
Front brake cut F BRAKE CUT 14 Added (ADD) If front brake cut function is installed, select ADD.
Set unit of speed as follows.
• When MPH is used: MPH
Unit selection • When km/h is used: km/h
SPEED (UNIT) 15 MPH
(MPH / km/h) a This item is not displayed in the case of machine
with SI specification.
a Do not change this setting, basically.
Maintenance
SENSOR 19 Not added (NO ADD) If maintenance sensor is installed, select ADD.
sensor
1. Switching to service mode

Switch to the service mode by referring to "1-1.
Setting of model selection".
2. Selecting and carrying out service menu

1) Select the optional selection function
(OPTIONAL SELECTION) in the service
menu selection screen by referring to "1-1.
Setting of model selection".
6 HD325-7, HD405-7
2) After selecting the optional selection func- a Perform after checking that the model has
tion, press [U] switch for longer than 5 been set.
seconds and display the setting screen for a Always check all the items.
the optional item selection. a Settle the first item by pressing the [U] switch
q [U]: Conduct the service menu. twice, even if the current setting is correct (to
a Press [U] switch for longer than 5 transmit the information to the other control-
seconds, otherwise it will not change lers).
to optional item selection screen. a After setting, be sure to turn the starting switch
a The setting status of that optional OFF and wait for 15 seconds to settle the
item is displayed at the left of the memory of each controller.
lower row.
q ADD: Option is set. 3. Setting of ARSC (02: ARSC)
q NO ADD: Option is not set. 1) While the optional item selection screen is
displayed, select ARSC (02: ARSC).
a The current setting condition is dis-
played on the left side of the lower
line.
q ADD: ARSC is set.
q NO ADD: ARSC is not set.

in the option item selection screen, the
optional item is displayed endlessly in the
order shown in the below table, so select
the necessary item.
a Be sure to start setting of optional
functions from code No. 02. 2) Check the installation condition of ARSC
q [>]: To proceed to next option item. and setting condition on the screen and
q [>]: To return to previous option item. press the [U] switch to settle the setting.
a Displayed option items: q [U]: Change setting (Display chang-
Display Check item
es).
q [t]: Return to optional item selection
02: ARSC ARSC screen.
03: ASR ASR q ADD: Set option.
04: ABS ABS q NO ADD: Set no option.
05: AUTO SUS Auto-suspension
a If the setting is settled with the [U]
switch, it is effective even after this
09: — — screen is turned OFF.
10: — —
11: — —
12: TIRE SIZE Tire size compensation
13: INCLINOMET. Inclinometer
14: F BRAKE CUT Front brake cut
Speed unit selection
15: SPEED (UNIT)
(Do not change, basically)
16: — —
19: SENSOR Maintenance sensor
HD325-7, HD405-7 7
4. Setting of ASR (03: ASR) 5. Setting of ABS (04: ABS)

1) While the optional item selection screen is 1) While the optional item selection screen is
displayed, select ASR (03: ASR). displayed, select ABS (04: ABS).
a The current setting condition is dis- a The current setting condition is dis-
played on the left side of the lower played on the left side of the lower
line. line.
q ADD: ASR is set. q ADD: ABS is set.
q NO ADD: ASR is not set. q NO ADD: ABS is not set.
2) Check the installation condition of ASR 2) Check the installation condition of ABS
and setting condition on the screen and and setting condition on the screen and
press the [U] switch to settle the setting. press the [U] switch to settle the setting.
q [U]: Change setting (Display chang- q [U]: Change setting (Display chang-
es). es).
q [ t]: Return to optional item selection q [t ]: Return to optional item selection
screen. screen.
q ADD: Set option. q ADD: Set option.
q NO ADD: Set no option. q NO ADD: Set no option.
a If the setting is settled with the [U] a If the setting is settled with the [U]
switch, it is effective even after this switch, it is effective even after this
screen is turned OFF. screen is turned OFF.
8 HD325-7, HD405-7
6. Setting of auto-suspension (05: AUTO SUS) 7. Setting of tire size compensation (12: TIRE
1) While the optional item selection screen is SIZE)
displayed, select the auto-suspension (05: 1) Select the tire size compensation (12:
AUTO SUS). TIRE SIZE) in the option item selection
a The current setting condition is dis- screen.
played on the left side of the lower a The present compensation value is
line. displayed at the left of the lower row.
q ADD: Auto-suspension is set. ***%: Rate of change from standard
q NO ADD: Auto-suspension is not set. tire
2) Check the installation condition of the 2) For changing the compensation value,
auto-suspension and setting condition on press the [U] switch to display the com-
the screen and press the [U] switch to pensation value input screen.
settle the setting. q [U]: To change compensation value.
q [U]: Change setting (Display chang- 3) After displaying the compensation value
es). input screen, operate each of the switches
q [ t]: Return to optional item selection [>], [<], [U] and [t] to input the compen-
screen. sation value directly.
q ADD: Set option. q [ > ]: To switch the cursor symbol (+/-);
q NO ADD: Set no option. To increase number.
a If the setting is settled with the [U] q [ < ] :To switch the cursor symbol (+/-);
switch, it is effective even after this To decrease number.
screen is turned OFF. q [U]: To determine compensation val-
ue.
q [t ]: Cursor moves to left end / To re-
turn to optional item selection
screen.
a The compensation value at the plant
before shipment is [+/- 00%] (In case
of inputting 00, +/- does not matter.)
a The compensation value can be input
within the range of [-10 % – +10 %].
HD325-7, HD405-7 9
8. Setting of inclinometer (13: INCLINOMET.) 9. Setting of front brake cut (14: F BRAKE CUT.)
1) While the optional item selection screen is 1) While the optional item selection screen is
displayed, select the inclinometer (13: displayed, select the front brake cut (14: F
INCLINOMET.). BRAKE CUT.).
a The current setting condition is dis- a The current setting condition is dis-
played on the left side of the lower played on the left side of the lower
line. line.
q ADD: Inclinometer is set. q ADD: Front brake cut is set.
q NO ADD: Inclinometer is not set. q NO ADD: Front brake cut is not set.
2) Check the installation condition of the 2) Check the installation condition of the front
inclinometer and setting condition on the brake cut function and setting condition on
screen and press the [U] switch to settle the screen and press the [U] switch to
the setting. settle the setting.
q [U]: Change setting q [U]: Change setting
(Display changes). (Display changes).
q [ t]: Return to optional item selection q [t ]: Return to optional item selection
screen. screen.
q ADD: Set option. q ADD: Set option.
q NO ADD: Set no option. q NO ADD: Set no option.
a If the setting is settled with the [U] a If the setting is settled with the [U]
switch, it is effective even after this switch, it is effective even after this
screen is turned OFF. screen is turned OFF.
10 HD325-7, HD405-7
10. Setting of maintenance sensor (19: SENSOR.) 11. Storing data in controller
1) While the optional item selection screen is 1) Check that the setting for all items has
displayed, select themaintenance sensor been completed in the sub menu screen
(19: SENSOR.). for the optional item selection function.
a The current setting condition is dis- 2) Turn the starting switch OFF and keep
played on the left side of the lower that condition for longer than 15 seconds.
line. a Unless the starting switch is turned off
q ADD: Maintenance sensor is set. for longer than 15 seconds, the new
q NO ADD: Maintenance sensor is not data is not memorized in the controller.
set. 3) Turn the starting switch ON again.
a After this operation the option setting
becomes effective.
2) Check the installation condition of the mai-

tenance sensor function and setting condi-
tion on the screen and press the [U]
switch to settle the setting.
q [U]: Change setting
(Display changes).
q [ t]: Return to optional item selection
screen.
q ADD: Set option.
q NO ADD: Set no option.
a If the setting is settled with the [U]
switch, it is effective even after this
screen is turned OFF.
HD325-7, HD405-7 11
1-3. OFF setting of maintenance monitor (corro- a Displayed maintenance items:

sion resistor)
Display Maintenance items and functions
1. Switching to service mode
Switch to the service mode by referring to "1-1. 41:FUEL P FILT Fuel pre filter
Setting of model selection". 01:ENG OIL Engine oil
02:ENG FILT Engine oil filter
2. Selecting and carrying out service menu 13:TM FILT Transmission oil filter
1) Select the filter and oil replacement time 03:FUEL FILT Fuel main filter
setting function (MAINTENANCE MONI-
06:CORR RES Corrosion resistor
TOR) in the service menu selec tion
screen referring to "1-1. Setting of model 24: Torque convertor/Transmission/
selection". TC/TM/BK OIL Brake oil
14:BK OIL FILT Brake oil filter
16:BK C FILT Brake cooling oil filter
04:HYD FILT Hydraulic oil filter
11:DIFF OIL Differential oil
08:FNL OIL Final drive oil
10:HYD OIL Hydraulic oil
INTIALIZE Setting default value for all items
ALL ITEMS Setting validity or invalidity for all items
a As for the use of maintenance items

besides the corrosion register, refer to
th e s ec ti on "Spe ci al fu nc tio n o f
machine monitor".
3. Displaying and selecting of maintenance item
1) While the filter and oil replacement time
setting function is selected, display the
maintenance item selection screen by
pressing the [U] switch.
4. OFF setting of corrosion register item

1) With the corrosion register selected, press
the [U] switch and display the interval
change screen.
q [U]: To carry out interval change.
in the maintenance item selection screen,
the maintenance item is displayed end-
lessly in the order shown in the below
table, so select the corrosion register (06:
CORR RES).
q [>]: To proceed to next maintenance
item.
q [<]: To return to previous mainte-
nance item.
12 HD325-7, HD405-7
2) After displaying the interval change

screen, press the [>] or [<] switch further
and display the setting screen for validity
or invalidity.
q [>]: Change the displayed screen
q [<]: Change the displayed screen
a If the present setting is ON, the
screen displays as above, and if the
present setting is OFF, it displays as
below.
a The default setting of the machine
monitor is ON (above).
a If the present setting is ON (above),
carry out the further operation to
change the setting to OFF.
a If the present setting is OFF (below),
press the [t] switch to complete the
setting.
3) In order to change the present setting

from ON to OFF, press the [U] switch to
display the setting change screen.
q [U]: Change setting.
4) After displaying the setting change
screen, operate [>], [<], and [t] switch to
determine OFF setting.
q [<]: Select YES (move cursor)
q [>]: Select NO (move cursor)
q [t]: To determine selection.
HD325-7, HD405-7 13
Special functions of machine monitor (EMMS) 1
t Normal functions and the special functions of machine monitor

The machine monitor is equipped with normal functions and special functions. Various items of data are dis-
played on the character display in the middle of the machine monitor. The display items are divided by the
internal setting of the machine monitor, into automatic display items and items displayed when the machine
monitor switches are operated.
1) Normal functions: Operator mode
Functions for which the content is normally displayed or which can be displayed and operated by the
operator operating the switches.
2) Special functions: Service mode
Functions which the serviceman can display and operate with the special switches to carry out inspec-
tion, maintenance, and troubleshooting.
14 HD325-7, HD405-7
Operator mode io Service mode

1 Service meter, odometer display function (default) 9 Electric system fault history display function
2 Dump counter display function (when option is selected) 10 Mechanical system fault history display function
3 Reverse travel distance display function 11 Real-time monitoring function
4 Filter replacement, oil change interval display function 12 Reduced cylinder mode
5 Telephone number input function 13 No-injection cranking function
6 Language selection function 14 Adjustment function
7 Action code display function 15 Filter replacement, oil change interval display function
8 Failure code display function 16 Operation information display function
17 Engine mode fixing function
18 Option selection function
19 Model selection function
20 Initialize function (factory use only)
HD325-7, HD405-7 15
Function and flow of each mode
16 HD325-7, HD405-7
Operator mode Character display portion

16 characters can be displayed on each upper and
a No. 2 – No. 6 is displayed endlessly by follow-
lower row of the character display section, and
ing the switch operation.
depending on the contents displays the combina-
a When a failure occurs, the screen changes
tion of the next figures, letters, and symbols.
automatically to No. 8 regardless of the dis-
1) Arabic numbers: 1, 2, 3, . . .
played screen.
2) Small letters: a, b, c, . . .
a If the switch is not operated for over 30 sec-
3) Capital letters: A, B, C, . . .
onds regardless of the display screen, the
4) Katakana: A, I, U, . . . (Only for Japanese dis-
screen automatically;
play)
q Changes to No. 1.
5) Symbols: @, ?, $, . . .
(If malfunction has not occurred.)
6) Special letters:
q Changes to No. 7.
(If malfunction has occurred.)
a After moving from No. 8 to No. 1 by the switch
operation, if no switch operation is performed
for longer than 10 seconds, then it automati-
cally moves to No. 7.
Service mode
a No. 9 – No. 20 is displayed endlessly by follow-
ing the switch operation.
a By inputting and determining the ID once, it will
be effective until the starting switch is turned
off.
Control switch section

All the display operation of the machine monitor is
operated by the machine monitor mode selector
switches (1) and (2).
Each switch of [U], [t], [>], [<] is assigned to the
following function.
1) U: Determine and execute
2) t : To cancel, release, and determine
(only YES and NO screen)
3) > : To right, to next, to proceed, to increase
(only when inputting Arabic numbers)
4) < : To left, to previous, to return, to decrease
(only when inputting Arabic numbers)
HD325-7, HD405-7 17
t Operator mode (Outline) [3] Integrated reverse travel odometer display

function
[1] Service meter and integrated odometer dis- Machine monitor displays the integrated reverse
play function travel odometer by operating the switch.
When turning the starting switch ON, the speed a For details, see operation manual.
meter and integrated odometer are displayed in the
upper and lower row respectively.
a For details, see operation manual.
[4] Filter and oil replacement time display

function
1. Replacement time display of filter and oil (dis-
[2] Dump counter display function played automatically)
(When option is selected) When the replacement interval for the various
Display the dump counter by operating the machine filters or oils approaches, the machine monitor
monitor switch. automatically displays the information to
a Dump counter is displayed only when the remind an operator of maintenance.
option selection is set to be effective in the ser-
vice mode.
18 HD325-7, HD405-7
2. Reset of replacement time (selection menu) [6] Language selection function

The machine monitor can reset the interval Display language of the machine monitor can be
time by operating the switch, if various filters selected with the switch operation.
and oils maintenances are finished. a The Service mode function is not included in
a For details, see operation manual. the display selection function, therefore always
a Replacement interval time setting can be displayed in English.
operated by the filter and oil replacement a For details, see operation manual.
time setting function in the service mode.
[5] Phone No. input function

Phone No. set in the machine monitor can be input-
ted, corrected, and released by the switch opera-
tion.
a Phone No. is displayed together with "CALL"
when action code "E03" is displayed.
HD325-7, HD405-7 19
[7] Action code display function [8] Failure code display function
When abnormal situations occur, the machine mon- By pressing the [>] switch once while the action
itor automatically displays the action code depend- code is displayed on the machine monitor, the
ing on the extent of the abnormality in order to present failure code is displayed.
remind the operator of proper remedy. q [>]: To display failure code.
a Below figure shows the example of displaying
action code "E03" and "CALL + phone No."
alternately.
a "CALL + phone No." is not displayed if the
action code "E01" or "E02" is displayed.
a The failure codes which have been detected in

the past are separated into electrical and
mechanical systems and recorded as failure
history (refer to service mode for a detail).
a If there are several failures, other failure codes
a Action code and remedy requested for an op- are displayed by pressing the [>] switch.
erator a After displaying all the failure codes by press-
ing the [>] switch, press [>] switch further to
Action CALL +
Remedy requested for operator return to the service meter and integrated
code phone No.
odometer display screen.
• Carry out test and maintenance Press the [>] switch again, and the failure code
E01 None when operation is finished or is displayed from the beginning.
operator is changed. a If there is no switch operation for longer than
• If related to an over run is dis- 10 seconds in the service meter and integrated
played:Travel keeping the engine odometer display screen, it automatically
speed and machine speed down. switches to the action code display screen.
E02 None • If related to an overheat is dis- a The following information is displayed in the
played:Stop machine and keep service code display function.
engine with no-load medium A: Failure code (4-digits device code + 2-digits
speed running. symptom code)
• Stop the engine and machine B: Controller code
E03 Yes immediately and contact the ser- MON: Machine monitor
vice personnel. ENG: Engine controller
TM: Transmission controller
BK: Retarder controller
ABS: ABS controller
(when option is selected)
C: Trouble occurring system
20 HD325-7, HD405-7
a Refer to "Failure code table" for details of dis-

played failure codes.
a Be careful of the partial difference in the dis-
played information for the failure code display
function and the failure history display function
(service mode).
HD325-7, HD405-7 21
Failure codes table

Failure Device in Action Category of
Trouble Contents of trouble
code charge code record
Mechanical
1500L0 Dual engagement TM E03
system
Mechanical
15B0NX Transmission oil filter Clogging TM E01
system
Mechanical
15F0KM R o F shifting abuse 1 Mistake in operation TM —
system
Mechanical
15F0MB R o F shifting abuse 2 Mistake in operation TM —
system
Mechanical
15F7KM Forward clutch disk abuse Mistake in operation or setting TM —
system
Electrical
15G0MW R clutch Slipping TM E03
system
Mechanical
15G7KM Reverse clutch disk abuse Mistake in operation or setting TM —
system
Electrical
15H0MW Hi clutch Slipping TM E03
system
Electrical
15J0MW Lo clutch Slipping TM E03
system
Electrical
15K0MW 1st clutch Slipping TM E03
system
Electrical
15L0MW 2nd clutch Slipping TM E03
system
Electrical
15M0MW 3rd clutch Slipping TM E03
system
Electrical
15N0MW 4th clutch Slipping TM E03
system
Fill signal is ON when command Electrical
15SBL1 R clutch solenoid TM E03
current is OFF system
Electrical
15SBMA R clutch solenoid Malfunction TM E03
system
15SCL1 Hi clutch solenoid TM E03
Electrical
15SCMA Hi clutch solenoid Malfunction TM E03
system
15SDL1 Lo clutch solenoid TM E03
Electrical
15SDMA Lo clutch solenoid Malfunction TM E03
system
15SEL1 1st clutch solenoid TM E03
Electrical
15SEMA 1st clutch solenoid Malfunction TM E03
system
15SFL1 2nd clutch solenoid TM E03
Electrical
15SFMA 2nd clutch solenoid Malfunction TM E03
system
15SGL1 3rd clutch solenoid TM E03
Electrical
15SGMA 3rd clutch solenoid Malfunction TM E03
system
Command current is OFF and fill Electrical
15SHL1 4th clutch solenoid TM E03
signal is ON system
Electrical
15SHMA 4th clutch solenoid Malfunction (MA) TM E03
system
22 HD325-7, HD405-7

Electrical
15SJMA Lockup clutch solenoid Malfunction TM E03
system
Engine over run prevention Mechanical
(989A00) Operating MON E02
command signal system
Mechanical
(989D00) Rear section tipping over alarm Alarm is activated MON —
system
Mechanical
2F00KM Parking brake Mistake in operation or setting TM —
system
Mechanical
2G42ZG Front accumulator Lowering of oil pressure TM E03
system
Mechanical
2G43ZG Rear accumulator Lowering of oil pressure TM E03
system
Mechanical
A570NX Engine oil filter Clogging BK E01
system
Mechanical
AA10NX Air cleaner element Clogging MON E01
system
Electrical
AB00MA Alternator Malfunction MON E03
system
Abnormal lowering of engine oil Mechanical
B@BAZG Lowering of oil pressure ENG E02
pressure system
Mechanical
B@BAZK Engine oil Level too low BK E01
system
Mechanical
B@BCZK Lowering of radiator coolant Lowering of level TM E01
system
Mechanical
B@BCNS Engine Overheat ENG E02
system
Mechanical
B@C7NS Brake cooling oil Overheating (Rear) MON E02
system
Mechanical
B@CENS Torque converter oil Overheating MON E02
system
Mechanical
B@GAZK Battery electrolyte level Lowering of level BK E01
system
Mechanical
B@HAZK Hydraulic oil level Lowering BK E01
system
Mechanical
B@JANS Steering oil Overheat TM E02
system
Electrical
CA111 Engine controller Abnormal ENG E03
system
Abnormal engine Ne and Bkup Both sensors have trouble Electrical
CA115 ENG E03
sensors simultaneously system
Electrical
CA122 Charge pressure sensor Too high ENG E03
system
Electrical
CA123 Charge pressure sensor Too low ENG E03
system
Electrical
CA131 Throttle sensor Too high ENG E03
system
Electrical
CA132 Throttle sensor Too low ENG E03
system
Electrical
CA135 Oil pressure sensor Too high ENG E01
system
Electrical
CA141 Oil pressure sensor Too low ENG E01
system
Electrical
CA144 Coolant temperature sensor Too high ENG E01
system
Electrical
CA145 Coolant temperature sensor Too low ENG E01
system
HD325-7, HD405-7 23

Electrical
CA153 Charge temperature sensor Too high ENG E01
system
Electrical
CA154 Charge temperature sensor Too low ENG E01
system
Electrical
CA187 Sensor power source 2 Too low ENG E03
system
Electrical
CA221 Atmospheric pressure sensor Too high ENG E01
system
Electrical
CA222 Atmospheric pressure sensor Too low ENG E01
system
Electrical
CA227 Sensor power source 2 Too high ENG E03
system
Mechanical
CA234 Engine over speed Over speed ENG E02
system
Electrical
CA238 Engine Ne speed sensor Abnormal power source ENG E03
system
Electrical
CA263 Fuel temperature sensor Too high ENG E01
system
Electrical
CA265 Fuel temperature sensor Too low ENG E01
system
Electrical
CA271 PCV1 short circuit Short circuit ENG E03
system
Electrical
CA272 PCV1 disconnection Disconnection ENG E03
system
Electrical
system
Electrical
system
Electrical
CA322 Injector No. 1 system Disconnection or short circuit ENG E03
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
CA342 Engine controller data consistency Abnormal ENG E03
system
Electrical
CA351 Injector drive circuit Abnormal ENG E03
system
Electrical
system
Electrical
system
Electrical
CA431 Idle validation switch Abnormal ENG E01
system
Electrical
CA432 Process with idle validation switch Abnormal ENG E03
system
Electrical
CA441 Power source voltage Too low ENG E03
system
Mechanical
CA442 Power source voltage Too high ENG E03
system
24 HD325-7, HD405-7

Electrical
CA449 Common rail pressure Too high 2 ENG E03
system
Electrical
CA451 Common rail pressure sensor Too high ENG E03
system
Electrical
CA452 Common rail pressure sensor Too low ENG E03
system
Electrical
system
Electrical
CA554 Common rail pressure sensor In-range error ENG E03
system
Loss of pressure feed from supply Electrical
CA559 Abnormal 1 ENG E03
pump system
Electrical
CA689 Engine Ne speed sensor Abnormal ENG E03
system
Electrical
CA731 Engine Bkup speed sensor phase Abnormal ENG E03
system
Electrical
CA757 All engine controller data Loss ENG E03
system
Electrical
CA778 Engine Bkup speed sensor Abnormal ENG E03
system
Electrical
CA1228 EGR valve servo 1 Abnormal ENG E03
system
Electrical
system
Electrical
CA1626 Bypass valve solenoid drive Short circuit ENG E03
system
Electrical
CA1627 Bypass valve solenoid drive Disconnection ENG E03
system
Electrical
CA1628 Bypass valve servo 1 Abnormal ENG E03
system
Electrical
system
Electrical
CA1631 Bypass valve lift sensor Too high ENG E03
system
Electrical
CA1632 Bypass valve lift sensor Too low ENG E03
system
Electrical
CA1633 KOMNET Abnormal ENG E03
system
Electrical
CA1642 EGR inlet pressure sensor Too low ENG E01
system
Electrical
CA1653 EGR inlet pressure sensor Too high ENG E01
system
Electrical
CA2185 Throttle sensor power source Too high ENG E03
system
Electrical
CA2186 Throttle sensor power source Too low ENG E03
system
Loss of pressure feed from supply Electrical
pump system
Electrical
CA2271 EGR valve lift sensor Too high ENG E03
system
Electrical
CA2272 EGR valve lift sensor Too low ENG E03
system
Electrical
CA2351 EGR valve solenoid drive Short circuit ENG E03
system
Electrical
CA2352 EGR valve solenoid drive Disconnection ENG E03
system
HD325-7, HD405-7 25

Electrical
CA2555 Intake air heater relay Disconnection ENG E01
system
Electrical
CA2556 Intake air heater relay Short circuit ENG E01
system
Electrical
D19HKB Stop lamp relay output system Short circuit BK E01
system
Electrical
D5ZKKZ Front brake cut-off solenoid valve Disconnection or short circuit BK E01
system
Electrical
DAF9KM Connector Wrong connection MON E03
system
Abnormal CAN communication Electrical
DAFRKR Abnormal communication MON E03
(machine monitor) system
Transmission controller direct power Electrical
DAQ0KK Lowering of source voltage TM E03
supply system
Transmission controller nonvolatile Electrical
DAQ0KT Abnormality in controller TM E01
memory system
Transmission controller solenoid Electrical
DAQ2KK Power source voltage too low TM E03
power source system
Transmission controller direct power Electrical
(DAQ0KK) Power source voltage too low TM E03
supply system
Electrical
DAQ9KQ Transmission controller Disagreement of model selection TM E03
system
CAN communication Electrical
DAQRKR Abnormality MON E03
(transmission controller) system
Transmission controller option Electrical
(DAQRMA) Malfunction MON E03
setting system
Retarder controller nonvolatile Electrical
DB10KT Abnormality in controller BK E01
memory system
Retarder controller solenoid power Electrical
DB12KK Power source voltage too low BK E03
source system
Retarder controller direct power Electrical
source system
DB1RKR Communication disabled TM E03
(retarder controller) system
Electrical
DB19KQ Retarder controller model selection Disagreement in model selection MON —
system
DB1RMA Retarder controller option setting Disagreement of option setting MON E03 —
(engine controller) system
DBC9KQ ABS controller model selection Disagreement in model selection MON E03 —
Electrical
DBCRKR CAN communication (ABS) Abnormality TM E03
system
DBCRMA ABS controller option setting Disagreement of option setting MON E03 —
Trouble in travel speed setting switch Electrical
DDD7KX Out of input signal range BK E03
system (If equipped) system
Electrical
DDD8KA ARSC system switch system Disconnection BK E03
system
Electrical
DDD8KB ARSC system switch system Short circuit BK E03
system
Electrical
DDDAKA ASR system switch (If equipped) Disconnection BK E01
system
Electrical
DDDAKB ASR system switch Short circuit BK E01
system
Electrical
DDTHKA Hi clutch fill switch Disconnection TM E03
system
26 HD325-7, HD405-7

Electrical
DDTJKA Lo clutch fill switch Disconnection TM E03
system
Electrical
DDTKKA 1st clutch fill switch Disconnection TM E03
system
Electrical
DDTLKA 2nd clutch fill switch Disconnection TM E03
system
Electrical
DDTMKA 3rd clutch fill switch Disconnection TM E03
system
Electrical
DDTNKA R clutch fill switch Disconnection TM E03
system
Electrical
DDTPKA 4th clutch fill switch Disconnection TM E03
system
Electrical
DF10KA Gear shift lever Disconnection TM E03
system
Electrical
DF10KB Gear shift lever Short circuit TM E03
system
Electrical
DGF1KX Transmission oil temperature sensor Out of input signal range TM E03
system
Disconnection or short Electrical
DGR2KZ Retarder oil temperature sensor BK E01
circuit system
Electrical
DGR6KX Steering oil temperature sensor Input signal out of range TM E01
system
Torque converter oil temperature Electrical
DGT1KX Out of input signal range TM E01
sensor system
Suspension pressure sensor system Electrical
DHP6KA Disconnection BK E01
(Rear right) system
Failure in suspension pressure Electrical
DHP6KX Out of input signal range BK E03
sensor system trouble (Rear right) system
Suspension pressure sensor system Electrical
(Rear left) system
Failure in suspension pressure Electrical
DHP7KX Out of input signal range BK E03
sensor system trouble (Rear left) system
Electrical
DHT5KX Torque converter oil pressure sensor Out of input signal range TM E01
system
Disagreement of run and stop Electrical
DHT5L6 Torque converter oil pressure sensor TM E01
condition with signal system
Front accumulator oil pressure Electrical
DHU2KX Out of input signal range BK E01
sensor system
Rear accumulator oil pressure Electrical
sensor system
Electrical
DJF1KA Fuel level sensor Disconnection TM E01
system
Electrical
DK30KX Steering angle potentiometer Disconnection BK E01
system
Potentiometer signal is inconsistent Electrical
DK51L5 Retarder lever potentiometer BK E03
with swich signal system
Electrical
DK52KX Failure in hoist lever potentiometer 1 Out of input signal range BK E03
system
Electrical
DK53L8 Failure in hoist lever potentiometer 2 Disagreement of analog signal BK E03
system
Electrical
DK54KX Body positioner sensor Out of input signal range BK E03
system
Failure in steering speed sensor Disagreement of run and stop Electrical
DKD0L6 — E01
(If equipped) condition with signal system
Electrical
DKH0KX Pitch angle sensor (If equipped) Out of input signal range TM E01
system
HD325-7, HD405-7 27

Transmission input shaft speed Electrical
DLF1KA Disconnection TM E03
sensor system
Transmission input shaft speed Disagreement of revolution speed Electrical
DLF1LC TM E03
sensor signal system
Transmission intermediate shaft Electrical
speed sensor system
Transmission intermediate shaft Disagreement of revolution speed Electrical
DLF2LC TM E03
speed sensor signal system
Electrical
DLF8KA Wheel speed sensor Disconnection (Right rear) BK E01
system
Electrical
DLF8LC Wheel speed sensor Trouble (Right rear) BK E01
system
Electrical
DLF9KA Wheel speed sensor Disconnection (Left rear) BK E01
system
Electrical
DLF9LC Wheel speed sensor Trouble (Left rear) BK E01
system
Transmission output shaft speed Electrical
DLT3KA Disconnection TM E03
sensor system
Transmission output shaft speed Disagreement of revolution speed Electrical
DLT3LC TM E03
sensor (If equipped) signal system
Transmission output shaft speed Electrical
DLT4KA Disconnection BK E03
sensor (If equipped) system
Transmission output shaft speed Disagreement of revolution speed Electrical
DLT4MA BK E01
sensor (If equipped) signal system
Electrical
DV00KB Buzzer output Short circuit MON E01
system
Failure in output system of auto Electrical
DW35KZ Disconnection or short circuit BK E01
suspension solenoid 1 (If equipped) system
Failure in output system of auto Electrical
suspension solenoid 2 (If equipped) system
Failure in kick-out solenoid output Electrical
DW72KZ Disconnection or short circuit TM E01
system system
Failure in hoist select valve output Electrical
system system
Failure in rear brake BCV command Electrical
output system system
Electrical
DWNBK4 ASR shut-off valve Trouble (Valve keeps operating) BK E01
system
Electrical
DWNBKA ASR shut-off valve output circuit Disconnection BK E01
system
Electrical
DWNBKB ASR shut-off valve output circuit Ground fault BK E01
system
Electrical
DWNBKY ASR shut-off valve output circuit Short circuit BK E01
system
Electrical
DWNBMA ASR shut-off valve Trouble (Valve does not operate) BK E01
system
Rear brake proportional pressure Electrical
DX11K4 Out of control BK E03
reducing solenoid valve system
DX11KA Disconnection BK E03
reducing solenoid valve output circuit system
DX11KB Short circuit BK E03
DX11KY Short circuit to power source line BK E03
Rear brake proportional pressure Mechanical
DX11MA Malfunction BK E03
28 HD325-7, HD405-7

Electrical
DX13KA Output circuit of hoist EPC valve Disconnection TM E03
system
Electrical
DX13KB Output circuit of hoist EPC valve Short circuit TM E03
system
Electrical
DX13KY Output circuit of hoist EPC valve Short circuit with power source line TM E03
system
ASR proportional pressure reducing Electrical
DX17K4 Trouble (Valve keeps operating) BK E01
solenoid valve (right) system
solenoid valve (right) output circuit system
DX17KB Ground fault BK E01
DX17KY Short circuit BK E01
DX17MA Trouble (Valve does not operate) BK E01
solenoid valve (right) system
DX18K4 Trouble (Valve keeps operating) BK E01
solenoid valve (left) system
solenoid valve (left) output circuit system
SR proportional pressure reducing Electrical
DX18KB Ground fault BK E01
DX18KY Short circuit BK E01
DX18MA Trouble (Valve does not operate) BK E01
solenoid valve (left) system
Electrical
DXH1KA Lockup clutch solenoid output circuit Disconnection TM E03
system
Electrical
DXH1KB Lock-up clutch solenoid output circuit Short circuit TM E03
system
Electrical
DXH1KY Lockup clutch solenoid output circuit Short circuit to power source line TM E03
system
Electrical
DXH2KA Hi clutch solenoid output circuit Disconnection TM E03
system
Electrical
DXH2KB Hi clutch solenoid output circuit Short circuit TM E03
system
Electrical
DXH2KY Hi clutch solenoid output circuit Short circuit to power source line TM E03
system
Electrical
DXH3KA Lo clutch solenoid output circuit Disconnection TM E03
system
Electrical
DXH3KB Lo clutch solenoid output circuit Short circuit TM E03
system
Electrical
DXH3KY Lo clutch solenoid output circuit Short circuit in power source line TM E03
system
Electrical
DXH4KA 1st clutch solenoid output circuit Disconnection TM E03
system
Electrical
DXH4KB 1st clutch solenoid output circuit Short circuit TM E03
system
Electrical
DXH4KY 1st clutch solenoid output circuit Short circuit to power source line TM E03
system
Electrical
DXH5KA 2nd clutch solenoid output circuit Disconnection TM E03
system
Electrical
DXH5KB 2nd clutch solenoid output circuit Short circuit TM E03
system
Electrical
DXH5KY 2nd clutch solenoid output circuit Short circuit in power source line TM E03
system
HD325-7, HD405-7 29

Electrical
DXH6KA 3rd clutch solenoid output circuit Disconnection TM E03
system
Electrical
DXH6KB 3rd clutch solenoid output circuit Short circuit TM E03
system
Electrical
DXH6KY 3rd clutch solenoid output circuit Short circuit to power source line TM E03
system
Electrical
DXH7KA R clutch solenoid output circuit Disconnection TM E03
system
Electrical
DXH7KB R clutch solenoid output circuit Short circuit TM E03
system
Electrical
DXH7KY R clutch solenoid output circuit Short circuit to power source line TM E03
system
Electrical
DXHHKA 4th clutch solenoid output circuit Disconnection TM E03
system
Electrical
DXHHKB 4th clutch solenoid output circuit Short circuit TM E03
system
Electrical
DXHHKY 4th clutch solenoid output circuit Short circuit to power source line TM E03
system
30 HD325-7, HD405-7
t Service mode
Procedure for switching to service mode and
screen display
a When using the service mode, change the
screen by the following special operation.
1. Confirming the screen display

Check that the machine monitor is in operator
mode and the screen is displaying either of the
"service meter and integrated odometer",
"action code", or "failure code".
2. Displaying ID input initial screen

Press the following 2 switches at the same
time for longer than 5 seconds to display the ID 4. Displaying service menu selection screen
input screen. After confirming all 4 digits of ID, display the
q [t] switch and [<] switch service menu selection screen in the service
a If the switch is pressed for longer than 5 mode.
seconds, the character display section a By inputting and determining the ID once,
becomes blank. After confirming this con- it will be effective until the starting switch
dition, release the switch. is turned off.
3. Input and determination of ID 5. Selection of the service menu

After displaying ID input screen, operate [>], If the [>] switch or [<] switch is pressed on the
[<], [U], and [t] switch and input 4 digits ID. service menu selection screen, the service
a ID: 6491 menu is displayed endlessly in the order of the
q [ > ]:Number at the cursor increases. following table, then select the menu that is
q [ < ]:Number at the cursor decreases used.
q [U]: Number at the cursor is determined q [>]: To proceed to next service menu.
q [t ]: Cursor moves to left end or the dis- q [<]: To return to previous service menu.
play returns to operator mode screen.
a If the ID input screen is left without switch
operation for longer than 60 seconds, it
automatically returns to the operator mode
screen.
HD325-7, HD405-7 31
a Displayed service menu: q When completing all operations:

Turn the starting switch OFF.
No. Display Function
[9] Electrical system failure history display
Electrical system failure history function (ELECTRIC FAULT)
1 ELECTRIC FAULT
display function The machine monitor retains the data for problems
Mechanical system failure that occurred in the electrical system in the past as
2 MACHINE FAULT
history display function failure history. They can be displayed as follows.
REAL-TIME 1. Selection of the service menu
3 Real-time monitoring function Select electrical system failure history display
MONITOR
CYLINDER function (ELECTRIC FAULT) in the service
4 Cylinder cutout mode function menu selection screen.
CUT-OUT
a The total number of failure history data
5 NO INJECTION No injection cranking function
items recorded in memory is displayed in
6 TUNING Adjusting function the [* *] portion.
MAINTENANCE Filter and oil replacement time
7
MONITOR setting function
Operation information display
8 OPERATION INFO
function
FIX POWER
9 Engine mode fixing function
MODE
OPTIONAL
10 Option selection function
SELECT
11 MACHINE Model selection function
Initialize function (exclusive
12 INITIALIZE
function for factory)
a The service menu is displayed in the

places marked with [*].
2. Failure history data display
With the service menu selected, press the [U]
switch and display the failure history data
recorded in memory.
6. Finishing mode and function

The current mode and function can be finished
by either of the following method, regardless of
the current function and hierarchy.
q When continuing operations in another
mode or function:
Press the [t] switch and return to the
mode screen to be used or menu screen
to be used.
a Note that if the [t] switch is pressed
on the YES/NO screen, the function
will be executed.
a If you return to the operator mode
screen by mistake, repeat the proce-
dure from step 1 above (however
there is no need to input the ID again).
32 HD325-7, HD405-7
3. Displayed failure history data 5. Deleting individual failure history data

With the electrical system failure history dis- 1) With the failure history data to be deleted
play function, the following data can be dis- displayed, press the [U] switch and dis-
played. play the individual deletion screen.
1: Record number (recorded up to a maxi- q [U]: Display the deletion screen
mum of 20 items) 2) When the individual deletion screen is dis-
A: Failure code (4-digits device code + 2-dig- played, operate each switch of [<], [>] and
its symptom code) [t].
2: Number of occurrences (number of occur- q [ <]: Select YES (move cursor)
rences of same code in the past) q [ >]: Select NO (move cursor)
3: Elapsed time 1 (time elapsed on service q [t]: Execute YES or NO
meter since first occurrence) a An information which is active cur-
4: Elapsed time 2 (time elapsed on service rently (display is flashing) cannot be
meter since last occurrence) deleted.
a Failure codes for problems that are still
existing are shown on a flashing display.
a Refer to failure code table of operator
mode for details of displayed failure
codes.
a Note that with the failure history display
function and failure code display function
(operator mode) for the electrical system,
the displayed data are partially different.
a If the fault history is not recorded, "-" is
displayed on the display section of 1/A/2/
3/4.
6. Deletion of all the failure history information

1) With the failure history data displayed,
press the [>] switch or [<] switch and dis-
play ALL CLEAR menu screen.
a The ALL CLEAR menu is displayed at
the end of failure history data.
4. Switching failure history display

If the [>] switch or [<] switch is pressed during
the display of failure history, the display
switches to another failure history data
recorded.
q [>]: To proceed to data for next record
number
q [<]: Go back to data for previous record 2) When the ALL CLEAR menu is displayed,
number press the [U] switch and display the ALL
CLEAR execution screen.
q [U]: Execute ALL CLEAR menu
HD325-7, HD405-7 33
3) When the ALL CLEAR execution screen is

displayed, operate each switch of [<], [>]
and [t].
q [ < ]: Select YES (move cursor)
q [ > ]: Select NO (move cursor)
q [t]: Execute YES or NO
a An information which is active cur-
rently (display is flashing) cannot be
deleted.
4) The screen changes to the fault history

screen. Check that the number of records
in ** is "0".
34 HD325-7, HD405-7
[10] Mechanical system failure history display 3. Displayed failure history data
function (MACHINE FAULT) With the mechanical system failure history dis-
The machine monitor retains the data for problems play function, the following data can be dis-
that occurred in the mechanical system in the past played.
as failure history. They can be displayed as fol- 1: Record number
lows. A: Failure code (4-digits device code + 2-dig-
its symptom code)
1. Selection of the service menu 2: Number of occurrences (number of occur-
Select mechanical system failure history dis- rences of same code in the past)
play function (MACHINE FAULT) in the service 3: Elapsed time 1 (time elapsed on service
menu selection screen. meter since first occurrence)
a The total number of failure history data 4: Elapsed time 2 (time elapsed on service
items recorded in memory is displayed in meter since last occurrence)
the [* *] portion. a Failure codes for problems that are still
existing are shown on a flashing display.
a Refer to failure code table of operator
mode for details of displayed failure
codes.
a Note that with the failure history display
function and failure code display function
(operator mode) for the mechanical sys-
tem, the displayed data are partially differ-
ent.
a If the fault history is not recorded, "-" is
displayed on the display section of 1/A/2/
3/4.
2. Failure history data display

switch and display the failure history data
recorded in memory.
4. Switching failure history display

If the [>] switch or [<] switch is pressed during
the display of failure history, the display
switches to another failure histor y data
recorded.
q [>]: To proceed to data for next record
number
q [<]: Go back to data for previous record
number
5. Deleting failure history data (not permitted)

a The failure history data for the mechanical
system cannot be deleted.
HD325-7, HD405-7 35
[11] Real time monitoring function (REAL-TIME q [>]: To proceed to next monitoring
MONITOR) system and function
The machine monitor can monitor the condition of q [<]: Go back to previous monitoring
the machine in real time through the signals from system and function
the sensors installed to various parts of the a Monitoring system and function to be
machine. displayed:
In the real time monitoring function, the following 2
No. Display System and function
types of display can be shown.
q 1 item independent display (for each controller) 1 MONITOR PANEL Machine monitor system
q 2 items simultaneous display (code input) 2 TRANSMISSION Transmission controller system
3 ENGINE Engine controller system
1. Selection of the service menu
4 BRAKE Retarder controller system
Select real time monitoring function (REAL-
TIME MONITOR) in the service menu selec- ABS controller
5 ABS
tion screen. (if equipped is installed)
2 items simultaneous monitor-
6 2 ITEMS
ing
a Monitoring system and function is dis-

played in the "*" section.
2. Display and selection of monitoring system

and function
1) With the service menu selected, press the
[U] switch to display the monitoring sys-
tem and function selection screen.
3. Setting 1 item individual monitoring
q [U]: Execute the service menu.
1) In the monitoring system and function
selection screen, select the monitoring
system (example: ENGINE) to be used.
2) If the [>] switch or [<] switch is pressed on

the monitoring system and function selec-
tion screen, the monitoring system and
device is displayed endlessly in the follow-
ing order, then select the system or func-
tion that is used.
36 HD325-7, HD405-7
2) With the monitoring system selected,

press the [U] switch and display the mon-
itoring display and item selection screen.
q [U]: Implement 1 system individual
monitoring
3) With the monitoring display and item
selection screen displayed, press the [>]
switch or [<] switch and select items to
monitor.
q [>]: To proceed to the next monitoring
item
q [<]: Return to the previous monitoring
item
a The monitored items are scroll-dis-
played due to internal setting. 5. Setting 2 items simultaneous monitoring
a If the switch is kept pressed, the mon- 1) Select 2 items simultaneous monitoring (2
itoring items scroll at high speed. ITEMS) in the monitoring system and
a In the monitoring display and item function selection screen.
selection screen, the information of 2) With 2 items simultaneous monitoring
the monitored items are displayed on selected, press the [U] switch to display
real time. the monitoring code input screen.
q [U]: Implement 2 system individual
monitoring
4) To hold or cancel monitoring data display:

If the [U] switch is pressed during moni-
toring, the monitoring data display is held
and the [U] mark flashes. If the [U]
switch is pressed again, hold is canceled
and it becomes active again.
q [U]: Hold and release of data display
4. Display data for 1 item individual monitoring

On the 1 item individual monitoring display
screen, the following data are displayed.
A: Item display
B: Monitoring code (5-digit)
1: Monitoring data (including unit)
a For details, see "Monitoring code table".
HD325-7, HD405-7 37
3) In the monitoring code input screen, oper- 6. Display data for 2 items simultaneous monitor-
ate each of the switches [>], [<], [U] and ing
[t], and directly input two monitoring On the 2 item simultaneous monitoring display
codes directly. screen, the following data are displayed.
q [ > ]: Number at the cursor increases. A : Monitoring code 1
q [ < ]: Number at the cursor decreases 1 : Monitoring data 1 (including unit)
q [U]: Number at the cursor is deter- B : Monitoring code 2
mined 2 : Monitoring data 2 (including unit)
q [ t]: Cursor moves to the left end / To a For details, see "Monitoring code table".
return to the monitoring system
and function selection screen.
4) When both of the monitoring codes have

been confirmed, the screen switches to
the 2 items simultaneous monitoring dis-
play screen.
5) To hold or cancel monitoring data display:

If the [U] switch is pressed during moni-
toring, the monitoring data display is held
and the [U] mark flashes.
If the [U] switch is pressed again, hold is
canceled and it becomes active again.
q [U]: Hold and release of data display
38 HD325-7, HD405-7
Monitoring code table
Monitor panel [machine monitor system]
Monitor-
No. Monitoring item Display of item Display range of data Unit
ing code
********
1 Part No. of software VERSION 20200 (8 digits/numerals and —
symbols)
********
2 Version No. of application VERSION (APP) 20221 (8 digits/numerals and —
symbols)
********
3 Version No. of data VERSION (DATA) 20222 (8 digits/numerals and —
symbols)
4 Rheostat (Night decrease light) RHEOSTAT 30300 0.0 – 51.0 V
0 – F, 0 – F, 0 – F, Display of
5 Rotary switch (SW1 - 3) SW1, SW2, SW3 30800
(SW1, SW2, SW3 from left) condition
ON/OFF, ON/OFF Display of
6 DIP switch (SW5-1, 2) SW5-1, SW5-2 30900
(SW5-1, SW5-2 from left) condition
01010101
10 Input signal (0 - 7) D-IN--0------7 40900 0:OFF/1:ON
(8 digits of 0/1. See detail.)
01010101
11 Input signal (8 - 15) D-IN--8-----15 40901 0:OFF/1:ON
01010101
12 Input signal (16 - 23) D-IN-16-----23 40902 0:OFF/1:ON
01010101
01010101
0101
15 Output signal (0 - 3) D-OUT-0--3 40925 0:OFF/1:ON
HD325-7, HD405-7 39
Detailed information of 40900 (D-IN--0------7) Detailed information of 40925 (D-OUT-0--3)

[0] : Dimmer switch (High beam: 1) [0] : Headlamp selection (ON: 1)
[1] : Machine monitor check switch (ON: 1) [1] : Buzzer (Operated: 1)
[2] : AISS LOW switch (ON: 1) [2] : (Unused)
[3] : (Unused) [3] : (Unused)
[4] : (Unused)
[5] : ABS system switch [If equipped]
(Installed: 1)
[6] : Dimmer switch (Passing: 1)
[7] : Power mode switch (Economy mode: 1)
Detailed information of 40901 (D-IN--8-----15)

[8] : Connector check (Always: 1)
[9]: Machine monitor mode switch
([t] is pressed: 1)
[10] : Machine monitor mode switch
([>] is pressed: 1)
([<] is pressed: 1)
[12] : Turn signal lever (Operated to right: 1)
[13] : Turn signal lever (Operated to left: 1)
([U] is pressed: 1)
[15] : (Unused)
Detailed information of 40902 (D-IN--16----23)

[16] : ARSC switch (Upper position: 1)
[17] : ARSC switch (Lower position: 1)
[18] : ABS switch (Upper position: 1)
[19] : ABS switch (Lower position: 1)
[20] : ASR switch (Upper position: 1)
[21] : ASR switch (Lower position: 1)
[22] : Front brake cut switch (ON: 1)
[23] : (Unused)

[24] : Headlamp switch (ON: 1)
[25] : Seat belt switch (Belt is fastened: 1)
[26] : (Unused)
[27] : (Unused)
[28] : (Unused)
[29] : (Unused)
[30] : (Unused)
[31] : (Unused)

[32] : (Unused)
[33] : (Unused)
[34] : Connector check (Always: 1)
[35] : (Unused)
[36] : (Unused)
[37] : (Unused)
[38] : (Unused)
[39] : (Spare for service)
40 HD325-7, HD405-7
Transmission [Transmission controller system]
Monitor-
ing code
********
1 Part No. of software VERSION 20201 (8 digits/numerals and —
symbols)
********
symbols)
********
symbols)
0 – 32767
4 Transmission input shaft speed T/M SPEED:IN 31200 rpm
Transmission intermediate shaft 0 – 32767
5 T/M SPEED:MID 31300 rpm
speed ---- [Other than above]
0 – 32767
6 Transmission output shaft speed T/M SPEED:OUT 31400 rpm
0 – 250
7 Fuel level FUEL SENSOR 04201 z
0.00 – 5.00
8 Fuel level FUEL SENSOR 04200 V
9 Alternator R ALTERNATOR R 04301 OFF/ON 0:OFF/1:ON
0 – 160
10 Torque converter oil temperature T/C OIL TEMP 30100 °C
0.00 – 5.00
11 Torque converter oil temperature T/C OIL TEMP 30101 V
0 – 160
12 Transmission oil temperature T/C OIL TEMP 32500 °C
0.00 – 5.00
13 Transmission oil temperature T/C OIL TEMP 32501 V
0 – 160
14 Steering oil temperature STRG OIL TEMP 32701 °C
0.00 – 5.00
15 Steering oil temperature STRG OIL TEMP 32702 V
0.00 – 5.00
16 Torque converter oil pressure T/C OIL PRESS 32600 MPa
0.00 – 5.00
17 Torque converter oil pressure T/C OIL PRESS 32605 V
0.00 – 99.99
18 Accumulator oil pressure (front) ACC OIL PRE F 35500 MPa
0.00 – 99.99
19 Accumulator oil pressure (rear) ACC OIL PRE R 35501 MPa
0.00 – 5.00
20 Accumulator oil pressure (front) ACC OIL PRE F 35504 V
0.00 – 5.00
21 Accumulator oil pressure (rear) ACC OIL PRE R 35505 V
HD325-7, HD405-7 41
Monitor-
ing code
0 – 1000
22 Solenoid output (high) ECMV H DIR 31600 mA
0 – 1000
23 Solenoid output (low) ECMV L DIR 31601 mA
0 – 1000
24 Solenoid output (1st) ECMV 1 DIR 31602 mA
0 – 1000
25 Solenoid output (2nd) ECMV 2 DIR 31603 mA
0 – 1000
26 Solenoid output (3rd) ECMV 3 DIR 31604 mA
0 – 1000
27 Solenoid output (4th) ECMV 4 DIR 31605 mA
0 – 1000
28 Solenoid output (R) ECMV R DIR 31606 mA
0 – 1000
29 Solenoid output (lockup) ECMV LU DIR 31609 mA
-180.0 – +180.0
30 Pitch angle sensor ANGLE SENSOR 32900 ° [degree]
0.00 – 5.00
31 Pitch angle sensor ANGLE SENSOR 32903 V
0 – 100
32 Brake output (front wheel) BK OUTP DIR F 33807 %
0 – 100
33 Brake output (rear wheel) BK OUTP DIR R 33806 %
-100 – 100
34 Throttle correction value THROTTLE MOD 36000 %
0/1 0: NORMAL
35 Skip shift holding state TM SKIP SHIFT 38600
(1 digit of 0/1) 1: KEEP
0 – 17
(Data transmitted from
36 Gear shift mode state TM SHIFT MODE 38700 transmission controller is —
displayed)
0 – 17
(Data transmitted from
TM OPERATE
37 Travel mode state 38701 transmission controller is —
MODE
displayed)
Low clutch trigger correction 00000000 – FFFFFFFF Display of
38 TRIGGER MOD L 38900
quantity (8 digits of 0 – F) condition
High clutch trigger correction 00000000 – FFFFFFFF Display of
39 TRIGGER MOD H 38901
1st clutch trigger correction 00000000 – FFFFFFFF Display of
40 TRIGGER MOD 1 38902
2nd clutch trigger correction 00000000 – FFFFFFFF Display of
42 HD325-7, HD405-7
Monitor-
ing code
3rd clutch trigger correction 00000000 – FFFFFFFF Display of
4th clutch trigger correction 00000000 – FFFFFFFF Display of
R clutch trigger correction 00000000 – FFFFFFFF Display of
44 TRIGGER MOD R 38906
0101010 Recognition of
45 Clutch fill switch FILL HL1234R 38919 (Data is displayed under fill switch
HL1234R) 0:OFF/1:ON
0101010 Learning flag
46 Trigger initial learning flag TRIG HL1234R 38920 (Data is displayed under of clutch
HL1234R) 0:OFF/1:ON
0 – 2550
47 Fill time (low) FILL TIME L 41800 ms
0 – 2550
48 Fill time (high) FILL TIME H 41801 ms
0 – 2550
49 Fill time (1st) FILL TIME 1 41802 ms
0 – 2550
50 Fill time (2nd) FILL TIME 2 41803 ms
0 – 2550
51 Fill time (3rd) FILL TIME 3 41804 ms
0 – 2550
52 Fill time (4th) FILL TIME 4 41805 ms
0 – 2550
53 Fill time (R) FILL TIME R 41806 ms
Throttle quantity lower limit value 0.0 – 100.0
54 THROT LIMIT LO 44201 %
output ---- [Other than above]
Throttle quantity upper limit value 0.0 – 100.0
55 THROT LIMIT HI 44200 %
output ---- [Other than above]
01010101
56 Input signal (0 – 7) D-IN--0------7 40905 0:OFF/1:ON
01010101
57 Input signal (8 – 15) D-IN--8-----15 40906 0:OFF/1:ON
01010101
58 Input signal (16 – 23) D-IN-16-----23 40907 0:OFF/1:ON
01010101
0
01010101
61 Output signal (0 – 7) D-OUT-0------7 40949 0:OFF/1:ON
01010101
62 Output signal (8 – 15) D-OUT-8-----15 40950 0:OFF/1:ON
01010101
63 Output signal (16 – 23) D-OUT-16----23 40951 0:OFF/1:ON
HD325-7, HD405-7 43
Detailed information of 40905 (D-IN--0------7) Detailed information of 40949 (D-OUT--0------7)

[1] : Transmission filter switch [1] : (Unused)
[3] : Emergency escape switch (ON: 1) [3] : (Unused)
[4] : Starting switch C terminal signal (Start of [4] : (Unused)
engine: 1) [5] : (Unused)
[6] : Emergency steering relay 1 (Driving: 1) [7] : (Unused)
[7] : Gearshift lever (N position: 1)
Detailed information of 40950 (D-OUT--8-----15)
Detailed information of 40906 (D-IN--8-----15) [8] : (Unused)
[8] : Low clutch fill switch (ON: 1) [9] : (Unused)
[9] : 4th clutch fill switch (ON: 1) [10] : (Unused)
[10] : High clutch fill switch (ON: 1) [11] : (Unused)
[11] : 1st clutch fill switch (ON: 1) [12] : (Unused)
[12] : 2nd clutch fill switch (ON: 1) [13] : (Unused)
[13] : 3rd clutch fill switch (ON: 1) [14] : (Unused)
[14] : Reverse clutch fill switch (ON: 1) [15] : (Unused)
[15] : (Unused)
Detailed information of 40951 (D-OUT--16-----23)
Detailed information of 40907 (D-IN--16----23) [16] : (Unused)
[16] : Gearshift lever (R position: 1) [17] : (Unused)
[17] : Gearshift lever (D position: 1) [18] : (Unused)
[18] : Gearshift lever (6 position: 1) [19] : (Unused)
[23] : Gearshift lever (L position: 1)

[24] : (Unused)
[25] : Coolant level
[26] : Air cleaner switch
[27] : Main pressure variable valve pressure switch
[28] : Main flow rate selector valve pressure switch
[29] : Lubricating oil quantity variable valve pres-
sure switch
[30] : (Unused)
[31] : (Unused)

[32] : (Unused)
44 HD325-7, HD405-7
Engine [Engine controller system]
Monitor-
ing code
1 Serial No. of hardware ECM S/N 20400 0 – 49999999 —
0.0 – 480.0
2 Battery voltage POWER SUPPLY 03200 V
0 – 4000
3 Engine speed ENG SPEED 01002 rpm
-40 – 210
4 Engine coolant temperature COOLANT TEMP 04104 °C
Engine coolant temperature sen- 0.00 – 5.00
5 COOLANT TEMP 04105 V
sor voltage ---- [Other than above]
-99.9 – 999.9
6 Oil pressure sensor ENG OIL PRESS 37200 kPa
0.00 – 5.00
7 Oil pressure sensor voltage ENG OIL PRESS 37201 V
-40 – 210
8 Engine oil temperature ENG OIL TEMP 42700 °C
Engine oil temperature sensor 0.00 – 5.00
9 ENG OIL TEMP 42702 V
voltage ---- [Other than above]
0 – 400
10 Common rail pressure RAIL PRESS 36400 MPa
Common rail pressure sensor 0.00 – 5.00
11 RAIL PRESS 36402 V
-99.9 – 999.9
12 Atmospheric pressure AMBIENT PRESS 37400 kPa
Atmospheric pressure sensor 0.00 – 5.00
13 AMBIENT PRESS 37402 V
-50 – 200
14 Intake air temperature INTAKE TEMP 18400 °C
Intake air temperature sensor 0.00 – 5.00
15 INTAKE TEMP 18401 V
-40 – 210
16 Fuel temperature FUEL TEMP 04204 °C
0.00 – 5.00
17 Fuel temperature sensor voltage FUEL TEMP 04201 V
-50 – 200
18 Boost temperature CHG TEMP 18500 °C
Boost temperature sensor volt- 0.00 – 5.00
19 CHG TEMP 18501 V
age ---- [Other than above]
-99.9 – 999.9
20 Boost pressure CHG PRESS-A 36500 kPa
0.00 – 5.00
21 Boost pressure sensor voltage CHG PRESS-A 36502 V
-99.9 – 999.9
22 EGR valve differential pressure EGR DIF PRESS 17900 kPa
EGR valve differential pressure 0.00 – 5.00
23 EGR DIF PRESS 17901 V
sensor voltage ---- [Other than above]
-99.9 – 999.9
24 EGR valve inlet pressure EGR IN PRESS-A 18000 kPa
HD325-7, HD405-7 45
Engine [Engine controller system]
Monitor-
ing code
EGR valve inlet pressure sensor 0.00 – 5.00
25 EGR IN PRESS-A 18002 V
0.00 – 99.99
26 EGR valve position EGR VALVE POS 18100 mm
EGR valve position sensor volt- 0.00 – 5.00
27 EGR VALVE POS 18101 V
age ---- [Other than above]
-24000 – 24000
28 Engine output torque OUTPUT TORQUE 18700 Nm
0 – 100
29 Converted torque TORQUE RATIO 36700 %
0 – 100
30 Final accelerator position FINAL THROTTLE 31706 %
0.0 – 999.9
31 Momentary fuel consumption FUEL RATE 37300 L/h
Final injection rate command 0 – 1000
32 INJECT COMMAND 18600 mg
(by weight) ---- [Other than above]
-180.0 – 180.0
33 Final injection timing command INJECT TIMING 36300 CA
0 – 100
34 Accelerator pedal position THROTTLE POS 31701 %
Accelerator pedal position sen- 0.00 – 5.00
35 THROTTLE POS 31707 V
sor voltage ---- [Other than above]
0.00 – 99.99
36 Bypass valve position BPS VALVE POS 18200 mm
Bypass valve position sensor 0.00 – 5.00
37 BPS VALVE POS 18202 V
38 Idling validation signal IVS 1 18300 ON or OFF —
39 Idling validation signal IVS 2 18301 ON or OFF —
-40 – 210
40 Controller inside temperture ECM IN TEMP 18900 °C
Final common rail pressure com- 0 – 400
41 PRESS COMMAND 36200 MPa
mand ---- [Other than above]
PCV valve closing timing (based -180 – 180
42 PCV TIMING 17201 CA
on BTDC) ---- [Other than above]
43 Engine mode selection POWER MODE 17500 0–4 —
Transmitted value is dis-

44 Selected model (left 8 digits) MACHINE ID (H) 00400 —
played (Left 8 of 16 letters)
45 Selected model (right 8 digits) MACHINE ID (L) 00401 —
played (Left 8 of 16 letters)
46 Build version No. BUILD VER 20216 —
played (8 letters)
47 Calibration data version No. CAL VER 20217 —
played (8 letters)
a "CA" in the unit column is an abbreviation for the Crankshaft Angle.
46 HD325-7, HD405-7
Brake [Retarder controller system]
Monitor-
ing code
********
1 Version of software VERSION 20214 (8 digits/numerals and —
symbols)
********
symbols)
********
symbols)
0.00 – 5.00
4 ARSC set switch ARSC SET SP SW 37701 V
Transmission output shaft 0 – 32767
5 T/M SPEED:OUT 31403 rpm
speed ---- [Other than above]
0 – 32767
6 Wheel speed (left) WHEEL SPEED L 39705 rpm
0 – 32767
7 Wheel speed (right) WHEEL SPEED R 39704 rpm
Retarder cooling oil tempera- 0 – 160
8 BRAKE OIL T R 30211 °C
ture (rear) ---- [Other than above]
Retarder cooling oil tempera- 0.00 – 5.00
9 BRAKE OIL T R 30212 V
ture (rear) ---- [Other than above]
0 – 1000
10 Brake output (front wheel) BK OUTP DIR F 33700 mA
0 – 1000
11 Brake output (rear wheel) BK OUTP DIR R 33806 mA
0.00 – 5.00
12 Retarder lever voltage RETARD LEVER 33900 V
0.00 – 5.00
13 Body positioner BODY POSITION 34602 V
Dump lever (Hoist lever) poten- 0.00 – 5.00
14 DUMP LEVER 1 34304 V
tiometer 1 ---- [Other than above]
Dump lever (Hoist lever) poten- 0.00 – 5.00
15 DUMP LEVER 2 34305 V
tiometer 2 ---- [Other than above]
0 – 1000
16 Hoist EPC output HOIST EPC DIR 45600 mA
Seating control command 0 – 1000
17 S CNT DIR H 45102 mA
(high) ---- [Other than above]
Seating control command 0 – 1000
18 S CNT DIR L 45103 mA
(low) ---- [Other than above]
Seating condition calibration 0.00 – 5.00
19 S CAL A 45201 V
value ( ) ---- [Other than above]
Cylinder stopper calibration 0.00 – 5.00
20 S CAL B 45301 V
value ( ) ---- [Other than above]
0.0 – 10.00
21 Seating control time (high) S CNT TIME H 45402 second
0.0 – 10.00
22 Seating control time (low) S CNT TIME L 45403 second
23 Shut-off valve output SHUT OFF VALVE 45700 0/1 (1 digit of 0/1) 0:OFF/1:ON
HD325-7, HD405-7 47
Brake [Retarder controller system]
Monitor-
ing code
-180.0 – +180.0
24 Steering angle sensor STRG ANGLE 35402 ° (degree)
0.00 – 5.00
25 Steering angle sensor STRG ANGLE 35400 V
0.0 – 99.99
26 Steering speed STRG ANG SPEED 35403 rad/second
0.00 – 20.10
27 Suspension pressure (left) SUS PRESS (L) 32814 MPa
0.00 – 5.00
28 Suspension pressure (left) SUS PRESS (L) 32815 V
0.00 – 20.10
29 Suspension pressure (right) SUS PRESS (R) 32816 MPa
0.00 – 5.00
30 Suspension pressure (right) SUS PRESS (R) 32817 V
0/1 (1 digit of 0/1) --- [Other
31 Judgment of empty/loaded EMPTY OR LOAD 39400 0:EMPTY/1:LOAD
than above]
0 – 1020
32 ASR output (left) command ASR OUTP DIR L 39601 mA
0 – 1020
33 ASR output (right) command ASR OUTP DIR R 39603 mA
01010101
34 Input signal (0 – 7) D-IN--0------7 40932 0:OFF/1:ON
01010101
35 Input signal (8 – 15) D-IN--8-----15 40933 0:OFF/1:ON
01010101
01010101
0
01010101
39 Output signal (0 – 7) D-OUT-0------7 40955 0:OFF/1:ON
01010101
40 Output signal (8 – 15) D-OUT-8-----15 40956 0:OFF/1:ON
01010101
41 Output signal (16 – 23) D-OUT-16----23 40957 0:OFF/1:ON
48 HD325-7, HD405-7
Detailed information of 40932 (D-IN--0------7) Detailed information of 40955 (D-OUT--0------7)

[0] : (Unused) [0] : Auto-suspension solenoid 1
[1] : Service brake switch [1] : Hoist selector valve
[2] : (Unused) [2] : Lever kick-out solenoid
[3] : Retarder switch (Rear) [3] : Auto-suspension solenoid 2
[4] : Validation switch 1 [4] : Front brake cut valve
[5] : Validation switch 2 [5] : (Unused)
[6] : Memory clear switch [6] : (Unused)
[7] : Brake oil filter [7] : (Unused)
Detailed information of 40933 (D-IN--8-----15) Detailed information of 40956 (D-OUT--8-----15)

[8] : ASR pressure switch (Rear left) [8] : (Unused)
[9] : ASR pressure switch (Rear right) [9] : (Unused)
[10] : Shut-off valve switch [10] : (Unused)
[11] : ASR check switch [11] : ASR shut-off valve
[12] : Parking brake pressure switch [12] : (Unused)
[13] : (Unused) [13] : (Unused)
[14] : (Unused) [14] : (Unused)
[15] : Secondary brake switch [15] : Body "Float" signal
Detailed information of 40934 (D-IN--16----23) Detailed information of 40957 (D-OUT--16-----23)

[16] : Starting switch C terminal signal [16] : Stop lamp relay
[17] : (Unused) [17] : (Unused)
[18] : (Unused) [18] : Sensor power supply (24 V)
[19] : Brake wear switch (Rear left) [19] : BCV relay
[20] : Brake wear switch (Rear right) [20] : (Unused)
[21] : (Unused) [21] : (Unused)
[22] : (Unused) [22] : (Unused)
[23] : (Unused) [23] : (Unused)

[24] : Steering wheel speed
[25] : (Unused)
[26] : Retarder cooling filter
[27] : Engine oil level switch
[28] : Engine oil filter
[29] : Steering hoist level switch
[30] : Steering hoist filter switch
[31] : Battery electrolyte level switch

[32] : Transmission/Brake oil level switch
HD325-7, HD405-7 49
ABS [ABS controller system] (If equipped)
Monitor-
ing code
1 Part No. of software VERSION 20210 ******** (8 digits/symbols) —
2 Version No. of application VERSION (APP) 20233 ******** (8 digits/symbols) —
3 Version No. of data VERSION (DATA) 20234 ******** (8 digits/symbols) —
0 – 3000
4 Wheel speed (front left) WHEEL SPEED FL 39706 rpm
0 – 3000
5 Wheel speed (front right) WHEEL SPEED FR 39707 rpm
0 – 3000
6 Wheel speed (rear left) WHEEL SPEED RL 39708 rpm
0 – 3000
7 Wheel speed (rear right) WHEEL SPEED RR 39709 rpm
01010101
8 Input signal (0 - 7) D-IN--0------7 40937 0:OFF/1:ON
01010101
9 Input signal (8 - 15) D-IN--8-----15 40938 0:OFF/1:ON
01010101
01010101
01010101
12 Output signal (0 - 7) D-OUT-0------7 40958 0:OFF/1:ON
01010101
13 Output signal (8 - 15) D-OUT-8-----15 40959 0:OFF/1:ON
01010101
14 Output signal (16 - 23) D-OUT-16----23 40960 0:OFF/1:ON
ABS control valve output 0 – 1000
15 ABS CNT VAL FL 43308 mA
(front left) ---- [Other than above]
16 ABS CNT VAL FR 43309 mA
(front right) ---- [Other than above]
17 ABS CNT VAL RL 43310 mA
(rear left) ---- [Other than above]
18 ABS CNT VAL RR 43311 mA
(rear right) ---- [Other than above]
ABS control oil pressure 0.00 – 99.99
19 CONT PRESS FL 43312 MPa
20 CONT PRESS FL 43313 V
21 CONT PRESS FR 43314 MPa
22 CONT PRESS FR 43315 V
50 HD325-7, HD405-7
ABS [ABS controller system] (If equipped)
Monitor-
ing code
23 CONT PRESS RL 43316 MPa
24 CONT PRESS RL 43317 V
25 CONT PRESS RR 43318 MPa
26 CONT PRESS RR 43319 V
HD325-7, HD405-7 51
Detailed information of 40937 (D-IN--0------7) Detailed information of 40959 (D-OUT--8-----15)

[0] : ABS cut pressure switch (Front) [8] : (Unused)
[1] : ABS cut pressure switch (Rear) [9] : (Unused)
Detailed information of 40938 (D-IN--8-----15) Detailed information of 40960 (D-OUT--16-----23)

[10] : (Unused) [18] : ABS cut valve (Front) (* Through relay)
[11] : (Unused) [19] : ABS control valve (Rear) (* Through relay)
[12] : (Unused) [20] : (Unused)
[13] : (Unused) [21] : (Unused)
[14] : (Unused) [22] : (Unused)
[15] : (Unused) [23] : (Unused)

[16] : Starting switch C terminal signal
[17] : (Unused)
[18] : (Unused)
[19] : (Unused)
[20] : (Unused)
[21] : (Unused)
[22] : (Unused)
[23] : (Unused)

[24] : (Unused)
[25] : (Unused)
[26] : (Unused)
[27] : (Unused)
[28] : (Unused)
[29] : (Unused)
[30] : (Unused)
[31] : (Unused)
Detailed information of 40958 (D-OUT--0------7)

[0] : (Unused)
[1] : (Unused)
[2] : (Unused)
[3] : (Unused)
[4] : (Unused)
[5] : (Unused)
[6] : (Unused)
[7] : (Unused)
52 HD325-7, HD405-7
[12] Reduced cylinder mode (CYLINDER CUT- 3. Setting cut-out cylinder

OUT) In the reduced cylinder mode execution
As one method of troubleshooting for the engine, screen, operate each of the switches [>], [<],
the machine monitor has a reduced cylinder mode [U] and [t] to select the cut-out cylinder.
that can set the desired cylinder to the no injection q [ > ]: Selector cursor moves to the right.
condition. q [ < ]: Selector cursor moves to the left.
q [U]: Determine the cylinder.
1. Starting engine q [ t]: To return to the service menu selec-
Use this function while the engine is running, tion screen.
because a defective cylinder is determined a When the [U] switch is used to confirm
depending on the engine speed in the reduced the cut-out cylinder, communication is car-
cylinder mode. ried out between the machine monitor and
engine controller. During this time, the cyl-
2. Selection in the service menu inder No. flashes.
1) Select the reduced cylinder mode (CYLIN- After completion of the communication,
DER CUT-OUT) in the service menu the segment under the cylinder No.
selection screen. becomes black to show that the cylinder
has been cut out.
a A single cylinder or multiple cylinders can
be cut out.

[U] switch and display the reduced cylin-
der mode implementation screen.
4. Canceling cylinder cut-out
a The cylinder No. and the engine
Cancellation of cylinder cut-out is done by the
speed are displayed on the upper
same procedure as setting cut-out cylinder.
line, and the final injection amount
a When the [U] switch is used to confirm
command is displayed on the lower
the cancellation of the cut-out cylinder,
line.
communication is carried out between the
a When being switched to the reduced
machine monitor and engine controller.
cylinder mode implementation
During this time, the cylinder No. flashes.
screen, the cursor of cylinder selec-
After completion of the communication,
tion is always displayed under the
the segment under the cylinder No.
No.1 cylinder.
becomes white to show that the cylinder
cut-out has been canceled.
HD325-7, HD405-7 53
[13] No injection cranking function 3. Setting is denied during engine running

(NO INJECTION) During engine running, if the setting of no
The machine monitor has the function of no injec- inj ec tion cr ank in g i s attemp ted, " STOP
tion cranking, which carries out cranking after long- ENGINE" is displayed in the lower line, and
term storage, stopping fuel injection of all the cylin- setting is rejected.
ders without starting the engine. a No injection cranking function cannot be
a The function of no injection cranking must be used during engine running.
operated under the condition that the engine is
stopped.
1. Selection in the service menu

In the service menu selection screen, select
none injection cranking function (NO INJEC-
TION).
4. Canceling no injection cranking

If the [t] switch is pressed on the no injection
cranking execution screen, the screen returns
to the service menu selection screen and the
no injection cranking is cancelled.
q [t]: To return to the service menu selec-
tion screen.
2. Establishment of no injection cranking
switch to display none injection cranking exe-
cution screen.
a If "CRANKING READY" is displayed on
the lower line, the no injection cranking is
set.
a If the starting switch is operated to the
START position under this condition, the
engine cranks but will not start.
54 HD325-7, HD405-7
[14] Adjustment function (TUNING) The adjustment is implemented by operating the

Machine monitor can run "Adjusting transmission machine monitor and machine body following the
ECMV electric current" and "Reset the transmission below procedures below.
initial learning and implement learning " through the 1. Preparing operations for "Adjusting transmis-
transmission controller. sion ECMV electric current"
When power train related operation such as the fol- (Real time monitoring function)
lowing is carried out, execute the adjustment oper- 2. Adjusting transmission ECMV electric current
ation. (02: AUTO of ECMV TUNING)
q When transmission is overhauled or changed 3. Reset the transmission initial learning and
q When transmission valve is replaced implement learning (TUNED/Real-time moni-
q Transmission controller has been replaced. toring function for 01: TM TRIGGER)
q When an abnormality occurred in the power a ( ) indicates service menu or adjustment func-
train speed sensor and has the sensor been tion used for the adjustment.
repaired (refer to the table below for failure a [MANUAL] menu of [02: ECMV TUNING] is the
code) function only used by plants and not used for
q If the transmission oil temperature sensor is field services.
troubled and repaired (refer to the below table a For details concerning the operation method of
for failure code) real time monitoring function, refer to "[11] real
q If the transmission oil filter is clogged and time monitoring function".
repaired (refer to the table below for failure
code)
1. Preparing operations for "Adjusting trans-

mission ECMV current"
Failure code Device name a The adjusting operation should be carried
DLF1KA out with the specified oil temperature.
Transmission input shaft speed
sensor Confirm the machine is not displaying
DLF1LC
abnormality and adjust the transmission oil
DLF2KA Transmission intermediate shaft temperature following the next procedure.
DLF2LC speed sensor 1) Select real time monitoring function
Transmission output shaft speed (REAL-TIME MONITOR) in the service
DLF3KA menu selection screen.
sensor
Transmission oil temperature
DGF1KX
sensor
15BONX Transmission oil filter
HD325-7, HD405-7 55
2) With the service menu selected, press the 7) Keep depressing the brake pedal, and set
[U] switch to display the monitoring sys- the gear shift lever to D position.
tem and function selection screen. a Confirm that the shift indicator dis-
q [U]: Execute service menu plays "F2".
3) In the monitoring system and function 8) Stall the torque converter to raise the
selection screen, press [>] switch or [<] transmission oil temperature up to 70 – 80
switch to select transmission system °C.
(TRANSMISSION). a Be careful not to overheat the oil
q [>]: To proceed to next monitoring while stalling the torque converter.
system and function 9) Return the gear shift lever to "N" position,
q [<]: To go back to previous monitoring keep it for 3 minutes, and confirm that the
system and function transmission oil temperature is stable
between 70 – 80 °C.
a In addition to the above, check that
the machine has not detected a trou-
ble.
2. Adjusting transmission ECMV electric cur-

rent
a Adjustment is carried out four times auto-
matically against the Hi, Lo, R, 1st, 2nd,
3rd and 4th valves respectively.
1) Refer to "1. Preparation of operations for
adjusting transmission ECMV electric cur-
rent", and select the monitoring code of
transmission oil temperature.
4) With the transmission system selected, q Monitoring code:
press the [U] switch to display the moni- 32500 (T/M OIL TEMP)
toring display and item selection screen. a At this time, do not start the engine.
q [U]: Execute 1 system individual mon-
itoring
q The program version No. is displayed
on ********.
5) In the monitoring display and item selec-
tion screen, press [>] switch or [<] switch
and select monitoring code of transmis-
sion oil temperature.
q [>]: Goes on to the next monitoring
item
q [<]: Goes back to the previous moni-
toring item
q Monitoring code:
32500 (T/M OIL TEMP)
2) Run the engine, set the machine to the
next condition, and confirm that the trans-
mission oil temperature is between 70 –
80 °C.
q Parking break switch: PARKING
q AISS LOW switch: LOW (low speed)
q Gear shift lever: N position
q Engine: Low idle
q Accelerator pedal: OFF (Released)
6) Confirm that the parking brake switch is

set to PARKING, and start the engine.
56 HD325-7, HD405-7
3) Return to the service menu selection a The figure shows the state in which
screen, and select the adjustment function the automatic compensation is
(TUNING). selected, therefore, [AUTO] is indi-
a Press [t] switch several times to cated in the lower line. \ In the state in
return to the service menu selection which the manual compensation is
screen. selected, [MANUAL] is indicated in
the lower line.
4) While the service menu is selected, hold

down the [U] switch for a minimum of 5 7) Confirm the machine condition again and
seconds to display the adjustment menu press the [U] switch to start adjustment.
selection screen. q [U] switch: To start the adjustment
q [U]: Execute service menu a The lower line display changes from
5) On the adjustment menu selection screen, "IP" to "IP ***".
press [>] switch or [<] switch, to select
ECMV current adjustment item (02: ECMV
TUNING).
q [>]: To proceed to the next adjust-
ment item
q [<]: To go back to the previous adjust-
ment item
a Adjustments are carried out 4 times

c on ti nu ous l y f or e ac h o bj ec ti v e
clutch, and the table below is dis-
played.
No. Valve 1st time 2nd time 3rd time 4th time
1 LOW IP L-1 IP L-2 IP L-3 IP L-4
6) With the adjustment item selected, press 2 HIGH IP H-1 IP H-2 IP H-3 IP H-4
[U] switch and display the automatic com- 3 1ST IP 1-1 IP 1-2 IP 1-3 IP 1-4
pensation (AUTO) or manual compensa-
4 2ND IP 2-1 IP 2-2 IP 2-3 IP 2-4
tion (MANUAL) selection screen. Press
[<] switch or [>] switch to select the auto- 5 3RD IP 3-1 IP 3-2 IP 3-3 IP 3-4
matic compensation (AUTO). 6 REV IP R-1 IP R-2 IP R-3 IP R-4
q [U]: To execute the adjustment menu 7 4TH IP 4-1 IP 4-2 IP 4-3 IP 4-4
q [ > ]: To switch to the next compensa-
tion screen.
q [ < ]: To switch to the previous com-
pensation screen.
q Compensation menu: AUTO
HD325-7, HD405-7 57
8) Normal and abnormal results are dis- 3. Reset the transmission initial learning and
played for each adjustment, therefore take implementation of learning
action depending on the display. a Before carrying out this adjustment item,
be sure to implement "2. Transmission
ECMV current adjustment".
a Before proceeding to the learning, confirm
that the transmission oil temperature is at
the specified temperature referring to "1.
Preparing operations for "Adjusting trans-
mission ECMV electric current". (If adjust-
ments are made at temperatures other than
specified temperature, time lag or gear
shift shock may occur.)
k The learning should be carried out in
an area with a sufficient traveling dis-
tance, paying attention to the sur-
q Indicated code for the normal or ab- roundings for safety.
normal result 1) Select the adjusting function (TUNING) in
Code Condition the service menu selection screen.
OK Normal result
NG1 Out of compensation conditions
Abnormal
NG2 No fill
result
NG3 Over the compensation values
q If "OK" (normal result) is displayed:
Adjustment is done without error.
q If "NG1" is displayed (out of compen-
sation condition):
Adjust the transmission oil tempera-
ture exactly, and confirm the machine
setting conditions again, then c a r r y
out the adjustment from procedure 1).
q If "NG2" (no fill) is displayed: 2) With the service menu selected, hold down
Carry out troubleshooting of failure the [U] switch for a minimum of 5 seconds
code [15S*MA][DDT*KA], and if the to display the adjustment menu selection
condition is confirmed to be normal, screen.
then start again from procedure 1) q [U]: Execute the service menu.
(The symbol with * mark varies by 3) On the adjustment menu selection screen,
objective clutches). confirm that the transmission trigger
q If "NG3" is displayed (compensation adjustment item (01: TM TRIGGER) is dis-
value over): played.
Carry out troubleshooting of failure
code [15S*L1], and if the condition is
confirmed to be normal, then start i t
again from procedure 1) (The symbol
with * mark varies by objective clutch-
es).
9) If the adjustments has been completed nor-
mally, the adjustment values are recorded
in the transmission controller about 3 sec-
onds after the starting switch has been
turned off.
a If the starting switch needs to be
turned ON soon after the adjustment,
keep the starting switch in the OFF
position for more than 10 seconds as
a precautionary measure then turn it
ON.
58 HD325-7, HD405-7
4) With the adjustment menu selected, press

the [U] switch to display the initial learn-
ing resetting screen.
q [U]: To execute the adjustment menu
a The current initialization state is dis-
played in the lower line.
q Initialization is done: INITIAL STATUS
q Initialization is not yet done: TUNED
a If [TUNED] is indicated, proceed to
the next procedure to initialize the
learning data.
a If the resetting operation is to be
aborted, press [t] switch to return to
the previous screen.
7) Return to service menu selection screen
q [t]: To return to the previous screen
and select real time monitoring function
(REAL-TIME MONITOR).
a Press [t] switch several times to
return to the service menu selection
screen.
5) With the initial learning resetting screen

displayed, press the [U] switch to display
the initializing operation screen.
q [U] switch:
To execute the initial learning reset
[U] switch to display the monitoring sys-
tem and function selection screen.
9) In the monitoring system and function
selection screen, press [>] switch or [<]
switch to select 2 items simultaneous
monitoring (2 ITEMS).
q [>]: To proceed to next monitoring
system and function
q [<]: Go back to previous monitoring
system and function
6) With the initialization operation screen dis-

played, operate each of the switches [<],
[>] and [t] to execute initialization.
q [ < ]: To select YES (The cursor moves)
q [ > ]: To select NO (The cursor moves)
a After initializing, confirm that the dis-
play on the lower line indicates that
initialization is completed.
q Initialization is done: INITIAL STATUS
HD325-7, HD405-7 59
10) With 2 items simultaneous monitoring se-

lected, press the [U] switch to display the
monitoring code input screen.
q [U]: Execute monitoring system and
function.
11) In the monitoring code input screen, oper-
ate the switches [>], [<], [U] and [t], to
input two monitoring codes directly.
q [ > ]: Number at the cursor increases.
q [ < ]: Number at the cursor decreases
q [U]: Number at the cursor is deter-
mined
q [ t]: Cursor moves to the left end / To
return to the monitoring system
15) Set the gearshift lever to the "6" position
and function selection screen.
and press the accelerator pedal fully to
q Monitoring code: 32500 and 38920
run the truck and shift up the gear to F6.
a Indicate the transmission oil tempera-
a Shift up: F1 o F2 o F3 o F4 o F5 o
ture in the upper row (32500) and
F6
study condition of clutch trigger in the
16) After the gear is shifted up to F6, release
lower row (38920) (0: not learned yet,
the accelerator pedal and shift down the
1: already learned).
gear to F1 by coasting run.
a Shift down: F6 o F5 o F4 o F3 o F2
o F1
a Do not apply the brake during coast-
ing run.
17) Check that the trigger learning of the 4th
clutch is displayed on the monitor.
a If "1" is displayed, go to the next step.
a If the display is "0", repeat procedure
15) – 16) until it becomes "1".
a If "1" is not displayed after repeating
the steps 4 times, the ECMV may be
defective. In this case, replace the
ECMV.
12) Set AISS LOW switch to LOW. a The * marked clutch display can be
13) Start the engine, keep the gear shift lever either "0" or "1".
at N position for 10 seconds with engine at
low idle, then operate the gear shift lever
as follows.
a Gear shift lever operation:
NoRoN
14) Confirm the trigger learning display of R
clutch in the monitoring display.
a Proceed to the next step if the display
is "1".
a If the display is "0", repeat procedure
13) until it becomes "1".
ECMV.
a The * marked clutch display can be
either "0" or "1".
60 HD325-7, HD405-7
18) Set the gearshift lever to the "4" position 23) Check that the trigger learning of the Hi
and press the accelerator pedal fully to clutch is displayed on the monitor.
run the truck and shift up the gear to F4. a If "1" is displayed, go to the next step.
a Shifting up: F1 o F2 o F3 o F4 a If "0" is displayed, repeat steps 21) –
19) After running the machine at F4 for 10 23) until "1" is displayed.
seconds, release the accelerator pedal a If "1" is not displayed after repeating
and shift down the gear to F1 by coasting the steps 4 times, the ECMV may be
run. defective. In this case, replace the
a Shifting down: F4 o F3 o F2 o F1 ECMV.
a Do not apply the brake during coast- a The * marked clutch display can be
ing run. either "0" or "1".
20) Check that the trigger learning of the 2nd
a If "1" is displayed, go to the next step.
a If "0" is displayed, repeat steps 18) –
20) until "1" is displayed.
ECMV.
a The * marked clutch display can be
either "0" or "1".

and press the accelerator pedal fully to shift
up the gear to F3 and then continue travel
at F3, adjusting the accelerator pedal.
a Shifting up: F1 o F2 o F3
25) After running the machine at F3 for 10
seconds, press the accelerator pedal fully
to shift up the gear to F4.
a Shifting up: F3 o F4
26) Stop the machine and check that the trig-
ger learning of the low clutch and 3rd
21) Set the gearshift lever to the "3" position clutch is displayed on the monitor.
and press the accelerator pedal fully to a If "1" is displayed, go to the next step.
run the truck and shift up the gear to F3. a If "0" is displayed, repeat steps 24) –
a Shifting up: F1 o F2 o F3 26) until "1" is displayed.
22) After running the machine at F3 for 10 a If "1" is not displayed after repeating
seconds, release the accelerator pedal the steps 4 times, the ECMV may be
and shift down the gear to F1 by coasting defective. In this case, replace the
run. ECMV.
a Shifting down: F3 o F2 o F1 a The * marked clutch display can be
a Do not apply the brake during coast- either "0" or "1".
ing run.
HD325-7, HD405-7 61

and press the accelerator pedal fully to
run the truck and shift up the gear to F2.
a Shifting up: F1 o F2
28) After running the machine at F2 for 10
seconds, release the accelerator pedal
and shift down the gear to F1 by coasting
run.
a Shifting down: F2 o F1
29) Check that the trigger learning of the 1st
a If "1" is displayed the initial learning
has completed finally.
a If "0" is displayed, repeat steps 27) –
29) until "1" is displayed.
ECMV.
30) In the monitiring display, confirm finally the

trigger learning display of lower line.
a If displayed as the drawing below, the
initial learning has completed nor-
mally.
31) Press [t] switch sereral times to exit the

service menu.
q [t]: To return to the previous screen.
62 HD325-7, HD405-7
[15] Filter and oil replacement time setting func- a Displayed maintenance item and
tion (MAINTENANCE MONITOR) function:
Machine monitor can set the maintenance intervals
Maintenance items
for various filters and oil which become the base of No. Display
and functions
replacement time display for filter and oil. Also the
machine monitor can activate or deactivate the dis- 1 41:FUEL P FILT Fuel pre filter
play function. 2 01:ENG OIL Engine oil
1. Selection of the service menu 3 02:ENG FILT Engine oil filter
Select the filter and oil replacement time set-
4 13:TM FILT Transmission oil filter
ting function (MAINTENANCE MONITOR) in
the service menu selection screen. 5 03:FUEL FILT Fuel main filter
6 06:CORR RES Corrosion resistor
Torque converter/
7 17:TC/TM/ BK OIL
Transmission/Brake oil
8 14:BK OIL FILT Brake oil filter
9 16:BK C FILT Brake cooling oil filter
10 04:HYD FILT Hydraulic oil filter
11 11:DIFF OIL Differential oil
12 08:FNL OIL Final drive oil
13 10:HYD OIL Hydraulic oil
Setting default value for all
14 INITIALIZE
items
Setting validity or invalidity for
15 ALL ITEMS
2. Displaying and selecting the maintenance item all items
and function
1) With the service menu selected, press the a No.1 – 13 are the maintenance items
[U] switch to display the maintenance where the setting is changed by item,
item and function selection screen. and No.14 – 15 are the functions
q [U]: Conduct the service menu. which allows to change the setting of
all items simultaneously.
a Display the item and function is dis-
played in the [*] section.
2) If [>] switch or [<] switch is pushed while

the maintenance item and function selec-
tion screen is displayed, the maintenance
item and function will be displayed end-
lessly in the order shown by the below
table. Select the item or the function
which will be used.
q [>]: To proceed to next maintenance
item and function.
q [<]: To return to the previous mainte-
nance item and function.
HD325-7, HD405-7 63
3. Display contents of the maintenance item

(Items No.1 – 13)
If the maintenance item for filter or oil is
selected, the following contents are displayed.
1: Code (2 digits)
A: Filter and oil replacement time set item
2: Remaining time to set replacement time
3: Number of times of replacement up to
present
3) When the interval time is completely

determined, the screen to confirm the
changes is displayed. Then, operate each
of the switches [<], [>] and [t].
q [ <]: To select YES (The cursor moves)
q [ >]: To select NO (The cursor moves)
4. Changing the interval time by maintenance

item (Items No.1 – 13)
1) With the item to change the interval time
(ex: FUEL P FILT) selected on the mainte-
nance item and the function selection
screen, press the [U] switch to display the
interval change screen.
q [U]: Execute the function to change
maintenance item.
a The current set interval is displayed
on the screen.
a With this screen displayed, if the [>] 5. Set the function activation or deactivation by
switch or the [<] switch is operated, maintenance item (items No.1 – 14).
the screen switches to the setting 1) With the item (ex: FUEL P FILT) to change
screen for enable and disable the the enable and disable of the function
maintenance item. selected on the maintenance item and
2) On the interval change screen, operate function selection screen, press the
each of the switches [>], [<], [U] and [t] [U]switch to display the interval input
to input the interval time. screen.
q [ > ]: Number at the cursor increases. q [U]: Implement the function to change
q [ < ]: Number at the cursor decreases. maintenance item.
q [U]: Number at the cursor is deter-
mined.
q [ t]: To return to the service menu
selection screen.
a The time must always be input with 4
digits. For the time with less than 4
digits, input 0s in place of the vacant
number.
64 HD325-7, HD405-7
2) After displaying the screen to input inter- a If the timer which has been OFF is
vals, press the [>] switch or the [<] switch turned ON, the interval is set to the
to display the activation or deactivation value before it was turned OFF and
setting screen. the rest of set time of the timer is
q [>]: Switch the setting screen. reset. The number of resetting times
q [<]: Switch the setting screen is set to the value before it was turned
a If the function is activated, it is dis- OFF.
played like the upper line. And if it is
deactivated, it is displayed like the 6. Setting default values of interval time for all
lower line. items (function of No.14)
3) After the activate or deactivate setting 1) With all item default value setting (INI-
screen is displayed, check the present TIALIZE) selected on the maintenance
setting status and the contents of change. item and function selection screen, press
Then operate the switches [U] or [t]. the [U] switch to display the all item
q [U]: Switch to the change confirma- default value setting screen.
tion screen q [U]: Implement the function to set the
q [t]: To return to the maintenance default values of all the items.
i te m an d fu nc ti on s e le ct io n
screen.
q [< ]: Switch to the interval change
screen.
2) After the all item default value setting

screen and operate each [<], [>] and [t]
switches.
q [ <]: To select YES (The cursor moves)
4) When the change confirmation screen is q [ >]: To select NO (The cursor moves)
displayed, operate [<], [>] and [t] switches. q [t]: Execute YES or NO
q [ < ]: To select YES (The cursor moves)
q [ > ]: To select NO (The cursor moves)
a All the items are set to their respec-

tive default values, regardless of the
ON or OFF state of each item.
a The rest of the set time of the timer is
set to the [default value/elapsed time
after the previous replacement].
HD325-7, HD405-7 65
a The number of resetting times is kept a If activation of all the items (ON) is
at the value before the default was set, the maintenance function of all
set. the items starts to work regardless of
a Each item is set turned ON. the setting of each maintenance item
and the interval is set to the previous
7. Setting the function activation or deactivation time before the interval has been
for all the items (function No.15) deactivated.
1) With the activation or deactivation setting a The timer is reset simultaneously and
for all items selected (ALL ITEMS) on the it restarts to count from 0 h.
maintenance item and function selection The number of resetting times is set
screen, press the [U] switch to display the to the value before it was turned OFF.
all items activation or deactivation setting
screen.
q [U]: Implement the function to set
activation or deactivation of all
the items.
4) When the change confirmation screen is

displayed, operate each [<], [>] and [t]
switches.
q [ <]: Select YES (move cursor)
q [ >]: Select NO (move cursor)
2) After the all items activation or deactiva- q [t]: Execute YES or NO
tion setting screen is displayed, press the
[>] switch or the [<] switch to display the
activation setting or deactivation setting
screen.
q [>]: Switch the setting screen.
q [<]: Switch the setting screen
a To deactivate all the items, display the
upper line setting screen (OFF), and
to activate all the items, display the
lower line setting screen (ON).
3) Confirm the setting screen, press the [U]
switch or the [t] switch to display the
change confirmation screen.
q [U]: To switch to the change confir-
mation screen.
q [ t]: To return to the maintenance
i te m an d fu nc ti on s e le ct io n
screen.
a If deactivation of all the items (OFF) is
set, it will stop the maintenance func-
tion of all the items, regardless of the
setting of each maintenance item.
66 HD325-7, HD405-7
Table of filter and oil replacement time set items

Replacement frequency
No. System and function Code Display Remarks
(Default value)
1 Fuel pre filter 41 FUEL P FILT 500
2 Engine oil 01 ENG OIL 500
3 Engine oil filter 02 ENG FILT 500
4 Transmission oil filter 13 TM FILT 500
5 Fuel main filter 03 FUEL FILT 1000
6 Corrosion resistor 06 CORR RES 1000
Torque converter/Transmission/ TC/TM/
7 24 1000
Brake oil BK OIL
8 Brake oil filter 14 BK OIL FILT 1000
9 Brake cooling oil filter 16 BK C FILT 1000
10 Hydraulic oil filter 04 HYD FILT 2000
11 Differential oil 11 DIFF OIL 2000
12 Final drive oil 08 FNL OIL 2000
13 Hydraulic oil 10 HYD OIL 4000
All item simultaneous
14 Setting default value for all items (None) INITIALIZE —
setting function
All item simultaneous
15 Setting enable and disable for all items (None) ALL ITEMS —
setting function
HD325-7, HD405-7 67
[16] Operation information display function a There are three types of information
(OPERATION INFO) screen.
Machine monitor can display the fuel consumption
per mile and per time, the fuel consumption per any 4. Information to be displayed (screen 1 – 3)
accumulated time and the travel distance, and the Above: Fuel consumption per km or mile from
fuel consumption during any accumulated time and the last reset point (distance unit is km
its accumulated time. or mile and it depends on the setting of
a Fuel consumption value is the integration of the integrated odometer in the opera-
the targeted injection rate signal which is sent tor mode).
from the engine controller. It is not the mea- Maximum display value:
surement of the actual fuel consumption. 99999.9 L/km (L/mile)
Therefore the displayed fuel consumption is Below: Fuel consumption per time started
used as a guide value. from the last reset point
Maximum display value: 99999.9 L/h
1. Selection of the service menu
Select the operation information display func-
tion (OPERATION INFO) on the service menu
selection screen.
Above: Integrated fuel consumption started

from the last reset point
Maximum display value: 9999999.9 L
Below: Accumulated travel distance from the
2. Displaying the operation information
last reset point (travel distance unit is
With the service menu selected, press the
km or mile and it depends on the set-
[U]switch and display the operation informa-
ting of the integrated odometer in the
tion and item selection screen.
operator mode).
Maximum display value:
9999999.9 km (mile)
3. Selecting displayed information

With the operation information and item selec-
tion screen displayed, operate the [>] switch or
the [<] switch to select the information screen
to display.
q [>]: To display the next information
screen.
q [<]: To display the previous informa-
tion screen.
68 HD325-7, HD405-7
Above: Integrated fuel consumption started 6. Correction of integrated fuel consumption

from the last reset point a When there is the difference between the
Maximum display value: 9999999.9 L integrated fuel consumption (L) in display
Below: Elapsed time from the last reset point and the actually measured fuel consump-
Maximum display value: 9999999.9 h tion, correct it in the following way.
1) With the reset screen displayed, press the
[>] switch or the [<] switch to display the
fuel consumption correction screen.
q [>]: Switch the displayed screen
q [<]: Switch the displayed screen
5. Resetting displayed information

1) With any information screen displayed,
press the [U] switch to display the reset
screen.
q [U]: Switch to the reset screen.
2) After the fuel consumption correction
2) After the reset screen is displayed, press
screen is displayed, press the [U] switch
the [U] switch or the [t] switch to execute
or the [t] switch to switch to the correction
or cancel the reset.
value input screen.
q [U]: Implement resetting.
q [U]: Switch to the correction value
q [ t]: Cancel resetting
input screen
a When the resetting is carried out, all
q [t ]: To return to the service menu
the information goes to "0", and the
screen
monitoring starts newly from that
point of time (Monitoring is only con-
ducted while engine is running.)
a If the [>] switch or the [<] switch is
operated with this screen displayed,
the screen is switched to the fuel con-
sumption correction screen.
HD325-7, HD405-7 69
3) After the compensation value input screen

is displayed, operate each of the switches
[>], [<], [U] and [t] to input the compen-
sation value directly.
q [ > ]: To switch the sign (+/-) / Number
increases.
q [ < ]: To switch the sign (+/-) / Number
decreases.
q [U]: Sign/number at the cursor is
determined.
q [ t]: Return to the fuel consumption
correction screen
a The correction value at the plant
before shipment is [+/-00.0%] (In
3. Selection of mode
case of inputting 00.0, +/- does not
While the service menu is selected, press the
matter.)
[U] switch to display the engine mode fixing
a The compensation value can be input
screen.
within the range of [-50.0% –
q [U]: Execute service menu
+50.0%].
4. Selection of displayed information

[17] Engine mode fixing function (FIX POWER While the engine mode fixing screen is dis-
MODE) played, select the information screen to be dis-
While the screen is displayed, the operator can played with the [>] or [<] switch.
measure the high idle speed and torque converter q [ > ] switch: Switch setting screen
stall speed to check the engine performance. q [ < ] switch: Switch setting screen
q Engine speed at high idling q [t] switch: Engine mode fixing function
q Engine speed at torque converter stall a The mode is four kind of A – D.
a Refer to "Standard valve table".
If a mode is selected by the following operation, it is 5. Finishing of display
sent to the transmission controller, which sends it to Press the [t] switch to return to the engine
the engine controller. mode fixing function screen.
1. Advance check q Fixing of the engine mode is reset.
Before the operation, check the following
items.
q Parking brake: ON (Parking)
q Failure code: Not displayed
a Refer to "Standard valve table" for mode
and value.
2. Selection of service menu

While the service menu selection screen is dis-
played, select the engine mode fixing function
(FIX POWER MODE).
70 HD325-7, HD405-7
[18] Option selection function [20] Initializing function (INITIALIZE)

(OPTIONAL SELECTION) a This function is exclusive for the plant, and is
Machine monitor can set and adjust various not used for field service.
optional devices which have been installed or
removed.
a The operating method of this function refers to
the item of "Setting and adjusting various
equipment".
[19] Model selection function (MACHINE)

Machine monitor is common among many models,
and if the machine monitor is replaced, select the
same model as the one currently installed.
a The operating method of this function refers to
the item of "Setting and adjusting various
equipment".
HD325-7, HD405-7 71

© 2007 KOMATSU
All Rights Reserved
72 HD325-7, HD405-7
SEN02401-01
DUMP TRUCK
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up

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
HD325-7, HD405-7 1
How to start operation of 3) When about 3 to 5 seconds elapsed after

the starting switch was set to ACC, make
KOMTRAX terminal 1 sure that the 7-segment indicator lamp
In the case where the KOMTRAX terminal has changes to hyphen “–” on the KOMTRAX
been installed at the plant before shipment: terminal.
a Implement the following procedure in the case
where the KOMTRAX terminal has already
been installed at the plant before shipment (as
standard equipment).
q In Japan: Register the machine with the
KOMTRAX client personal computer.
a See "KOMTRAX instruction manual for
responsible person for operation".
a For information to be checked in advance,
see "2. Application for the start of use".
q Out of Japan: Carry out "3. Opening station
request of ORBCOMM terminal".
q Register the machine with the KOMTRAX
client personal computer.
In the case where KOMTRAX terminal is retrofit-

ted on machine after shipment:
a Implement the following procedure in the case
where the KOMTRAX terminal is retrofitted after
shipment of the machine (retrofitted machine).
q In Japan: Execute "1. Opening station inspec-
tion of machine side" and register the machine
with the KOMTRAX client personal computer.
q Out of Japan: Execute "1. Opening station
inspection of machine side" and "2. Application
of start of use" and "3. Opening station request
of ORBCOMM terminal".
q Register the machine with the KOMTRAX
client personal computer.
4) Disconnect inspection connector 1, and
wait for about 3 to 5 seconds as it is.
How to start operation
a Ensure that the connector is discon-
1. Station opening check in machine side
nected.
a Complete steps 3) to 5) within 60 sec-
onds. If 60 seconds or above elapsed, 5) Reconnect inspection connector 1, and
begin with step 1) again. wait for about 3 to 5 seconds as it is.
1) Turn OFF the starting switch and then, a If the KOMTRAX terminal detects that
a ft e r m a k i n g s u r e 5 s e c o n d s h a v e the connector was disconnected and
elapsed, proceed to the next step. connected, the dot on the 7-segment
2) Visually check that check connectors 1 indicator lamp blinks a few times.
and 2 are connected.
q Check connector 1: CHK1
q Check connector 2: CHK2
2 HD325-7, HD405-7
6) Make sure that the 7-segment indicator 7) Turn the starting switch to START position
lamp is indicated normally on the for about 3 to 5 seconds, and make sure
KOMTRAX terminal. that the engine does not start.
a If so, the 7-segment indicator lamp will a If the engine starts, re-execute the
indicate characters “d”, “0”, and “–” procedure above from step 1).
repeatedly for 30 seconds after step 5) a Do not return the starting switch to
was ended. OFF position.
a Those characters, even if displayed 8) Turn the starting switch from ACC position
normally, will change to a character to START position again, and make sure
other than hyphen “–”after 30 sec- that the engine starts.
onds or above elapsed. 9) Make sure that the KOMTRAX terminal's
The display may change to a charac- indicator lamps are normally turned on.
ter other than “0” even within 30 sec- a Move on to the next step if you can
onds. check that the display is [Normal]. (It
takes from 90 seconds to 15 minutes
before the display turns normal.)
a If [GPS position data detection trou-
ble] is indicated, check if there is any
abnormality on the GPS antenna or
cable. If there is any abnormality,
repair it and start from procedure 1)
again.
a If [Reception trouble] is indicated,
check if there is any abnormality on
the appearance of the communication
antenna or cable. If there is any
abnormality, repair it then repeat from
procedure 1) again.
a If [GPS position data detection trou-
ble and reception trouble] is indi-
cated, check if there is any
abnormality on the GPS antenna/
cable or communication antenna/
cable. If there is any abnormality,
repair it and start from procedure 1)
again.
a If [Network trouble] is indicated,
check the display of [LED-C4] refer-
ring to “Lamp display of KOMTRAX
terminal”. If the CAN is not recog-
nized, check the CAN harness of the
a As [Normal] is indicated, proceed to KOMTRAX terminal, and then if there
the next step. is any abnormality, repair it and start
a If “–” remains displayed, execute from procedure 1) again.
steps 1) to 5) again.
HD325-7, HD405-7 3
[A]: Normal
[B]: GPS position data detection trou-
ble
[C]: Reception trouble
[D]: GPS position data detection trou-
ble and reception trouble
[E]: Network trouble
12) When station opening check ended nor-

m a l l y, a c o m m u n i c a t i o n w i t h t h e
KOMTRAX server starts automatically,
and settings are stored in KOMTRAX.
(This requires about 25 minutes to 4
hours.)
a During this time, you may turn the
starting switch OFF and start the
engine.
a During the communication and check
above, you should park the machine
outside to enable a frequent communi-
cation with the ORBCOMM satellite.
The station opening check may not be
completed in doors that cause radio
waves from the satellite to be inter-
cepted.
10) Turn the starting switch OFF.

11) Make sure that the 7-segment indicator
lamp is displayed normally after 5 seconds
elapsed.
a When [Normal] appears, station open-
ing check is completed.
a If [Abnormal] appears, station open-
ing check does not end normally, so
you should perform the procedure
above from step 1) again.
a If station opening check ends nor-
mally, it should not be rechecked.
4 HD325-7, HD405-7
2. Application for the start of use 3. Opening station request of ORBCOMM ter-
a Application for the start of use is made minal
only after the sign-up test on the machine Fill in the necessary matters in the paper of
side is finished. "opening request of ORBCOMM terminal" and
1) Notify to the KOMTRAX operations ad- send KOMTRAX service hotline by fax or mail.
ministrator the following information con-
cerning the machine whose sign-up test
on the machine is completed.
(1) Information on the machine whose
sign-up test on the machine system is
completed (model, model number
and serial number).
(2) Part number and serial number of the
KOMTRAX terminal
(3) Reading of the service meter when
the KOMTRAX terminal is installed
(0.1 h unit)
2) The KOMTRAX operations administrator

registers the body using a KOMTRAX cli-
ent personal computer.
a For the procedure, see the following;
In Japan: "KOMTRAX instruction manual
for responsible person for operation"
Out of Japan: "Global KOMTRAX Web
Reference Manual" (For key person)
HD325-7, HD405-7 5
6 HD325-7, HD405-7
Lamp display of KOMTRAX terminal 1
CPU LED 7 segments and dot for CPU

1. LED-C1 (R signal, ACC signal) 7. 7 segments (number of mails not yet sent)
2. LED-C2 (Starting output status) 8. Dot (GPS positioning status)
3. LED-C3 (S-NET, C signal status)
4. LED-C4 (Condition of CAN communication)
5. LED-C5 (downloading and writing status)
6. LED-C6 (downloading and writing status)
HD325-7, HD405-7 7
In the KOMTRAX system, various information and processing details are displayed on the LEDs on the
upper surface of the KOMTRAX terminal. Therefore, if a detect is suspected in the system, perform the fol-
lowing checks.
q Check of antennas
q Check of terminal LED displays
Application for the start of use and sign-up test on the vehicle bodies should be completed before using
KOMTRAX system.
Check of antennas
a Before checking the LED displays, check that there is no abnormality around the communication
antenna and GPS antenna.
q The communication antenna should not be disconnected or damaged.
q The communication antenna cable should not be broken and be connected normally with the
KOMTRAX terminal.
q The GPS antenna should not be disconnected or damaged.
q The GPS antenna cable should not be broken and normally be connected to the KOMTRAX terminal.
Check of terminal LED displays

1. Display contents of LED for CPU
a The LED displays should be checked with the starting switch ON, starting switch START, or with the
engine started.
Display
No. LED Name and function Display contents
(refer to *1)
Lighting on Starting switch ACC signal: ON, alternator R signal: ON
Starting switch ACC Fast blinking Starting switch ACC signal: OFF, alternator R signal: ON
1 LED-C1 signal and alternator
R signal Slow blinking Starting switch ACC signal: ON, alternator R signal: OFF
Lighting off Starting switch ACC signal: OFF, alternator R signal: OFF
Engine control signal Lighting on Engine control signal: ON
2 LED-C2
status Lighting off Engine control signal: OFF
Lighting on S-NET: connected, starting switch C signal: OFF
S-NET connection Fast blinking Starting switch C signal: ON
3 LED-C3 status and starting
switch C signal status Slow blinking (Not used)
Lighting off S-NET: disconnected, starting switch C signal: OFF
Lighting on CAN: active (fuel sensor: inactive)
Fast blinking CAN: active (fuel sensor: active)
4 LED-C4 CAN status
Slow blinking CAN: inactive (fuel sensor: active)
Lighting off CAN: inactive (fuel sensor: inactive)
Downloading and writing status (special function for system
5 LED-C5 Downloading and One side is ON
administrator)
writing status
6 LED-C6 Both lighting off Normal operation mode
* 1: Blinking type and time

Fast blinking: blinking on an approximately 1 second cycle
Slow blinking: blinking on an approximately 4 second cycle
8 HD325-7, HD405-7
2. Display contents of 7-segment and dot for CPU

a LED displays should be checked with the starting switch ON.
Display
No. LED Name and function Display contents
(refer to *2)
Number means number of mails not yet sent (9 is displayed
0–9
Number of mails not even if there are more than 9 mails). Lighting on indicates status
lighting on
7 seg- yet sent and waiting acquiring satellite.
7
ments status acquiring Number means number of mails not yet sent (9 is displayed
satellite 0–9
even if there are more than 9 mails). Fast blinking means
fast blinking
waiting status acquiring satellite.
GPS positioning has been completed. (Position has been
Lighting on
GPS positioning recognized. Refer to *3.)
8 Dot
status GPS positioning has not been completed. (Position has not
Lighting off
been recognized. Refer to *3.)
* 2: Blinking type and time

Fast blinking: blinking on an approximately 1 second cycle
Slow blinking: blinking on an approximately 4 second cycle
* 3: Supplementary explanation of GPS positioning status
It may take more than 1 minute from turning on the starting switch to the completion of positioning even
in an outdoor place where radio wave can reach.
Positioning is impossible in areas with extremely weak radio waves or areas beyond the reach of radio
waves.
HD325-7, HD405-7 9
Pm Clinic check sheet 1

HD325-7 #7001 and up
HD405-7 #3001 and up
Machine Serial No. #
Hour check Engine Serial No. SAA6D140E-5#
Work direction No. Date of inspection Service meter Inspector

Year Month Day
hours
Interview with operator and walk-around inspection

Is there any abnormality before starting inspection? Ambient temperature
Max. °C
Min. °C
Altitude m
Max. level of coolant temperature Max. level of torque converter and transmission Max. level of retarder oil temperature
(During work) oil temperature (During work) (During work)
White Green Green Green Green Red Red Green Green Green Green Green Red Red Green Green Green Green Green Red Red
1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7
Items Condition Diagnosis result Accepted Rejected

Monitor
Self-diagnosis Starting switch

display OFF o ON
a After starting engine

Standard value Service limit Measurement
Item Condition Unit Accepted Rejected
of new machine value result
Engine: Low idle (Power mode) 700 – 750 700 – 750
Engine: Full throttle (Power mode) 2,275 – 2,325 2,275 – 2,325
Engine speed Torque converter stall rpm 1,830 – 2,030 1,830 – 2,030
(Power mode)
Torque converter stall
1,720 – 1,920 1,720 – 1,920
(Economy mode)
kPa Max. 2.94 Max. 3.92
Blow-by pressure Torque converter stall
Engine
{mmAq} {Max. 300} {Max. 400}

Min. 0.34 Min. 0.21
Engine: Full throttle
MPa {Min. 3.5} {Min. 2.0}
Engine oil pressure
{kg/cm2} Min. 0.1 Min. 0.08
Engine: Low idle
{Min. 1.0} {Min. 0.8}
kPa Min. 183 Min. 156
Boost pressure Torque converter stall
{mmHg} {Min. 1,370} {Min. 1,170}
Exhaust Ambient temperature — —
°C
temperature Torque converter stall Max. 650 Max. 700
Engine: Low idle

Gear shift lever: Neutral (SAE30) 2.96 – 3.36 2.96 – 3.36
Oil temperature: 70 – 90 °C (Level {30.3 – 34.3} {30.3 – 34.3}
T/C, T/M
Main relief No. 3) MPa

pressure Engine: Full throttle {kg/cm2}
Gear shift lever: Neutral (SAE30) 3.28 – 3.68 3.28 – 3.68
Oil temperature: 70 – 90 °C (Level {3.35 – 37.5} {3.35 – 37.5
No. 3)
Replace oil and clean inside and strainer of the transmission case at 1,000-hour maintenance.
Visual inspection of
There is not excessive metal power or black
T/M
transmission case —
powder.
strainer
Lock-to-lock All engine speed range: Right to left Max. 4.0 Max. 4.0
sec.
Steering
steering time All engine speed range: Left to right Max. 4.0 Max. 4.0
Steering relief MPa 20.62 – 22.58 20.62 – 22.58
pressure {kg/cm2} {210 – 230} {210 – 230}
10 HD325-7, HD405-7
HD325-7 #7001 and up

HD405-7 #3001 and up
Machine Serial No. #
Hour check Engine Serial No. SAA6D140E-5#
< >: Reference value
Standard value Service limit Measurement
Item Condition Unit Accepted Rejected
of new machine value result
14.2 – 14.69 14.2 – 14.69
Cut-in
Accumulator MPa {145 – 150} {145 – 150}
charge pressure {kg/cm2} 20.6 – 21.58 20.6 – 21.58
Cut-out
{210 – 220} {210 – 220}
Brake
Service brake Apply brake, set gear shift lever in Min. 1,550 Min. 1,550
Retarder brake D, raise engine speed gradually, Min. 1,200 Min. 1,200
rpm
Parking brake and measure engine speed at Min. 1,600 Min. 1,600
Emergency brake which machine starts moving. Full throttle Full throttle
Hydraulic equipment
Hydraulic oil
°C — —
temperature
Hoist relief MPa 20.6 – 21.58 20.6 – 21.58
pressure {kg/cm2} {210 – 220} {210 – 220}
Dump body raising
Engine: Full throttle sec 8.5 – 11.5 8.5 – 11.5
speed
Set dump body and stop engine.

Hydraulic oil
— °C — —
temperature
Hydraulic drift of hoist Set dump body to 200-mm extrac- mm/
Max. 85 Max. 85
cylinder tion point of No. 2 cylinder. 5 min
Replace drain plug with spare plug.

Visual check of There is not excessive metal
Engine: Stopped —
differential drain plug powder.
Visual check of final Left side There is not excessive metal
—
drive drain plug Right side powder.
Every 1000-hour maintenance

Front brake (Pad Left side 19.5 3.0
thickness) Right side (Initial thickness) 3.0
Brake
mm
Rear brake (Disc Left side 19.5 Wear limit
wear gauge) Right side (Initial thickness) Wear limit
Left front Suspension cylinder length mm Proper range Proper range

suspension Oil/Gas leakage — No leakage
Suspension cylinder
Right front Suspension cylinder length mm Proper range Proper range

Left rear Suspension cylinder length mm Proper range Proper range
Right rear Suspension cylinder length mm Proper range Proper range
Contact of rear Left side No contact
—
suspension stopper Right side No contact
Memo: Enter phenomena and information you noticed during today's check.
HD325-7, HD405-7 11
Setting of card-type payload meter (PLM- ) after installation or

replacement 1
In the following cases, set the rotary switches and DIP switches on the side of the card-type payload meter
and set the threshold value of turning on the external indicator lamp and option code with the switches on the
front.
q When card-type payload meter is installed for the first time

q When card-type payload meter is replaced
1. Setting of switches
1) Remove cover (1) from the left side of the card-type payload meter.
2) Set the following switches. (See view Z in the above figure.)

q Set the model selector switch (No. 4).
Position of rotary switch Model
3 HD325-7
8 HD405-7
q Set weight unit setting switch (No. 7).
Position of switch Model
Upper Metric ton
Lower American ton (Short ton)
12 HD325-7, HD405-7
q Set buzzer volume switch (B) and switch forcible prohibition switch (No. 8), if necessary.
When changing these switches from the initial positions, be sure to check with the Operation
and Maintenance Manual.
q Do not change the load weight correction trimmer (No. 1) from the initial position.
q Do not change the speed correction switch (No. 2), distance correction switch (No. 3), memory
card using switch (No. 5), and clinometer using switch (No. 6) from the initial positions.
Switch Initial setting
Speed correction switch (No. 2) Switch position: 7
Distance correction switch (No. 3) Switch position: 7
Memory card using switch (No. 5) Switch position: Lower (Use)
Clinometer using switch (No. 6) Switch position: Lower (Use)
Switch forcible prohibition switch (No. 8) Switch position: Upper (Permission)
a You can carry out the operations of calibration, clearing all data, dumping card, and setting
date by turning switches No. 5 and No. 8 ON or OFF. (See the Operation and Maintenance
Manual.)
2. Setting of option code

a Required for communication with personal computer
The option code is set to zero (0) initially. For HD325-7 and HD405-7, check that the option code is zero
by the following method.
When the power is turned ON, "OP: 0" is indicated before the normal operation display starts.
(See Operation and Maintenance Manual, Handling of payload meter (card type), Contents of indica-
tion.)
Optional setting
Transmis- Execution of
sion baud automatic
Option code Type of transmission of data
rate transmission Setting of Setting of
when dumping is finished
(bit/sec) function TALKS PMC
(when PMC is set)
0 9600 NO NO NO —
1 9600 YES NO NO —
2 1200 NO NO NO —
3 1200 YES NO NO —
4 9600 NO YES NO —
5 9600 YES YES NO —
6 1200 NO YES NO —
7 1200 YES YES NO —
8 9600 NO YES YES Z1
9 9600 NO YES YES Z2
10 9600 NO NO YES Z3
11 9600 NO NO YES Z4
HD325-7, HD405-7 13
3. Method of changing option code

1) Set the gearshift lever in "N" and the dump lever in "FLOAT".
Operation switches to be used

q MODE (2)
q LIGHT/INC (3)
q TOTAL/SFT (4)
q CAL/CLR (5)
Screen (6)
a While watching the screen, operate switches (2) – (5) to set values.
14 HD325-7, HD405-7
2) Display the option code screen according 3) Changing set value of option code
to the following procedure. a You can change the digit at the blink-
1] Press MODE switch (2) for 2 sec- ing place.
onds.
Display: Cd: dp (Cd lights up and dp q Changing ones digit
blinks)
2] Press MODE switch (2).

Display: A. CLE (A lights up and CLE
blinks)

Display: F. CHE (F. CHE blinks)

Display: d. XXX (d. XX lights up and
X at ones place blinks)
q XXX = Currently set machine ID
1] Press LIGHT/INC switch (3).
Display: OP: XX (OP: X lights up and
Displa:y 0. XXX (0. XX lights up and
q XX = Ones digit of currently set
q XXX = Currently set operator ID
option code is increased by 1.
q Changing tens digit
Display: SP: XX (SP: X lights up and
1] Press TOTAL/SFT switch (4).
q The blinking point moves to the
q XX = Current set limit speed
tens place.
(km/h)

q XX = Current set option code

X at tens place blinks)
q XX = Tens digit of currently set
option code is increased by 1.
HD325-7, HD405-7 15
q Changing place to be changed 6] Press CAL/CLR switch (5).

1] Press TOTAL/SFT switch (4). Display: P. SEL (P. SEL lights up)
q The blinking point moves to the
ones place. 7] Press CAL/CLR switch (5).
Display: H. SEL (H. SEL lights up)
8] Press CAL/CLR switch (5).

Display: E. SEL (E. SEL lights up)
9] Press TOTAL/SFT switch (4).

Display: A. XXX (A. lights up and
XXX blinks)
q XXX = Currently set display level
of external lamp 1

Display: b. XXX (b. lights up and XXX
4) Finishing setting blinks)
Press MODE switch (2). q XXX = Currently set display level
of external lamp 2
4. Setting threshold value of external indica-
tor lamp 11] Press CAL/CLR switch (5).
a When installing the card-type payload Display: c. XXX (c. lights up and XXX
meter to a machine having the 3-bulb blinks)
external indicator lamp (HD325-7, HD405- q XXX = Currently set display level
7), be sure to set the threshold value of of external lamp 3
the external indicator lamp.
1) Set the gearshift lever in "N" and the dump Display: c. XXX (c. lights up and XXX
lever in "FLOAT". blinks)
2) Set the threshold value of the external q XXX = Set to 050.
indicator lamp according to the following a If LIGHT/INC switch (3) is held,
procedure. XXX increases to 255 and then
a For the setting switches, see "2. Set- returns to 0.
t i ng o f o pt i on c o de " , M e th o d o f
changing option code. 13] Press CAL/CLR switch (5).
1] Press MODE switch (2) and LIGHT/ Display: d. XXX (d. lights up and XXX
INC switch (3) simultaneously for 3 blinks)
seconds. q XXX = Currently set display level
Display: CHEC (CHEC blinks) of external lamp 4
2] Press TOTAL/SFT switch (4) and 14] Press LIGHT/INC switch (3).
LIGHT/INC switch (3) simultaneously Display: d. XXX (d. lights up and XXX
for 2 seconds. blinks)
Display: S. SEL (S. SEL lights up) q XXX = Set to 090.
a If LIGHT/INC switch (3) is held,
3] Press CAL/CLR switch (5). XXX increases to 255 and then
Display: UP: XX (UP: lights up and returns to 0.
XX blinks)
4] Press CAL/CLR switch (5). Display: E. XXX (E. lights up and
Display: PL: XX (PL: lights up and XX XXX blinks)
blinks) q XXX = Currently set display level
of external lamp 5
Display: O. SEL (O. SEL lights up)
16 HD325-7, HD405-7

Display: E. XXX (E. lights up and
XXX blinks)
q XXX = Set to 105. (HD325-7)
q XXX = Set to 100. (HD405-7)
a If LIGHT/INC switch (3) is held,
XXX increases to 255 and then
returns to 0.

Display: CHEC (CHEC blinks)
18] Press MODE switch (2) and finish

setting.
5. Check of setting
For 30 seconds after the card-type payload
meter is turned ON, the model selection code,
setting of memory card using switch, setting of
clinometer using switch, setting of weight unit
setting switch, setting of switch forcible prohibi-
tion switch, and setting of option code are dis-
played. Check that they are correct.
a For contents of indication made when the
power is turned ON, see Operation and
Maintenance Manual, Handling of payload
meter (card type), Contents of indica-
tion.
HD325-7, HD405-7 17

© 2007 KOMATSU
All Rights Reserved
18 HD325-7, HD405-7
SEN01185-01
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up
40 Troubleshooting 1
General information on troubleshooting
Points to remember when troubleshooting ..................................................................................................... 2
Sequence of events in troubleshooting........................................................................................................... 3
Checks before troubleshooting ....................................................................................................................... 4
Classification and procedures of troubleshooting ........................................................................................... 5
Connection table for connector pin numbers .................................................................................................. 6
T-adapter box and T-adapter table................................................................................................................ 29
HD325-7, HD405-7 1
SEN01185-01 40 Troubleshooting
Points to remember when troubleshooting 1

k Stop the machine in a level place, and check that the lock pin, blocks, and parking brake are
securely fitted.
k When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to
understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
1. When carrying out troubleshooting, do not 4) Other maintenance items can be checked
hurry to disassemble the components. externally, so check any item that is con-
If components are disassembled immediately sidered to be necessary.
any failure occurs:
q Parts that have no connection with the fail- 4. Confirming failure
ure or other unnecessary parts will be dis- Confirm the extent of the failure yourself, and
assembled. judge whether to handle it as a real failure or
q It will become impossible to find the cause as a problem with the method of operation, etc.
of the failure. a When operating the machine to reenact
It will also cause a waste of manhours, parts, the troubleshooting symptoms, do not
or oil or grease, and at the same time, will also carry out any investigation or measure-
lose the confidence of the user or operator. For ment that may make the problem worse.
this reason, when carrying out troubleshooting, 5. Troubleshooting
it is necessary to carry out thorough prior Use the results of the investigation and inspec-
investigation and to carry out troubleshooting tion in Items 2 – 4 to narrow down the causes
in accordance with the fixed procedure. of failure, then use the troubleshooting table or
2. Points to ask user or operator troubleshooting flowchart to locate the position
of the the failure exactly.
1) Have any other problems occurred apart
a The basic procedure for troubleshooting is
from the problem that has been reported?
as follows.
2) Was there anything strange about the
1] Start from the simple points.
machine before the failure occurred?
2] Start from the most likely points.
3) Did the failure occur suddenly, or were
there problems with the machine condition 3] Investigate other related parts or
before this? information.
4) Under what conditions did the failure 6. Measures to remove root cause of failure
occur? Even if the failure is repaired, if the root cause
5) Had any repairs been carried out before of the failure is not repaired, the same failure
the failure? When were these repairs car- will occur again.To prevent this, always investi-
ried out? gate why the problem occurred. Then, remove
6) Has the same kind of failure occurred the root cause.
before?
3. Check before troubleshooting
1) Is there any sign of irregularities of the
machine?
2) Make checks before starting day's work.
3) Make checks of other items.
2 HD325-7, HD405-7
Sequence of events in troubleshooting 1
HD325-7, HD405-7 3
Checks before troubleshooting 1
Check item Judgement value Remedy

1. Check fuel level and type — Add oil
2. Check for impurities in fuel — Clean, drain
3. Check hydraulic oil level — Add oil
4. Check hydraulic oil strainer — Clean, drain
5. Check power train oil level — Add oil
Lubricating 6. Check engine oil level (engine oil pan level) and
— Add oil
oil, coolant type
7. Check coolant level — Add coolant
8. Check dust indicator for clogging — Clean or replace
9. Check power train oil filter — Replace
10. Check hydraulic oil filter — Replace
11. Check final drive oil level — Add oil
1. Check for looseness and corrosion of battery
— Retighten or replace
cable terminals
2. Check for looseness and corrosion of alternator
Electrical — Retighten or replace
harness terminals
equipment
3. Check for looseness and corrosion of starting
— Retighten or replace
motor harness terminals
4. Check operation of instruments — Repair or replace
Hydraulic 1. Check for abnormal noise and smell — Repair
and 2. Check for oil leakage — Repair
mechanical
equipment 3. Carry out air bleeding — Bleed air
1. Check battery voltage (engine stopped) 20 – 26 V Replace
2. Check battery electrolyte level — Refill or replace
3. Check for discoloration, burnout of wiring, and
— Replace
peeling of harness coating
4. Check for missing wiring clamps and a slack of
— Repair
wire
Electrical 5. Check for water leaking on wiring
equipment Disconnect connector
(pay particularly careful attention to water leaking —
and dry
on connectors or terminals)
6. Check for blown or corroded fuse — Replace
7. Check alternator voltage (engine running at half After running for several
Replace
throttle or above) minutes: 27.5 – 29.5 V
8. Check operating noise of battery relay (when
— Replace
turning the starting switch ON or OFF)
4 HD325-7, HD405-7
Classification and procedures of troubleshooting 1

Classification of troubleshooting code
Troubleshooting
Content
code
Code display Troubleshooting by [electric system] or [mechanical system] failure code
E mode Troubleshooting of the electrical system
H mode Troubleshooting of the hydraulic and mechanical system
S mode Troubleshooting of engine
Troubleshooting procedures
If a problem occurs on the machine, or if it is felt that there is a problem, carry out troubleshooting as follows.
1. When machine monitor displays failure code

If a failure code is displayed on the machine monitor at the same time as the problem occurs, check the
content of the display, then go to the applicable troubleshooting chart for the failure code.
2. When machine monitor does not display failure code, but failure history is recorded
If a problem occurs but the failure code display cannot be checked on the machine monitor, use the fail-
ure history display function in the machine monitor service mode to check for a failure code.
If a failure code is recorded, there is a high probability that this is the cause, so go to the applicable trou-
bleshooting chart.
3. When a failure code is not displayed and failure history is not recorded either.
If a problem occurs but the failure code display cannot be checked on the machine monitor, and also the
problem is not recorded by the failure history display function in the machine monitor service mode, the
problem of the electrical, hydraulic or mechanical system that cannot be detected by a controller may
have occurred.
In this case, check the symptom of the trouble and go to the applicable troubleshooting chart.
HD325-7, HD405-7 5
Connection table for connector pin numbers 1

a The terms male and female refer to the pins, while the terms male housing and female housing refer to
the mating portion of the housing.
X type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010
2 799-601-7020
Part No.: 08055-00282 Part No.: 08055-00292
3 799-601-7030
Part No.: 08055-00381 Part No.: 08055-00391
4 799-601-7040
Part No.: 08055-00481 Part No.: 08055-00491

Terminal part No.: 79A-222-3370 Terminal part No.: 79A-222-3390
• Electric wire size: 0.85 • Electric wire size: 0.85
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty : 20
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
6 HD325-7, HD405-7
SWP type connector

No.of
pins T-adapter
Part No.
6 799-601-7050
Part No.: 08055-10681 Part No.: 08055-10691
8 799-601-7060
Part No.: 08055-10881 Part No.: 08055-10891
12 799-601-7310
Part No.: 08055-11281 Part No.: 08055-11291
14 799-601-7070
Part No.: 08055-11481 Part No.: 08055-11491
HD325-7, HD405-7 7
SWP type connector

No. of
pins T-adapter
Part No.
16 799-601-7320
Part No.: 08055-11681 Part No.: 08055-11691

Terminal part No.: Terminal part No.:
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty: 20
Terminal part No.: Terminal part No.:
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
8 HD325-7, HD405-7
M type connector
No.of
pins T-adapter Part
No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
Part No.: 08056-00271 Part No.: 08056-00281
3 799-601-7110
Part No.: 08056-00371 Part No.: 08056-00381
4 799-601-7120
Part No.: 08056-00471 Part No.: 08056-00481
6 799-601-7130
Part No.: 08056-00671 Part No.: 08056-00681
8 799-601-7340
Part No.: 08056-00871 Part No.: 08056-00881
HD325-7, HD405-7 9
S type connector
No.of
pins T-adapter
Part No.
8 799-601-7140
Part No.: 08056-10871 Part No.: 08056-10881
10
799-601-7150
(White)
Part No.: 08056-11071 Part No.: 08056-11081
12
799-601-7350
(White)
Part No.: 08056-11271 Part No.: 08056-11281
16
799-601-7330
(White)
Part No.: 08056-11671 Part No.: 08056-11681
10 HD325-7, HD405-7
S type connector
No.of
pins T-adapter
Part No.
10
—
(Blue)
— —
12
799-601-7160
(Blue)
Part No.: 08056-11272 Part No.: 08056-11282
16
799-601-7170
(Blue)
Part No.: 08056-11672 Part No.: 08056-11682
HD325-7, HD405-7 11
MIC type connector

No.of
pins T-adapter Part
No.
7 Body part No.: 79A-222-2640 (Q’ty: 5) Body part No.: 79A-222-2630 (Q’ty: 5) —
11 Body part No.: 79A-222-2680 (Q’ty: 5) Body part No.: 79A-222-2670 (Q’ty: 5) —
5 799-601-2710
Body part No.: 79A-222-2620 (Q’ty: 5) Body part No.: 79A-222-2610 (Q’ty: 5)
9 799-601-2950
13 799-601-2720
12 HD325-7, HD405-7
MIC type connector

No.of
pins T-adapter Part
No.
17 799-601-2730
21 799-601-2740
—
(Q’ty: 50) (Q’ty: 50)
HD325-7, HD405-7 13
AMP040 type connector

No.of
pins T-adapter Part
No.
8 799-601-7180
— Housing part No.: 79A-222-3430 (Q’ty: 5)
12 799-601-7190
16 799-601-7210
20 799-601-7220
a Terminal part No.: 79A-222-3470 (No relation with number of pins)
14 HD325-7, HD405-7
AMP070 type connector

No.of
pins T-adapter Part
No.
10 799-601-7510
— Part No.: 7821-92-7330
12 799-601-7520
— Part No.: 7821-92-7340
14 799-601-7530
— Part No.: 7821-92-7350
18 799-601-7540
— Part No.: 7821-92-7360
20 799-601-7550
— Part No.: 7821-92-7370
HD325-7, HD405-7 15
L type connector
No.of
pins T-adapter Part
No.
2 —
— —
Connector for PA
No.of
pins T-adapter Part
No.
9 —
— —
Bendix MS connector
No.of
pins T-adapter Part
No.
10 799-601-3460
— —
16 HD325-7, HD405-7
KES 1 (Automobile) connector

No.of
pins T-adapter Part
No.
2 —
Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
Part No.:08027-10310 Part No.:08027-10360
4 —
08027-10420 (Black) 08027-10470 (Black)
6 —
08027-10620 (Black) 08027-10670 (Black)
HD325-7, HD405-7 17
KES 1 (Automobile) connector

No.of
pins T-adapter Part
No.
8 —
08027-10820 (Black) 08027-10870 (Black)
Connector for relay (Socket type)

No.of
pins T-adapter Part
No.
5 799-601-7360
— —
6 799-601-7370
— —
18 HD325-7, HD405-7
F type connector
No.of
pins T-adapter
Part No.
4 —
— —
HD325-7, HD405-7 19
[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 Series connector
(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.
Pin (male terminal) Pin (female termial)
799-601-9210
Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102,

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male termial)
799-601-9210
Part No.: 08191-12201, 08191-12202, Part No.: 08191-13101, 08191-13102,

08191-12205, 08191-12206 08191-13105, 08191-13106
799-601-9220
Part No.: 08191-21201, 08191-12202, Part No.: 08191-24101, 08191-24102,

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220
Part No.: 08191-22201, 08191-22202, Part No.: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106
20 HD325-7, HD405-7
(shell
size T-adapter
code) Part No.
799-601-9230
18-20 Part No.:08191-31201, 08191-31202 Part No.:08191-34101, 08191-34102

799-601-9230
Part No.:08191-32201, 08191-32202 Part No.:08191-33101, 08191-33102

799-601-9240
18-21 Part No.:08191-41201, 08191-42202 Part No.:08191-44101, 08191-44102

799-601-9240
Part No.:08191-42201, 08191-42202 Part No.:08191-43101, 08191-43102
HD325-7, HD405-7 21
(shell
size T-adapter
code) Part No.
799-601-9250
24-9 Part No.:08191-51201, 08191-51202 Part No.:08191-54101, 08191-54102

799-601-9250
Part No.:08191-52201, 08191-52202 Part No.:08191-53101, 08191-53102

799-601-9260
Part No.: 08191-61201, 08191-62202, Part No.: 08191-64101, 08191-64102,

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260
Part No.: 08191-62201, 08191-62202, Part No.: 08191-63101, 08191-63102,

08191-62205, 08191-62206 08191-63105, 08191-63106
22 HD325-7, HD405-7
(shell
size T-adapter
code) Part No.
799-601-9270
Part No.: 08191-71201, 08191-71202, Part No.: 08191-74101, 08191-74102,

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270
Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102,

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part No.: 08191-81201, 08191-81202 Part No.: 08191-84101, 08191-84102

08191-81203, 08191-81204 08191-84103, 08191-84104
24-23 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part No.: 08191-82201, 08191-82202 Part No.: 08191-83101, 08191-83102

08191-82203, 08191-82204 08191-83103, 08191-83104
08191-82205, 08191-82206 08191-83105, 08191-83106
HD325-7, HD405-7 23
(shell
size T-adapter
code) Part No.
Pin (male termial) Pin (female terminal)
799-601-9290
Part No.: 08191-91203, 08191-91204, Part No.: 08191-94103, 08191-94104,

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290
Part No.: 08191-92203, 08191-92204, Part No.: 08191-93103, 08191-93104,

08191-92205, 08191-92206 08191-93105, 08191-93106
24 HD325-7, HD405-7
DT Series connector
No.of
pins T-adapter
Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
HD325-7, HD405-7 25
No.of DT Series connector
pins Body (plug) Body (receptacle) T-adapter Part No.
8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9090
Part No.: 08192-1820! (normal type) Part No.: 08192-1810! (normal type)
08192-2820! (fine wire type) 08192-2810! (fine wire type)
12GR:799-601-9110
12B: 799-601-9120
12
12G: 799-601-9130
12BR:799-601-9140
Part No.: 08192-1920! (normal type) Part No.: 08192-1910! (normal type)
08192-2920! (fine wire type) 08192-2910! (fine wire type)
26 HD325-7, HD405-7
DTM Series connector
No.of
pins T-adapter Part
No.
799-601-9010
2
Part No.: 08192-02200 Part No.: 08192-02100
DTHD Series connector
No.of
pins T-adapter Part
No.
2 —
Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
HD325-7, HD405-7 27
DRC26 Series connector
No.of
pins T-adapter Part
No.
24 799-601-9360
— Part No.:7821-93-3110
40
799-601-9350
(A)
— Part No.:7821-93-3120
40
799-601-9350
(B)
— Part No.:7821-93-3130
28 HD325-7, HD405-7
T-adapter box and T-adapter table 1

a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Out of kit
Identifica-
Part No. Part name
tion symbol
799-601-2600 T-box (for ECONO) 21 q q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3300 T-box (for ECONO) 24 q
799-601-3360 • Plate for MS (24-pin) q
799-601-3370 • Plate for MS (17-pin) q
799-601-3380 • Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q q
799-601-3510 Adapter for BENDIX (MS) 5 MS-5S q q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4210 Adapter for DRC 50 DRC50 q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
HD325-7, HD405-7 29
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Out of kit
Identifica-
Part No. Part name
tion symbol
799-601-7070 Adapter for SWP 14 SW14P q q

799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
30 HD325-7, HD405-7
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Out of kit
Identifica-
Part No. Part name
tion symbol

799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for DT/HD) 12 q q q
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410 Adapter for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 3 A3 q
799-601-9430 2 P q
799-601-9440 Adapter for engine (CRI-T2) 3 1,2,3 q
795-799-5520 Adapter for engine (HPI-T2) 2 S q
Adapter for engine (HPI-T2)
795-799-5530 2 C q
Adapter for engine (HPI-T2)
795-799-5540 2 A q
795-799-5460 Cable for engine (HPI-T2) 3 q
799-601-4160 Adapter for engine (CRI-T3) 2 OIL q
799-601-4130 Adapter for engine (CRI-T3) 3 FCIN q
799-601-4140 Adapter for engine (CRI-T3) 3 FCIG q
799-601-4150 Adapter for engine (CRI-T3) 3 FCIB q
799-601-4180 Adapter for engine (CRI-T3) 3 FCIP3 q
799-601-4230 Adapter for engine (CRI-T3) 4 1,2,3,4 q
799-601-4260 Adapter for controller (ENG) 4 DTP4 q
799-601-4210 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4280 Box for controller (PUMP) 121 q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9370 Adapter for controller (HST) 26 HST26A q
HD325-7, HD405-7 31

© 2007 KOMATSU
All Rights Reserved
32 HD325-7, HD405-7
SEN01186-01
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up
Troubleshooting by failure code, General
Failure codes table.......................................................................................................................................... 2
Before troubleshooting by failure codes........................................................................................................ 10
Contents of troubleshooting table ................................................................................................................. 14
HD325-7, HD405-7 1
Failure codes table 1

Troubleshooting by failure code, Part 1 (SEN01187-00)
Failure codes table

Failure Device in Action Category of Reference
code charge code record document No.
Mechanical
1500L0 Dual engagement TM E03
system
Mechanical
15B0NX Transmission oil filter Clogging TM E01
system
Mechanical
15F0KM R o F shifting abuse 1 Mistake in operation TM —
system
Mechanical
15F0MB R o F shifting abuse 2 Mistake in operation TM —
system
Mistake in operation or Mechanical
15F7KM Forward clutch disk abuse TM —
setting system
Electrical
15G0MW R clutch Slipping TM E03
system
15G7KM Reverse clutch disk abuse TM —
setting system
Electrical
15H0MW Hi clutch Slipping TM E03
system
Electrical
15J0MW Lo clutch Slipping TM E03
system
Electrical
15K0MW 1st clutch Slipping TM E03
system
Electrical
15L0MW 2nd clutch Slipping TM E03
system
SEN01187-00
Electrical
15M0MW 3rd clutch Slipping TM E03
system
Electrical
15N0MW 4th clutch Slipping TM E03
system
Fill signal is ON when Electrical
15SBL1 R clutch solenoid TM E03
command current is OFF system
Electrical
15SBMA R clutch solenoid Malfunction TM E03
system
15SCL1 Hi clutch solenoid TM E03
Electrical
15SCMA Hi clutch solenoid Malfunction TM E03
system
15SDL1 Lo clutch solenoid TM E03
Electrical
15SDMA Lo clutch solenoid Malfunction TM E03
system
15SEL1 1st clutch solenoid TM E03
Electrical
15SEMA 1st clutch solenoid Malfunction TM E03
system
15SFL1 2nd clutch solenoid TM E03
2 HD325-7, HD405-7

Electrical
15SFMA 2nd clutch solenoid Malfunction TM E03
system
15SGL1 3rd clutch solenoid TM E03
Electrical
15SGMA 3rd clutch solenoid Malfunction TM E03
system
Command current is OFF and Electrical
15SHL1 4th clutch solenoid TM E03
fill signal is ON system
Electrical
15SHMA 4th clutch solenoid Malfunction (MA) TM E03
system
Electrical
15SJMA Lockup clutch solenoid Malfunction TM E03
system
Engine over run prevention
(989A00) Operating MON E02 —
command signal
Rear section tipping over
(989D00) Alarm is activated MON — —
alarm
2F00KM Parking brake TM E03
setting system
Mechanical
2G42ZG Front accumulator Lowering of oil pressure BK E03
system
SEN01187-00
Mechanical
2G43ZG Rear accumulator Lowering of oil pressure BK E03
system
Mechanical
A570NX Engine oil filter Clogging BK E01
system
Mechanical
AA10NX Air cleaner element Clogging MON E01
system
Mechanical
AB00MA Alternator Malfunction MON E03
system
Abnormal lowering of engine Mechanical
B@BAZG Lowering of oil pressure ENG E02
oil pressure system
Mechanical
B@BAZK Engine oil Level too low BK E01
system
Mechanical
B@BCZK Lowering of radiator coolant Lowering of level MON E01
system
Mechanical
B@BCNS Engine Overheat ENG E02
system
Mechanical
B@GAZK Battery electrolyte level Lowering of level BK E01
system
Mechanical
B@JANS Steering oil Overheat TM E02
system
Electrical
CA111 Engine controller Abnormal ENG E03
system
Abnormal engine Ne and Both sensors have trouble Electrical
CA115 ENG E03
Bkup sensors simultaneously system
Electrical
CA122 Charge pressure sensor Too high ENG E03
system
Electrical
CA123 Charge pressure sensor Too low ENG E03
system
SEN01188-00
Electrical
CA131 Throttle sensor Too high ENG E03
system
Electrical
CA132 Throttle sensor Too low ENG E03
system
Electrical
CA135 Oil pressure sensor Too high ENG E01
system
Electrical
CA141 Oil pressure sensor Too low ENG E01
system
HD325-7, HD405-7 3

Electrical
CA144 Coolant temperature sensor Too high ENG E01
system
Electrical
CA145 Coolant temperature sensor Too low ENG E01
system
Electrical
CA153 Charge temperature sensor Too high ENG E01
system
Electrical
CA154 Charge temperature sensor Too low ENG E01
system
Electrical
system
Electrical
CA221 Atmospheric pressure sensor Too high ENG E01
system
Electrical
CA222 Atmospheric pressure sensor Too low ENG E01
system
Electrical
system
Mechanical
CA234 Engine over speed Over speed ENG E02
system
Electrical
CA238 Engine Ne speed sensor Abnormal power source ENG E03
system
Electrical
CA263 Fuel temperature sensor Too high ENG E01
system
Electrical
CA265 Fuel temperature sensor Too low ENG E01
system
Electrical
system
Electrical
system
SEN01188-00
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Engine controller data Electrical
CA342 Abnormal ENG E03
consistency system
Electrical
CA351 Injector drive circuit Abnormal ENG E03
system
Electrical
system
Electrical
system
Electrical
CA431 Idle validation switch Abnormal ENG E01
system
Process with idle validation Electrical
switch system
4 HD325-7, HD405-7

Electrical
CA441 Power source voltage Too low ENG E03
system
Mechanical
CA442 Power source voltage Too high ENG E03
system
Electrical
system
Electrical
CA451 Common rail pressure sensor Too high ENG E03
system
Electrical
CA452 Common rail pressure sensor Too low ENG E03
system
Electrical
system
Electrical
CA554 Common rail pressure sensor In-range error ENG E03
system
Loss of pressure feed from Electrical
supply pump system
Electrical
CA689 Engine Ne speed sensor Abnormal ENG E03
system
SEN01188-00
Engine Bkup speed sensor Electrical
phase system
Electrical
CA757 All engine controller data Loss ENG E03
system
Electrical
CA778 Engine Bkup speed sensor Abnormal ENG E03
system
Electrical
system
Electrical
system
Electrical
CA1626 Bypass valve solenoid drive Short circuit ENG E03
system
Electrical
CA1627 Bypass valve solenoid drive Disconnection ENG E03
system
Electrical
system
Electrical
system
Electrical
CA1631 Bypass valve lift sensor Too high ENG E03
system
Electrical
CA1632 Bypass valve lift sensor Too low ENG E03
system
Electrical
CA1633 KOMNET Abnormal ENG E03
system
Electrical
CA1642 EGR inlet pressure sensor Too low ENG E01
system
Electrical
CA1653 EGR inlet pressure sensor Too high ENG E01
system
SEN01189-00
Electrical
CA2185 Throttle sensor power source Too high ENG E03
system
Electrical
CA2186 Throttle sensor power source Too low ENG E03
system
Loss of pressure feed from Electrical
supply pump system
Electrical
CA2271 EGR valve lift sensor Too high ENG E03
system
Electrical
CA2272 EGR valve lift sensor Too low ENG E03
system
HD325-7, HD405-7 5

Electrical
CA2351 EGR valve solenoid drive Short circuit ENG E03
system
Electrical
CA2352 EGR valve solenoid drive Disconnection ENG E03
system
Electrical
CA2555 Intake air heater relay Disconnection ENG E01
system
Electrical
CA2556 Intake air heater relay Short circuit ENG E01
system
Stop lamp relay output Electrical
D19HKB Short circuit BK E01
system system
Front brake cut-off solenoid Electrical
D5ZKKZ Disconnection or short circuit BK E01
valve system
Abnormal CAN communica- Electrical
DAFRKR Abnormal communication MON E03
tion (machine monitor) system
Transmission controller direct Electrical
DAQ0KK Lowering of source voltage TM E03
power supply system
Transmission controller Electrical
DAQ0KT Abnormality in controller TM E01
nonvolatile memory system
DAQ2KK Power source voltage too low TM E03
solenoid power source system
Disagreement of model Electrical
(DAQ9KQ) Transmission controller TM E03
selection system
(DAQRMA) Malfunction MON E03
option setting system
Retarder controller nonvola- Electrical
DB10KT Abnormality in controller BK E01
tile memory system
Retarder controller solenoid Electrical
power source system SEN01189-00
Retarder controller direct Electrical
power source system
(retarder controller) system
Electrical
DB1SKQ Model selection Wrong information BK E03
system
(engine controller) system
Trouble in travel speed
Electrical
DDD7KX setting switch system Out of input signal range BK E03
system
(If equipped)
Electrical
DDD8KA ARSC system switch system Disconnection BK E03
system
Electrical
DDD8KB ARSC system switch system Short circuit BK E03
system
ASR system switch Electrical
DDDAKA Disconnection BK E01
(If equipped) system
Electrical
DDDAKB ASR system switch Short circuit BK E01
system
Electrical
DDTHKA Hi clutch fill switch Disconnection TM E03
system
Electrical
DDTJKA Lo clutch fill switch Disconnection TM E03
system
Electrical
DDTKKA 1st clutch fill switch Disconnection TM E03
system
Electrical
DDTLKA 2nd clutch fill switch Disconnection TM E03
system
6 HD325-7, HD405-7

Electrical
DDTMKA 3rd clutch fill switch Disconnection TM E03
system
Electrical
DDTNKA R clutch fill switch Disconnection TM E03
system
Electrical
DDTPKA 4th clutch fill switch Disconnection TM E03
system
Electrical
DF10KA Gear shift lever Disconnection TM E03
system
Electrical
DF10KB Gear shift lever Short circuit TM E03 SEN01189-00
system
Transmission oil temperature Electrical
DGF1KX Out of input signal range TM E03
sensor system
Retarder oil temperature Disconnection or short Electrical
DGR2KZ BK E01
sensor circuit system
Steering oil temperature Electrical
DGR6KX Input signal out of range TM E01
sensor system
Torque converter oil Electrical
DGT1KX Out of input signal range TM E01
temperature sensor system
Suspension pressure sensor Electrical
system (Rear right) system
Failure in suspension pres-
Electrical
DHP6KX sure sensor system trouble Out of input signal range BK E03
system
(Rear right)
Suspension pressure sensor Electrical
system (Rear left) system
Failure in suspension pres-
Electrical
DHP7KX sure sensor system trouble Out of input signal range BK E03
system
(Rear left)
Torque converter oil pressure Electrical
DHT5KX Out of input signal range TM E01
sensor system
Torque converter oil pressure Disagreement of run and stop Electrical
DHT5L6 TM E01
sensor condition with signal system
Front accumulator oil Electrical
Rear accumulator oil Electrical
Electrical
DJF1KA Fuel level sensor Disconnection TM E01 SEN01190-00
system
Potentiometer signal is incon- Electrical
DK51L5 Retarder lever potentiometer BK E03
sistent with swich signal system
Failure in hoist lever Electrical
DK52KX Out of input signal range BK E03
potentiometer 1 system
Failure in hoist lever Disagreement of analog Electrical
DK53L8 BK E03
potentiometer 2 signal system
Electrical
DK54KX Body positioner sensor Out of input signal range BK E03
system
Failure in steering speed Disagreement of run and stop Electrical
DKD0L6 — E01
sensor (If equipped) condition with signal system
Pitch angle sensor Electrical
DKH0KX Out of input signal range TM E01
(If equipped) system
Transmission input shaft Electrical
speed sensor system
Transmission input shaft Disagreement of revolution Electrical
DLF1LC TM E03
speed sensor speed signal system
Transmission intermediate Electrical
shaft speed sensor system
HD325-7, HD405-7 7

Transmission intermediate Disagreement of revolution Electrical
DLF2LC TM E03
shaft speed sensor speed signal system
Transmission output shaft Electrical
DLT3KA Disconnection TM E03
speed sensor system
Transmission output shaft Disagreement of revolution Electrical
DLT3LC TM E03
speed sensor (If equipped) speed signal system
Transmission output shaft Electrical
DLT4KA Disconnection BK E03
speed sensor (If equipped) system
Transmission output shaft Disagreement of revolution Electrical
DLT4LC BK E01
speed sensor (If equipped) speed signal system
Failure in output system of
Electrical
DW35KZ auto suspension solenoid 1 Disconnection or short circuit BK E01
system
(If equipped)
Failure in output system of
Electrical
DW36KZ auto suspension solenoid 2 Disconnection or short circuit BK E01
system
(If equipped)
Failure in kick-out solenoid Electrical
output system system
Failure in hoist select valve Electrical
output system system SEN01190-00
Failure in rear brake BCV Electrical
command output system system
Rear brake proportional pres- Electrical
DX11K4 Out of control BK E03
sure reducing solenoid valve system
Rear brake proportional pres-
Electrical
DX11KA sure reducing solenoid valve Disconnection BK E03
system
output circuit
Rear brake proportional pres- Electrical
DX11KB Short circuit BK E03
Rear brake proportional pres- Short circuit to power source Electrical
DX11KY BK E03
sure reducing solenoid valve line system
Rear brake proportional pres- Mechanical
DX11MA Malfunction BK E03
Output circuit of hoist EPC Electrical
DX13KA Disconnection TM E03
valve system
Output circuit of hoist EPC Electrical
DX13KB Short circuit TM E03
valve system
Output circuit of hoist EPC Short circuit with power Electrical
DX13KY TM E03
valve source line system
Lockup clutch solenoid output Electrical
DXH1KA Disconnection TM E03
circuit system
Lock-up clutch solenoid Electrical
DXH1KB Short circuit TM E03
output circuit system
Lockup clutch solenoid output Short circuit to power source Electrical
DXH1KY TM E03
circuit line system
Hi clutch solenoid output Electrical
circuit system
SEN01191-00
Hi clutch solenoid output Electrical
circuit system
Hi clutch solenoid output Short circuit to power source Electrical
DXH2KY TM E03
circuit line system
Lo clutch solenoid output Electrical
circuit system
Lo clutch solenoid output Electrical
circuit system
8 HD325-7, HD405-7

Lo clutch solenoid output Short circuit in power source Electrical
DXH3KY TM E03
circuit line system
1st clutch solenoid output Electrical
circuit system
1st clutch solenoid output Electrical
circuit system
1st clutch solenoid output Short circuit to power source Electrical
DXH4KY TM E03
circuit line system
2nd clutch solenoid output Electrical
circuit system
2nd clutch solenoid output Electrical
circuit system
2nd clutch solenoid output Short circuit in power source Electrical
DXH5KY TM E03
circuit line system
3rd clutch solenoid output Electrical
circuit system
SEN01191-00
3rd clutch solenoid output Electrical
circuit system
3rd clutch solenoid output Short circuit to power source Electrical
DXH6KY TM E03
circuit line system
R clutch solenoid output Electrical
circuit system
R clutch solenoid output Electrical
circuit system
R clutch solenoid output Short circuit to power source Electrical
DXH7KY TM E03
circuit line system
4th clutch solenoid output Electrical
DXHHKA Disconnection TM E03
circuit system
4th clutch solenoid output Electrical
DXHHKB Short circuit TM E03
circuit system
4th clutch solenoid output Short circuit to power source Electrical
DXHHKY TM E03
circuit line system
HD325-7, HD405-7 9
Before troubleshooting by failure codes 1

Wiring table for circuit breaker and slow blow fuse
a This wiring table shows apparatuses to which electric power is supplied through the circuit breakers or
slow blow fuses. (The switched power supply supplies power when the starting switch is ON, and the
constant power supply supplies power when the starting switch is OFF.)
a When proceeding to a troubleshooting by failure code, first inspect the circuit breaker to check if the
power source is supplied properly.
Type of
Breaker name Content Destinations of electric power distribution
power supply
• Fuse (BT3) (inlet terminal No.)
80 A (3), (5), (7), (9), (11), (13), (15), (17)
80A
(FUB2) • Fuse (BT4) (inlet terminal No.)
(1), (3), (5), (7)
Power source of switch • Fuse (BT1) (inlet terminal No.)

(Terminal M of (1), (3), (5), (7), (13), (15), (19)
battery relay) • Fuse (BT2) (inlet terminal No.)
80 A (7), (9), (11), (15)
80A
(1)
(9), (11), (13), (15), (17), (19)
30 A • Fuse (BT3) (inlet terminal No.)
30A
(FUA1) (21), (23)
Constant power source
(Terminal B of • Fuse (BT2) (inlet terminal No.)
battery relay) 30 A (13), (17), (19), (21), (23), (27), (29)
30A
(FUA2) • Fuse (BT3) (inlet terminal No.)
(29)
Power source of switch
(Terminal M of Slow blow fuse 300A • Engine intake air heater relay
battery relay)
10 HD325-7, HD405-7
Connection table of fuse box

a This wiring table shows apparatuses to which electric power is supplied through the fuse box. (The
switched power supply supplies power when the starting switch is ON, and the constant power supply
supplies power when the starting switch is OFF.)
a When proceeding to a troubleshooting by failure code, first inspect the fuse box to check if the power
source is supplied properly.
a Fuse numbers are indicated in the order of the fuse outlet No. o inlet No.
Type of power supply Fuse No. Fuse capacity Destination of power
(4) – (3) 20A Air conditioner
(6) – (5) 20A Heater
(8) – (7) 20A Heater
(10) – (9) 20A ABS controller
(12) – (11) 20A Retarder controller
BT3
(14) – (13) 10A Transmission controller
Switched power supply
Gearshift lever
(Battery relay
terminal M) (16) – (15) 10A Automatic emergency steering
(Circuit breaker) P/B relay
(80 A)
(18) – (17) 10A Radio
(SUB2)
(2) – (1) 10A Room lamp 2
Engine compartment lamp
(4) – (3) 10A Engine pre-heat power supply
BT4
(6) – (5) 20A Rotary lamp
Step lamp
(8) – (7) 20A Side lamp
(2) – (1) 10A Main lamp
Small lamp
(4) – (3) 10A Winker lamp
(6) – (5) 20A Headlamp (Low)
BT1
(8) – (7) 20A Headlamp (High)
(14) – (13) 10A Stop lamp
(16) – (15) 20A Backup lamp
(20) – (19) 20A Spare
Switched power supply (8) – (7) 20A Power window (Left)
(Battery relay (10) – (9) 20A Power window (Right)
terminal M) BT2
(12) – (11) 10A PLM2 controller
(Circuit breaker)
(80 A) (16) – (15) 10A Machine monitor
(SUB1) BT3 (2) – (1) 20A Fog lamp
(10) – (9) 20A Operator's seat heater
Air suspension seat
(12) – (11) 20A PLM external pilot lamp
(14) – (13) 10A Tachograph
BT4
Cigarette lighter
(18) – (17) 20A Spare power supply
(20) – (19) 20A Front wiper
HD325-7, HD405-7 11

Constant power supply (22) – (21) 30A Engine controller
(Battery relay
terminal B)
BT3
(Circuit breaker) (24) – (23) —
(30 A)
(SUA1)
(14) – (13) 10A Horn
(20) – (19) 20A Steering switch terminal B
Constant power supply (22) – (21) 10A Retarder controller
(Battery relay ABS controller
terminal B) BT2
(24) – (23) 20A Hazard lamp
(Circuit breaker)
(30 A) (28) – (27) 10A Room lamp
(SUA2) Radio
(30) – (29) 10A Machine monitor
KOMTRAX
BT3 (30) – (29) 20A Spare
BT1 (12) – (11) 20A Headlamp (High)
(18) – (17) 10A Small lamp
Fuse in circuit
BT2 PLM2 controller
(26) – (25) 10A Emergency steering power supply
(20) – (19) 5A Engine controller
BT3
12 HD325-7, HD405-7
HD325-7, HD405-7 13
Contents of troubleshooting table 1

a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
Action code Failure code
Machine Names of the failure symptoms displayed in the failure history
Machine monitor Trouble
monitor on the machine monitor
display
display
Contents of
State where the machine monitor or controller detects the trouble
trouble
Action of
Action to be taken to protect the system and equipment when the machine monitor or control-
machine moni-
ler detects a trouble
tor or controller
Problem that
Problem that appears as an abnormality in the machine by the action (above) taken by monitor
appears on
or controller
machine
Related
Information related to troubles occurred or troubleshooting
information
Cause Standard value in normal state/Remarks on troubleshooting

<Described contents>
• Standard value when normal required to judge the possi-
ble cause
• Remarks required to judge whether any cause is right or
1 not
<Symptoms of defective harness>

• Disconnection in wiring
The connector connection is defective or the wiring har-
ness is disconnected.
• Defective grounding
A harness not connected to GND (ground) circuit comes
into contact with the GND (ground) circuit.
• Hot short defect
A harness not connected to the electric power supply
2 (24V) circuit comes into contact with the electric power
supply (24V) circuit.
• Short circuit
Possible causes Cause by which a trouble is A harness abnormally comes into contact with a harness
and standard assumed to be detected of separate circuit.
value in normal (The order number indicates
state a serial number, not a priority <Points to remember when troubleshooting>
sequence.) (1) Method of indicating connector numbers and handling T-
adapter
For troubleshooting, insert or connect the T- adapter as
3 described below unless especially specified.
• When “male“or “female“ is not indicated for a connec-
tor number, disconnect the connector, and insert the T-
adapter in both the male and female.
• When “male“or “female“ is indicated for a connector
number, disconnect the connector, and insert the T-
adapter in only either the male or female.
(2) Pin number description sequence and tester lead han-
dling
For troubleshooting, connect the plus (+) and minus (-)
leads of the tester as described below unless especially
4 specified.
• Connect the plus (+) lead to a pin number or harness
indicated in the front.
• Connect the minus (-) lead to a pin number or harness
indicated in the rear.
14 HD325-7, HD405-7
Circuit diagram related
This drawing is a part of the electric circuit diagram related to trouble-

shooting.
• Connector No.: Indicates (Model - Number of pins) and (Color).
• “Connector No. and pin No.“ from each branching/merging point:
Shows the ends of branch or source of merging within the parts of the
same wiring harness.
• Arrow ( ): Roughly shows the location on the machine.
HD325-7, HD405-7 15

© 2007 KOMATSU
All Rights Reserved
16 HD325-7, HD405-7
SEN01187-01
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up
Troubleshooting by failure code, Part 1
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).............................................................................. 28
Failure code [15SCL1] (Hi clutch solenoid: Fill signal is ON when command current is OFF) ..................... 30
HD325-7, HD405-7 1
Failure code [15SCMA] (Hi clutch solenoid: Malfunction) ............................................................................. 34

Failure code [15SDL1] (Lo clutch solenoid: Fill signal is ON when command current is OFF)..................... 36
Failure code [15SDMA] (Lo clutch solenoid: Malfunction) ............................................................................ 40
Failure code [15SEL1] (1st clutch solenoid: Fill signal is ON when command current is OFF) .................... 42
Failure code [15SEMA] (1st clutch solenoid: Malfunction)............................................................................ 46
Failure code [15SFL1] (2nd clutch solenoid: Fill signal is ON when command current is OFF) ................... 48
Failure code [15SFMA] (2nd clutch solenoid: Malfunction)........................................................................... 52
Failure code [15SGL1] (3rd clutch solenoid: Fill signal is ON when command current is OFF) ................... 54
Failure code [15SGMA] (3rd clutch solenoid: Malfunction) ........................................................................... 58
Failure code [15SHL1] (4th clutch solenoid: Command current is OFF and fill signal is ON) ....................... 60
Failure code [15SHMA] (4th clutch solenoid: Malfunction (MA))................................................................... 64
Failure code [15SJMA] (Lockup clutch solenoid: Malfunction)...................................................................... 66
Failure code [989A00] (Engine over run prevention command signal: Operating) ....................................... 68
Failure code [989D00] (Rear section tipping over alarm: Alarm is activated) ............................................... 68
Failure code [2F00KM] (Parking brake: Mistake in operation or setting) ...................................................... 70
Failure code [2G42ZG] (Front accumulator: Lowering of oil pressure) ......................................................... 72
Failure code [2G43ZG] (Rear accumulator: Lowering of oil pressure).......................................................... 72
Failure code [A570NX] (Engine oil filter: Clogging)....................................................................................... 73
Failure code [AA10NX] (Air cleaner element: Clogging) ............................................................................... 74
Failure code [AB00MA] (Alternator: Malfunction).......................................................................................... 76
Failure code [B@BAZG] (Abnormal lowering of engine oil pressure: Lowering of oil pressure)................... 78
Failure code [B@BAZK] (Engine oil: Level too low)...................................................................................... 80
Failure code [B@BCZK] (Lowering of radiator coolant: Lowering of level) ................................................... 82
Failure code [B@BCNS] (Engine: Overheat) ................................................................................................ 84
Failure code [B@GAZK] (Battery electrolyte level: Lowering of level) .......................................................... 85
Failure code [B@JANS] (Steering oil: Overheat) .......................................................................................... 86
2 HD325-7, HD405-7
Failure code [1500L0] (Dual engagement) 1

Action code Failure code Dual engagement:
Trouble
E03 1500L0 (Machine monitor system)
Contents of
• Fill switch signals have been inputted from 2 clutches that do not form a normal combination.
trouble
Action of • Suddenly shifts to Neutral while traveling, and cannot move off again.
controller • Even after the repair, does not resume to normal unless starting switch is once turned OFF.
Problem that
• The gear speed is shifted to Neutral.
appears on
machine • Turns transmission Neutral relay OFF.
Related
• Other problem (clutch pressure control valve system failure code [15S*L1]) occurs at same time.
information

Possible causes Clutch pressure control valve
and standard 1 system failure code (15S*L1) Troubleshooting by the active failure code.
value in normal has occurred
state Defective transmission
2 Troubleshooting by the active failure code.
controller
HD325-7, HD405-7 3
Failure code [15B0NX] (Transmission oil filter: Clogging) 1

Action code Failure code Transmission oil filter: Clogging
Trouble
E01 15B0NX (Machine monitor system)
Contents of • When the torque converter oil temperature is above 50°C, the signal circuit of the transmission
trouble clogging sensor is opened (disconnected from GND).
Action of
• None in particular.
controller
Problem that
appears on • If the machine is used without repairing, dust may enter the transmission circuit.
machine
• This failure can be checked in the monitoring function (Code: 33300).
Related
information • After repairing the failure and confirming resetting of the machine, perform the initial learning of the
transmission controller, referring to Testing and adjusting, "Inspection of machine monitor".

Clogging of transmission
1 • Clean or replace.
filter
2) Disconnect connector TMF1.
3) Connect T-adapter.
Transmission filter clogging
2 Resis-
sensor defective Filter is normal Max. 1 z
Between TMF1 tance
(male) (1) – (2) Resis-
Filter is clogged Min. 1 Mz
tance
Possible causes 1) Turn the starting switch OFF.

and standard 2) Disconnect connectors ATC1 and TMF1.
Disconnection in wiring 3) Connect T-adapter.
value in normal
harness
state 3 Wiring harness between ATC1 (female) (17) Resis-
(Disconnection or defective Max. 1 z
– TMF1 (female) (1) tance
contact)
Wiring harness between TMF1 (female) (2) Resis-
Max. 1 z
– ground tance
2) Disconnect connectors ATC1.
3) Insert T-adapter.
Transmission controller 4) Connect conector.
4 5) Turn the starting switch ON.
defective
Between ATC1 Filter is normal Voltage Max. 1V
(female) (17) –
ground Filter is clogged Voltage 20 – 30 V
4 HD325-7, HD405-7
HD325-7, HD405-7 5
Failure code [15F0KM] (R o F shifting abuse 1: Mistake in operation) 1

Action code Failure code R o F shifting abuse 1: Mistake in operation
Trouble
— 15F0KM (Machine monitor system)
Contents of • When output shaft speed is 200 – 300 rpm (about 5 – 7 km/h), gear shifting from reverse to forward
trouble has been detected.
Action of
• Takes no particular action.
controller
Problem that
• If the machine is operated in as-is condition, the machine may be damaged.
appears on
machine • Only recorded in failure history.
Related
• Output shaft speed can be checked by monitoring function (code: 31400).
information
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal A forward-reverse shifting should be performed when the machine
1 Abuse
state is stationary.
Failure code [15F0MB] (R o F shifting abuse 2: Mistake in operation) 1

Action
Failure code R o F shifting abuse 2: Mistake in operation
code Trouble
(Machine monitor system)
— 15F0MB
Contents of • When output shaft speed is above 300 rpm (about 7 km/h), gear shifting from reverse to forward
trouble has been detected.
Action of
controller
Problem that
• If the machine is operated in as-is condition, the machine may be damaged.
appears on
Related
• Output shaft speed can be checked by monitoring function (code: 31400).
information

and standard
1 Abuse
6 HD325-7, HD405-7
Failure code [15F7KM] (Forward clutch disk abuse: Mistake in operation

or setting) 1
Action code Failure code Forward clutch disc abuse: Mistake in operation or setting
Trouble
— 15F7KM (Machine monitor system)
Contents of • When the engine speed is above 1,800 rpm, gear shifting from neutral or reverse to forward has
trouble been detected.
Action of
controller
Problem that
• Repeated abnormal operations may cause machine damage.
appears on
Related
information

and standard
1 Abuse
HD325-7, HD405-7 7
Failure code [15G0MW] (R clutch: Slipping) 1

Action code Failure code R clutch: Slipping
(Command is holding pressure, fill switch is ON, and slipping
Trouble
E03 15G0MW detected)
(Transmission controller system)
• When a signal is output to the R clutch ECMV, the value calculated from the signals of the transmis-
Contents of
sion input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission out-
trouble
put shaft speed sensor is abnormal.
• Sets gear in neutral.
Action of
• Shifts up and keeps gear according to gear speed before trouble and Table 1.
controller
• Turns lockup system OFF.
Problem that
appears on • Machine cannot travel in reverse.
machine
• Can be checked with monitoring function (Code: 31606).
• If electrical system is normal, check reverse clutch and mechanical/hydraulic system of pressure
Related
control valve for defect.
information
• When carrying out emergency escape operation, see "Emergency escape method when electrical
system has trouble".

2) Disconnect connector CN12.
1 Hi clutch ECMV defective Resis-
Between CN12 (male) (1) – (2) 5 – 15 z
tance
Resis-
Between CN12 (male) (1), (2) – ground Min. 1 Mz
tance
Possible causes 2) Disconnect connectors ATC3 and CN12.
and standard Disconnection in wiring 3) Connect T-adapter.
value in normal harness
2 Wiring harness between ATC3 (female) (25) Resis-
state (Disconnection or defective Max. 1 z
– CN12 (female) (1) tance
contact)
Wiring harness between ATC3 (female) (23) Resis-
Max. 1 z
Defective sensing by speed
3 • Troubleshooting by the failure codes of DL**KA, and DL**LC.
sensor
2) Disconnect connector ATC3.
Transmission controller 3) Connect T-adapter.
4
defective
5 – 15 z
– ATC3 (female) (23) tance
8 HD325-7, HD405-7
Table 1
Remedy against trouble
Speed when trouble
Failed clutch Action of controller ON/OFF state of
was detected
(Selected clutch, gear speed) lockup clutch
4th 4th OFF NEUTRAL OFF
F7
High High OFF NEUTRAL OFF
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
Reverse Reverse OFF NEUTRAL OFF
R1
Low Low RH R2 OFF
HD325-7, HD405-7 9
Failure code [15G7KM] (Reverse clutch disk abuse: Mistake in operation

or setting) 1
Action code Failure code Reverse clutch disc abuse: Mistake in operation or setting
Trouble
— 15G7KM (Machine monitor system)
Contents of • When the engine speed is above 1,800 rpm, gear shifting from neutral or forward to reverse has
trouble been detected.
Action of
controller
Problem that
• Repeated abnormal operations may cause machine damage.
appears on
Related
information

and standard
1 Abuse
10 HD325-7, HD405-7
HD325-7, HD405-7 11
Failure code [15H0MW] (Hi clutch: Slipping) 1

Action code Failure code Hi clutch: Slipping
Trouble
E03 15H0MW detected)
• When a signal is output to the Hi clutch ECMV, the value calculated from the signals of the trans-
Contents of
mission input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission
trouble
output shaft speed sensor is abnormal.
Action of • Shifts up and keeps gear according to gear speed before trouble and Table 1.
controller • Turns lockup system OFF.
Problem that
appears on • Machine travels at gear speeds which do not use Hi clutch.
machine
• If electrical system is normal, check Hi clutch and mechanical/hydraulic system of pressure control
Related
valve for defect.
information

1 Hi clutch ECMV defective Resis-
Between CN19 (male) (1) – (2) 5 – 15 z
tance
Resis-
tance
contact)
Max. 1 z
sensor
4
defective
5 – 15 z
12 HD325-7, HD405-7
Table 1
Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R1
Low Low RH R2 OFF
HD325-7, HD405-7 13
Failure code [15J0MW] ( Lo clutch: Slipping) 1

Action code Failure code Lo clutch: Slipping
Trouble
E03 15J0MW detected)
• When a signal is output to the Lo clutch ECMV, the value calculated from the signals of the trans-
Contents of
mission input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission
trouble
output shaft speed sensor is abnormal.
Problem that
appears on • Machine travels at gear speeds which do not use Lo clutch.
machine
• If electrical system is normal, check Lo clutch and mechanical/hydraulic system of pressure control
Related
valve for defect.
information

1 Lo clutch ECMV defective Resis-
Between CN17 (male) (1) – (2) 5 – 15 z
tance
Resis-
tance
contact)
Max. 1 z
sensor
4
defective
5 – 15 z
14 HD325-7, HD405-7
Table 1
Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R1
Low Low RH R2 OFF
HD325-7, HD405-7 15
Failure code [15K0MW] (1st clutch: Slipping) 1

Action code Failure code 1st clutch: Slipping
(1st command holding pressure, 1st clutch fill switch ON, slipping
Trouble
E03 15K0MW detected)
• During an output to the 1st clutch ECMV, an abnormality exists in the value calculated from the
Contents of
signals of transmission input shaft speed sensor, transmission intermediate shaft speed sensor
trouble
and transmission output shaft speed sensor.
• Shifts up and holds the gear speed depending on the gear speed before failure as mentioned in
Action of
Table 1.
controller
• Turns lock up to OFF.
• If gearshift lever is set in neutral, machine cannot start.
• Operator can move machine by following escape procedure.
1) Stop travel and set gearshift lever in N position.
Problem that 2) Disconnect emergency escape connectors A1 (female) and A2 (male) and connect them to each
appears on other to set machine in emergency escape mode.
machine 3) Operate gearshift lever and start machine again.
a When operating gearshift lever, release accelerator pedal.
a Operate gearshift lever from N to D – 1 or from N to R1 – R2.
a Machine is kept in emergency escape mode until starting switch is turned OFF.
• Electric current of output to ECMV can be checked by monitoring function (code: 31602)
Related
information • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 1st
clutch or pressure control valve.

1) Turn starting switch OFF.
2) Connect T-adapter to connector CN6 (male).
Resis-
1 Defective 1st clutch ECMV Between CN6 (male) (1) – (2) 5 – 15 z
tance
Resis-
tance
Possible causes 2) Connect T-adapter to connectors ATC3 (female) and CN6
and standard Disconnection in wiring (female).
contact)
Max. 1 z
Defective speed sensor
3 • Troubleshooting by failure code DL**KA, DL**LC
detection
Defective transmission 2) Connect T-adapter to connector ATC3 (female).
4
controller Wiring harness between ATC3 (female) (36) Resis-
5 – 15 z
– (3) tance
16 HD325-7, HD405-7
Table 1
Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R1
Low Low RH R2 OFF
HD325-7, HD405-7 17
Failure code [15L0MW] (2nd clutch: Slipping) 1

Action code Failure code 2nd clutch: Slipping
(2nd command holding pressure, 2nd clutch fill switch ON, slipping
Trouble
E03 15L0MW detected)
• During an output to the 2nd clutch ECMV, an abnormality exists in the value calculated from the
Contents of
trouble
Action of
Table 1.
controller
Related
information • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 2nd

Resis-
1 Defective 2nd clutch ECMV Between CN8 (male) (1) – (2) 5 – 15 z
tance
Resis-
Between CN8 (male) (1), (2) and ground Min. 1 Mz
tance
contact)
Max. 1 z
detection
4
5 – 15 z
– (23) tance
18 HD325-7, HD405-7
Table 1
Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R1
Low Low RH R2 OFF
HD325-7, HD405-7 19
Failure code [15M0MW] (3rd clutch: Slipping) 1

Action code Failure code 3rd clutch: Slipping
(3rd command holding pressure, 3rd clutch fill switch ON, slipping
Trouble
E03 15M0MW detected)
• During an output to the 3rd clutch ECMV, an abnormality exists in the value calculated from the
Contents of
trouble
Action of • Shifts up and holds the gear speed depending on the gear speed before failure as mentioned in
controller Table 1.
Related
information • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 3rd

Resis-
1 Defective 3rd clutch ECMV Between CN10 (male) (1) – (2) 5 – 15 z
tance
Resis-
tance
contact)
Max. 1 z
detection
4
5 – 15 z
– (13) tance
20 HD325-7, HD405-7
Table 1
Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R1
Low Low RH R2 OFF
HD325-7, HD405-7 21
Failure code [15N0MW] (4th clutch: Slipping) 1

Action code Failure code 4th clutch: Slipping
(4th command holding pressure, 4th clutch fill switch ON, slipping
Trouble
E03 15N0MW detected)
• During an output to the 4th clutch ECMV, an abnormality exists in the value calculated from the
Contents of
trouble
Action of
Table 1.
controller
Related
information • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 4th

Resis-
1 Defective 4th clutch ECMV Between CN14 (male) (1) – (2) 5 – 15 z
tance
Resis-
tance
contact)
Max. 1 z
detection
4
5 – 15 z
– (3) tance
22 HD325-7, HD405-7
Table 1
Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R1
Low Low RH R2 OFF
HD325-7, HD405-7 23
Failure code [15SBL1] (R clutch solenoid: Fill signal is ON when

command current is OFF) 1
Action code Failure code R clutch solenoid: Fill signal is ON when command current is OFF
Trouble
E03 15SBL1 (Transmission controller system)
Contents of • Even when output to the R clutch ECMV is turned OFF, the signal from the fill switch stays ON and
trouble the clutch is not released.
Action of
Table 2.
controller
Problem that
appears on • Once the gear shift lever is set to neutral, the machine can not move off in any gear speeds.
machine
Related • Electric current of output to ECMV can be checked by monitoring function (code: 31606)
information • Fill switch input signal can be checked with code: 38919.

When R
Resis-
Defective for R clutch fill is disen- Min. 1 Mz
1 tance
switch Between CN13 (male) (1) – gaged
ground When R
Resis-
is Max. 1 z
tance
engaged
Possible causes 1) Turn starting switch OFF.
and standard 2) Disconnect connectors ATC3 and CN13.
value in normal Defective harness grounding 3) Connect T-adapter to ATC3 (female).
2
state (Contact with ground circuit)
Min. 1 Mz
2) Connect T-adapter to connector ATC3 (female).
When R
Resis-
Defective transmission is disen- Min. 1 Mz
3 tance
controller Between ATC3 (female) (29) – gaged
ground When R
Resis-
is Max. 1 z
tance
engaged
24 HD325-7, HD405-7
Table 2
Speed when trouble Failed clutch
was detected (Fill switch ON) Action of controller ON/OFF state of
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
F7 1st OFF NEUTRAL OFF
High
Reverse OFF NEUTRAL OFF
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
R1 2nd OFF NEUTRAL OFF
Low
1st OFF NEUTRAL OFF
High RH R2 OFF
N ANY NONE No reaction —
HD325-7, HD405-7 25
26 HD325-7, HD405-7
HD325-7, HD405-7 27
Failure code [15SBMA] (R clutch solenoid: Malfunction) 1

Action code Failure code R clutch solenoid: Malfunction
(R command holding pressure, R clutch fill switch OFF, slipping
Trouble
E03 15SBMA detected)
• The signal from the fill switch stays OFF during an output to the R clutch ECMV and an abnormality
Contents of
exists in the value calculated from the signals of transmission input shaft speed sensor, transmis-
trouble
sion intermediate shaft speed sensor and transmission output shaft speed sensor.
Action of
Table 1.
controller
Problem that
appears on • Machine cannot travel in reverse.
machine
Related
information • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for R

Resis-
1 Defective R clutch ECMV Between CN12 (male) (1) – (2) 5 – 15 z
tance
Resis-
tance
contact)
Max. 1 z
detection
4
5 – 15 z
– (23) tance
28 HD325-7, HD405-7
Table 1
Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R1
Low Low RH R2 OFF
HD325-7, HD405-7 29
Failure code [15SCL1] (Hi clutch solenoid: Fill signal is ON when

Action code Failure code Hi clutch solenoid: Fill signal is ON when command signal is OFF
Trouble
E03 15SCL1 (Transmission controller system)
Contents of • Even when output to the Hi clutch ECMV is turned OFF, the signal from the fill switch stays ON and
trouble the clutch is not released.
Action of
Table 2.
controller
Problem that
• Machine travels at gear speeds which use Hi clutch.
appears on
machine • Machine cannot travel in reverse.

When Hi
Resis-
is disen- Min. 1 Mz
1 Defective Hi clutch fill switch tance
Between CN20 (male) (1) – gaged
ground When Hi
Resis-
is Max. 1 z
tance
engaged
Possible causes
2) Disconnect connectors ATC3 and CN20.
and standard
2
state (Contact with ground circuit) Between ground and wiring harness
Resis-
between ATC3 (female) (30) – CN20 Min. 1 Mz
tance
(female) (1)
When Hi
Resis-
Defective transmission is disen- Min. 1 Mz
3 tance
controller Between ATC3 (female) (30) – gaged
ground When Hi
Resis-
is Max. 1 z
tance
engaged
30 HD325-7, HD405-7
Table 2
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R2 OFF
HD325-7, HD405-7 31
32 HD325-7, HD405-7
HD325-7, HD405-7 33
Failure code [15SCMA] (Hi clutch solenoid: Malfunction) 1

Action code Failure code Hi clutch solenoid: Malfunction
(Hi command holding pressure, Hi clutch fill switch OFF, slipping
Trouble
E03 15SCMA detected)
• The signal from the fill switch stays OFF during an output to the Hi clutch ECMV and an abnormality
Contents of
trouble
Action of
Table 1.
controller
Problem that
appears on • Machine travels at gear speeds which do not use Hi clutch.
machine
Related
information • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for Hi

Resis-
1 Defective Hi clutch ECMV Between CN19 (male) (1) – (2) 5 – 15 z
tance
Resis-
tance
contact)
Max. 1 z
detection
4
5 – 15 z
– (3) tance
34 HD325-7, HD405-7
Table 1
Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R1
Low Low RH R2 OFF
HD325-7, HD405-7 35
Failure code [15SDL1] (Lo clutch solenoid: Fill signal is ON when

Action code Failure code Lo clutch solenoid: Fill signal is ON when command current is OFF
Trouble
E03 15SDL1 (Transmission controller system)
Contents of • Even when output to the Lo clutch ECMV is turned "OFF", the signal from the fill switch stays "ON"
trouble and the clutch is not released.
• Shifts up and holds the gear speed as shown in Table 2 depending on the gear speed before fail-
Action of
ure.
controller
Problem that
• Machine travels at gear speeds which use Lo clutch.
appears on
machine • Machine cannot travel in reverse.

When Lo
Resis-
is Min. 1 Mz
1 Defective Lo clutch fill switch tance
Between CN18 (male) (1) – released
ground When Lo
Resis-
is Max. 1 z
tance
engaged
Possible causes
and standard
2
Resis-
tance
(female) (1)
When Lo
Resis-
Defective transmission is Min. 1 Mz
3 tance
controller Between ATC3 (female) (10) – released
ground When Lo
Resis-
is Max. 1 z
tance
engaged
36 HD325-7, HD405-7
Table 2
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R2 OFF
HD325-7, HD405-7 37
38 HD325-7, HD405-7
HD325-7, HD405-7 39
Failure code [15SDMA] (Lo clutch solenoid: Malfunction) 1

Action code Failure code Lo clutch solenoid: Malfunction
(Lo command holding pressure, Lo clutch fill switch OFF, slipping
Trouble
E03 15SDMA detected)
• The signal from the fill switch stays OFF during an output to the Lo clutch ECMV and an abnormality
Contents of
trouble
Action of
ure.
controller
Problem that
appears on • Machine travels at gear speeds which do not use Lo clutch.
machine
Related
information • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for Lo

Resis-
1 Defective Lo clutch ECMV Between CN17 (male) (1) – (2) 5 – 15 z
tance
Resis-
tance
contact)
Max. 1 z
detection
4
5 – 15 z
– (13) tance
40 HD325-7, HD405-7
Table 1
Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R1
Low Low RH R2 OFF
HD325-7, HD405-7 41
Failure code [15SEL1] (1st clutch solenoid: Fill signal is ON when

Action code Failure code 1st clutch solenoid: Fill signal is ON when command current is OFF
Trouble
E03 15SEL1 (Transmission controller system)
Contents of • Even when output to the 1st clutch ECMV is turned "OFF", the signal from the fill switch stays "ON"
Action of
ure.
controller
Problem that
appears on • Machine travels at gear speeds which use 1st clutch.
machine

When 1st
Resis-
is Min. 1 Mz
1 Defective 1st clutch fill switch tance
Between CN7 (male) (1) – released
ground When 1st
Resis-
is Max. 1 z
tance
engaged
Possible causes
and standard
2
Resis-
between ATC3 (female) (40) – CN7 (female) Min. 1 Mz
tance
(1)
When 1st
Resis-
3 tance
ground When 1st
Resis-
is Max. 1 z
tance
engaged
42 HD325-7, HD405-7
Table 2
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R2 OFF
HD325-7, HD405-7 43
44 HD325-7, HD405-7
HD325-7, HD405-7 45
Failure code [15SEMA] (1st clutch solenoid: Malfunction) 1

Action code Failure code 1st clutch solenoid: Malfunction
(1st command holding pressure, 1st clutch fill switch OFF, slipping
Trouble
E03 15SEMA detected)
• The signal from the fill switch stays OFF during an output to the 1st clutch ECMV and an abnormal-
Contents of
ity exists in the value calculated from the signals of transmission input shaft speed sensor, transmis-
trouble
Action of
ure.
controller
Problem that
appears on • Machine travels at gear speeds which do not use 1st clutch.
machine
Related
information • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 1st

Resis-
tance
Resis-
tance
2 Wiring harness between ACT3 (female) (36) Resis-
contact)
Max. 1 z
detection
4
5 – 15 z
– (3) tance
46 HD325-7, HD405-7
Table 1
Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R1
Low Low RH R2 OFF
HD325-7, HD405-7 47
Failure code [15SFL1] (2nd clutch solenoid: Fill signal is ON when

Action code Failure code 2nd clutch solenoid: Fill signal is ON when command current is
Trouble OFF
E03 15SFL1 (Transmission controller system)
Contents of • Even when output to the 2nd clutch ECMV is turned "OFF", the signal from the fill switch stays "ON"
Action of
ure.
controller
Problem that
appears on • Machine travels at gear speeds which use 2nd clutch.
machine

When 2nd
Resis-
Defective fill switch for 2nd is Min. 1 Mz
1 tance
clutch Between CN9 (male) (1) – released
ground When 2nd
Resis-
is Max. 1 z
tance
engaged
Possible causes
and standard
2
Resis-
tance
(1)
When 2nd
Resis-
3 tance
ground When 2nd
Resis-
is Max. 1 z
tance
engaged
48 HD325-7, HD405-7
Table 2
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R2 OFF
HD325-7, HD405-7 49
50 HD325-7, HD405-7
HD325-7, HD405-7 51
Failure code [15SFMA] (2nd clutch solenoid: Malfunction) 1

Action code Failure code 2nd clutch solenoid: Malfunction
(2nd command holding pressure, 2nd clutch fill switch OFF, slip-
Trouble
E03 15SFMA ping detected)
• The signal from the fill switch stays OFF during an output to the 2nd clutch ECMV and an abnormal-
Contents of
trouble
Action of
ure.
controller
Problem that
appears on • Machine travels at gear speeds which do not use 2nd clutch.
machine
Related
information • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 2nd

Resis-
tance
Resis-
tance
contact)
Max. 1 z
detection
4
controller Wiring harness between ACT3 (female) (5) Resis-
5 – 15 z
– (23) tance
52 HD325-7, HD405-7
Table 1
Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R1
Low Low RH R2 OFF
HD325-7, HD405-7 53
Failure code [15SGL1] (3rd clutch solenoid: Fill signal is ON when

Action code Failure code 3rd clutch solenoid: Fill signal is ON when command current is
Trouble OFF
E03 15SGL1 (Transmission controller system)
Contents of • Even when output to the 3rd clutch ECMV is turned "OFF", the signal from the fill switch stays "ON"
Action of
ure.
controller
Problem that
appears on • Machine travels at gear speeds which use 3rd clutch.
machine

When 3rd
Resis-
Defective 3rd clutch fill is Min. 1 Mz
1 tance
switch Between CN11 (male) (1) – released
ground When 3rd
Resis-
is Max. 1 z
tance
engaged
Possible causes
and standard
2
Resis-
tance
(female) (1)
When 3rd
Resis-
3 tance
ground When 3rd
Resis-
is Max. 1 z
tance
engaged
54 HD325-7, HD405-7
Table 2
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R2 OFF
HD325-7, HD405-7 55
56 HD325-7, HD405-7
HD325-7, HD405-7 57
Failure code [15SGMA] (3rd clutch solenoid: Malfunction) 1

Action code Failure code 3rd clutch solenoid: Malfunction
(3rd command holding pressure, 3rd clutch fill switch OFF, slipping
Trouble
E03 15SGMA detected)
• The signal from the fill switch stays OFF during an output to the 3rd clutch ECMV and an abnormal-
Contents of
trouble
Action of
ure.
controller
Problem that
appears on • Machine travels at gear speeds which do not use 3rd clutch.
machine
Related
information • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 3rd

Resis-
tance
Resis-
tance
contact)
Max. 1 z
detection
4
5 – 15 z
– (13) tance
58 HD325-7, HD405-7
Table 1
Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R1
Low Low RH R2 OFF
HD325-7, HD405-7 59
Failure code [15SHL1] (4th clutch solenoid: Command current is OFF

and fill signal is ON) 1
Trouble 4th clutch solenoid: Command current is OFF and fill signal is ON.
E03 15SHL1
Contents of • When output to 4th clutch ECMV is turned OFF, signal from fill switch is kept ON and clutch is not
trouble disengaged.
Problem that
• Gear is set in neutral suddenly during travel.
appears on
machine • Machine travels at gear speeds which use 4th clutch.
Related • Current output to ECMV can be checked with monitoring function (Code: 31605).

1 Defective 4th clutch fill switch When dis- Resis-
Min. 1 Mz
Between CN15 (male) (1) – engaged tance
ground When Resis-
Max. 1 z
engaged tance
value in normal Ground fault in wiring 3) Connect T-adapter to ATC3 (female).
2
state harness
Min. 1 Mz
Defective transmission
3 When dis- Resis-
controller Min. 1 Mz
Between ATC3 (female) (20) – engaged tance
ground When Resis-
Max. 1 z
engaged tance
60 HD325-7, HD405-7
Table 2
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R2 OFF
HD325-7, HD405-7 61
62 HD325-7, HD405-7
HD325-7, HD405-7 63
Failure code [15SHMA] (4th clutch solenoid: Malfunction) 1

Action code Failure code 4th clutch solenoid: Malfunction
Trouble (Command is holding pressure, fill switch is ON, and slipping
E03 15SHMA detected)
• When a signal is output to the 4th clutch ECMV, the signal from the fill switch is kept OFF and the
Contents of
value calculated from the signals of the transmission input shaft speed sensor, transmission inter-
trouble
mediate shaft speed sensor, and transmission output shaft speed sensor is abnormal.
• The controller sets the gear in Neutral.
Action of • Shifts up and holds the gear speed depending on the gear speed before failure as mentioned in
controller Table 1.
Problem that
• The gear is set in Neutral suddenly during travel.
appears on
machine • Machine travels at gear speeds which do not use 4th clutch.
Related
information • If the electric system is normal, check the hydraulic/mechanical system of the 4th clutch and pres-
sure control valve for a defect.

1 4th clutch ECMV defective Resis-
Between CN14 (male) (1) – (2) 5 – 15 z
tance
Resis-
tance
contact)
Max. 1 z
sensor
4
defective
5 – 15 z
– (3) tance
64 HD325-7, HD405-7
Table 1
Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R1
Low Low RH R2 OFF
HD325-7, HD405-7 65
Failure code [15SJMA] (Lockup clutch solenoid: Malfunction) 1

Action code Failure code Lockup clutch solenoid: Malfunction
(Lockup command holding pressure is applied and slipping
Trouble
E03 15SJMA detected)
• During an output to the lockup clutch solenoid, an abnormality exists in the value calculated from
Contents of
the signals of engine speed sensor, transmission intermediated shaft speed sensor, and transmis-
trouble
sion output shaft speed sensor.
Action of • Holds gear speed during traveling and turns lock up to OFF.
controller • Holds neutral when gear shift lever is set to "N".
Problem that
• Lockup is released and gear shift is disabled.
appears on
machine • If gear shift lever is shifted to "N", machine does not start unless it is stopped.
Related
information • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for
lockup clutch or pressure control valve.

Defective lockup clutch Resis-
1 Between CN16 (male) (1) – (2) 5 – 15 z
solenoid tance
Resis-
tance
contact)
Max. 1 z
detection
4
5 – 15 z
– (23) tance
66 HD325-7, HD405-7
HD325-7, HD405-7 67
Failure code [989A00] (Engine over run prevention command signal:

Operating) 1
Action code Failure code Engine over run prevention command signal: Operating
Trouble
E02 989A00 (Transmission controller system)
Contents of • When gear speed is set at the position other than neutral, transmission input shaft speed signal
trouble exceeds the input shaft speed which is set for each gear speed to prevent over run.
Action of
• Send out command signal to retarder controller and activate brake.
controller
Problem that
appears on • Brake becomes activated and travel speed lowers.
machine
• Input shaft speed can be checked in monitoring function (code: 31200).
Related
information • Information on operation of engine overrun prevention command is obtained from transmission con-
troller through network.

a If machine is so traveling that transmission input shaft speed sig-
Possible causes
1 Engine over run nal exceeds 2,600 rpm (or 2,400 rpm at R2), engine is overrun-
and standard
ning.
value in normal
state • If machine is not so traveling that transmission input shaft speed
2 signal exceeds 2,600 rpm (or 2,400 rpm at R2), transmission
controller
controller is defective.
Failure code [989D00] (Rear section tipping over alarm: Alarm is

activated) 1
Action code Failure code Rear section tipping over alarm: Alarm is activated
Trouble (Lift operation when machine is inclined)
— 989D00 (Machine monitor system)
Contents of
• Body is lifted when machine is inclined.
trouble
Action of • Inclination caution lamp
controller • Turns on centralized warning lamp and sounds alarm buzzer.
Problem that
appears on • If body is lifted in such condition, machine body may tip over.
machine
• Input signal from pitch angle sensor can be checked with monitoring function (code: 32900, 32903).
Related
information • Information on operation of inclination alarm activation is obtained from transmission controller
through network.

and standard
value in normal 1 Mistake in operation Do not lift body when machine is inclined for more than 15°.
state
68 HD325-7, HD405-7
HD325-7, HD405-7 69
Failure code [2F00KM] (Parking brake: Mistake in operation or setting) 1

Action code Failure code Parking brake: Mistake in operation or setting
Trouble (Parking brake drags)
E03 2F00KM (Retarder controller system)
Contents of • When the output shaft speed is above 200 rpm (approx. 5 km/h), the parking brake or emergency
trouble brake is operated.
Action of
controller
Problem that
appears on • If the machine is used without repairing, it may be broken.
machine
Related
information

• Set the parking brake switch in the FREE position and then start
Mistake in operation of the machine.
1
parking brake switch • Stop the machine perfectly, and then set the emergency brake
switch in the FREE position and start the machine.
2) Replace R03 with normal one.
When the parking Relay (R03) is
Yes
brake relay (R03) is normal
replaced, is failure Relay (R03) is
repaired? No
defective
2) Disconnect connector R03.
3) Check the relay.
Parking brake relay (R03)
2 Resis- 200 – 400
defective Between R03 (male) (1) – (2)
tance z
and standard 2) Disconnect connector R03.
value in normal 3) Check the relay.
state 4) Apply voltage between R03 (male) (1) – (2).
Apply 24 V between Resis-
Min. 1 Mz
Between R03 (male) (1) – (2) tance
(3) – (6) Do not apply 24 V Resis-
Max. 1 z
between (1) – (2) tance
2) Connect T-adapter to connector PSWR (male).
3) Start engine.
Set parking brake
Parking brake oil pressure Resis-
3 switch in FREE Min. 1 Mz
switch defective tance
Between PSWR position
(male) (1) – (2) Set parking brake
Resis-
switch in PARK Max. 1 z
tance
position
Mistake in operation of
emergency brake
4 • Operate the emergency brake only when necessary.
(Operation of emergency
brake during travel)
70 HD325-7, HD405-7

2) Connect T-adapter to connector R03 (female).
Wiring harness between R03 (female) (2), Resis-
Max. 1 z
Disconnection in wiring (6) – chassis ground tance
harness 1) Turn starting switch OFF.
5
(Disconnection or defective 2) Connect T-adapter to connectors R03, BT3, and PSWR (female).
contact) Wiring harness between fuse BT3 (16) – Resis-
Max. 1 z
PSWR (female) (1) tance
Wiring harness between R03 (female) (1) – Resis-
Max. 1 z
and standard 2) Disconnect connectors BRC3 and R03.
Ground fault of wiring 3) Connect T-adapter.
value in normal 6
harness
state Wiring harness between BRC3 (female) (9), Resis-
Min. 1 Mz
R03 (female) (3) – ground tance
2) Disconnect connector BRC3.
4) Connect connector BRC3
7 Retarder controller defective Set parking brake
switch in FREE Voltage Max. 1 V
Between BRC3 (9) – position
ground Set parking brake
switch in PARK Voltage 20 – 30 V
position
HD325-7, HD405-7 71
Failure code [2G42ZG] (Front accumulator: Lowering of oil pressure) 1

Action code Failure code Front accumulator: Lowering of oil pressure
Trouble
E03 2G42ZG (Retarder controller system)
Contents of • The signal of the front accumulator oil pressure sensor lowers below 12.7 MPa {130 kg/cm2} while
trouble the engine is running (continuously for more than 30 seconds).
Action of
controller
Problem that
appears on • If the machine is used without repairing, the front brake may not work.
machine
Related
• This failure can be checked in the monitoring function (Code: 35500, 35504)
information

Possible causes • The front accumulator (brake) oil pressure is normal.
Lowering of front accumula-
and standard 1 a If the oil pressure is not normal, perform troubleshooting for
tor (brake) oil pressure
value in normal hydraulic/mechanical system.
state
• If the front accumulator (brake) oil pressure is normal, the
2 Retarder controller defective
retarder controller is defective.
Failure code [2G43ZG] (Rear accumulator: Lowering of oil pressure) 1

Action code Failure code Rear accumulator: Lowering of oil pressure
Trouble
E03 2G43ZG (Retarder controller system)
Contents of • The signal of the rear accumulator oil pressure sensor lowers below 8.83 MPa {90 kg/cm2} while the
trouble engine is running (continuously for more than 30 seconds).
Action of
controller
Problem that
appears on • If the machine is used without repairing, the rear brake may not work.
machine
Related
• This failure can be checked in the monitoring function (Code: 35501, 35505)
information

Possible causes • The rear accumulator (brake) oil pressure is normal.
Lowering of rear accumulator
and standard 1 a If the oil pressure is not normal, perform troubleshooting for
(brake) oil pressure
value in normal hydraulic/mechanical system.
state
• If the rear accumulator (brake) oil pressure is normal, the
retarder controller is defective.
72 HD325-7, HD405-7
Failure code [A570NX] (Engine oil filter: Clogging) 1

Action code Failure code Engine oil filter: Clogging
Trouble
E01 A570NX (Retarder controller system)
• When engine speed is above 500 rpm and torque converter oil temperature is above 50°C, and
Contents of
engine coolant temperature is above 67°C, oil filter circuit is opened (disconnected from ground cir-
trouble
cuit).
Action of
controller
Problem that
appears on • If engine is used for long hours, it may be seized.
machine
Related
information

When maintenance caution lamp
1 Clogged oil filter Oil filter is probably clogged
is lighting
2) Disconnect switch terminal E05.
Resis-
Defective oil filter clogging Terminal of switch Oil filter
2 tance
switch
When normal Max. 1 z
Between E05 – ground When clogging
Min. 1 Mz
Possible causes switch is open
and standard 1) Turn starting switch OFF.
value in normal Disconnection in wiring 2) Disconnect connector BRC2 and switch terminal E05.
state harness 3) Connect T-adapter to BRC2 (female).
3
(Disconnection in wiring or
defective contact in connector) Wiring harness between BRC2 (female) Resis-
Max. 1 z
(13) – terminal E05 tance
2) Insert T-adapter in connector BRC2.
3) Turn starting switch ON.
4 Defective retarder controller BRC2 Oil filter Voltage
When normal Max. 1 V
Between (13) – ground When clogging
20 – 30 V
switch is open
HD325-7, HD405-7 73
Failure code [AA10NX] (Air cleaner element: Clogging) 1

Action code Failure code Air cleaner element: Clogging
Trouble
E01 AA10NX (Transmission controller system)
Contents of
• The air cleaner clogging signal circuit is opened (disconnected from GND).
trouble
Action of
controller
Problem that
appears on • If the machine is used without repairing, the suction performance of the engine may be lowered.
machine
Related
information

The dust indicator is not red Air cleaner is normal
1 Clogging of air cleaner
The dust indicator is red Air cleaner is clogged
2) Replace R32 with normal one.
3) Turn the starting switch ON.
Relay (R32) is
When the dust indicator relay No
normal
(R32) is replaced, is failure
repaired? Relay (R32) is
Yes
defective
Dust indicator relay (R32) 3) Check the relay.
2
defective Resis- 200 – 400
Between R32 (male) (1) – (2)
tance z
Possible causes
3) Check the relay.
and standard
4) Apply voltage between R32 (male) (1) – (2).
value in normal
state Apply 24 V between Resis-
Min. 1 Mz
Between R32 (male) (1) – (2) tance
(3) – (6) Do not apply 24 V Resis-
Max. 1 z
between (1) – (2) tance
2) Disconnect connector FR01.
Air cleaner clogging sensor
3 Resis-
defective Air cleaner is normal Max. 1 z
Between FR01 tance
(male) (1) – (2) Resis-
Air cleaner is clogged Min. 1 Mz
tance
2) Disconnect connectors ATC3, ATC2 and R32.
harness
– R32 (female) (6) tance
contact)
Max. 1 z
– R32 (female) (3) tance
74 HD325-7, HD405-7

2) Disconnect connectors R32 and FR01.
Ground fault of wiring har- 3) Connect T-adapter.
5
Possible causes ness
and standard Min. 1 Mz
FR01 (female) (1) – ground tance
value in normal
state 1) Turn starting switch OFF.
2) Insert T-adapter in connectors ATC3 and ATC2.
Transmission controller 3) Turn starting switch ON.
6
defective
Between ATC2 (17) – Air cleaner is normal Voltage 20 – 30 V
ATC3 (21) Air cleaner is clogged Voltage Max. 1 V
HD325-7, HD405-7 75
Failure code [AB00MA] (Alternator: Malfunction) 1

Action code Failure code Alternator: Malfunction
Trouble (Failure in battery charging circuit)
E03 AB00MA (Transmission controller system)
Contents of
• A generation signal is not input from the alternator while the engine is running.
trouble
Action of
controller
Problem that
• If the machine is used without repairing, the source voltage may lower so much that the machine
appears on
cannot travel.
machine
Related
This failure can be checked in the monitoring function (Code: 04301).
information

2) Disconnect connector alternator terminal R.
1 Alternator defective 27.5 – 29.5
Between alternator R – E Voltage
V
a If the battery is deteriorated or used in a cold district, the volt-
age may not rise for a while after the engine is started.
Possible causes 27.5 – 29.5
Disconnection in wiring Voltage
and standard Wiring harness between ATC1 (female) (1) V
value in normal harness – alternator terminal R
2 Resis-
tance
contact)
Wiring harness between battery relay termi- Resis-
Max. 1 z
nal M – alternator terminal R tance
Transmission controller 4) Start the engine.
3
defective
Between ATC1 (1) – chassis ground Voltage 20 – 30 V
76 HD325-7, HD405-7
HD325-7, HD405-7 77
Failure code [B@BAZG] (Abnormal lowering of engine oil pressure:

Lowering of oil pressure) 1
Action code Failure code Abnormal lowering of engine oil pressure: Lowering of oil pressure
Trouble
E02 B@BAZG (Mechanical system)
Contents of • While engine was running, signal circuit of engine oil pressure switch detected lowering of engine
trouble oil pressure (opening of sensor contact).
Action of • Displays engine oil pressure monitor on machine monitor.
machine monitor • Sets oil pressure to default value (250 kPa {2.5 kg/cm2}) and continues operation.
Problem that
appears on • Engine is used as it is, it may be damaged.
machine
• Input condition (voltage) from oil pressure sensor can be checked with monitoring function
(Code: 37200, 27201).
Related
• Engine oil pressure switch signal is input to engine controller and its information is transmitted
information
through communication system to machine monitor.
• Method of reproducing failure code: Start engine.

Defective sensor power If code [CA187] or [CA227] is displayed, carry out troubleshooting
1
supply system for it first.
a Prepare with starting switch OFF, then turn starting switch ON
or start engine and carry out troubleshooting.
POIL Voltage
Defective oil pressure sensor
2 Between (1) – (2) Power supply 4.75 – 5.25 V
(Internal defect)
Sensor voltage is measured with wiring harness connected.
Accordingly, if voltage is abnormal, check wiring harness and con-
troller, too, for another cause of trouble, and then judge.
a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
Possible causes Disconnection in wiring Wiring harness between ENG (female) (37) Resis-
Max. 1 z
and standard harness – POIL (female) (1) tance
3
value in normal (Disconnection in wiring or Wiring harness between ENG (female) (47) Resis-
state defective contact in connector) Max. 1 z
– POIL (female) (2) tance
Wiring harness between ENG (female) (13) Resis-
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
Ground fault in wiring
4 harness Min. 1 Mz
(Contact with GND circuit)
Min. 1 Mz
or start engine and carry out troubleshooting.
5 Defective engine controller
ENG Voltage
Between (37) – (47) Power supply 4.75 – 5.25 V
78 HD325-7, HD405-7
HD325-7, HD405-7 79
Failure code [B@BAZK] (Engine oil: Level too low) 1

Action code Failure code Engine oil: Level too low
Trouble
E01 B@BAZK (Machine monitor system)
Contents of
• Engine oil level switch circuit has become "OPEN" (disconnected with GND).
trouble
Action of
• Turn on the maintenance caution lamp.
controller
Problem that
appears on • If machine is operated in such a condition, engine may be seized.
machine
Related • This trouble is not detected while engine coolant temperature is above 60°C.
information • This failure code is reset when engine is started.

• Engine oil level is normal.
1 Engine oil level is too low. a If engine oil level is too low, check for an oil leakage around
engine before refilling.
a Prepare with starting switch OFF and troubleshooting with
starting switch still OFF.
Defective engine oil level Engine oil level is Resis-
2 Max. 1 z
switch Between E04 (male) normal tance
Possible causes (1) and ground Engine oil level is too Resis-
Min. 1 Mz
and standard low tance
value in normal
Disconnection in wiring a Prepare with starting switch OFF and troubleshooting with
state
harness starting switch still OFF.
3
(Disconnection or defective Wiring harness between BRC2 (female) (7) Resis-
contact) Max. 1 z
– E04 (female) (1) tance
starting switch ON.
Defective retarder Engine oil level is
4 Voltage Max. 1V
controller Between BRC2 (7) – normal
ground Engine oil level is too
Voltage 20 – 30 V
low
80 HD325-7, HD405-7
HD325-7, HD405-7 81
Failure code [B@BCZK] (Lowering of radiator coolant: Lowering of

level) 1
Action code Failure code Lowering of radiator coolant: Lowering of level
Trouble
E01 B@BCZK (Machine monitor system)
Contents of
• The radiator coolant level switch signal circuit is opened (disconnected from GND).
trouble
Action of
controller
Problem that
appears on • If the machine is used without repairing, the engine may overheat.
machine
Related
information

• The radiator coolant level is normal.
Lowering of radiator coolant
1 a If the radiator coolant level is low, check around the engine
level
and radiator for coolant leakage before adding coolant.
2) Disconnect connector FR02.
Radiator coolant level switch
2 Radiator coolant Resis-
defective Max. 1 z
Between FR02 level is normal tance
(male) (1) – (2) Radiator coolant Resis-
Min. 1 Mz
level is low tance
and standard 2) Disconnect connectors ATC2, ATC3 and FR02.
value in normal Disconnection in wiring 3) Connect T-adapter.
state harness
– FR02 (female) (1) tance
contact)
Wiring harness between FR02 (female) (2) Resis-
Max. 1 z
2) Disconnect connectors ATC2, ATC3.
Transmission controller 4) Turn the starting switch ON.
4
defective Radiator coolant
Between ATC2 Voltage Max. 1V
level is normal
(female) (27) – ATC3
(female) (21) Radiator coolant
Voltage 20 – 30 V
level is low
82 HD325-7, HD405-7
HD325-7, HD405-7 83
Failure code [B@BCNS] (Engine: Overheat) 1

Action code Failure code Engine: Overheat
Trouble
E02 B@BCNS (Machine monitor system)
Contents of • Coolant temperature sensor signal circuit detected a coolant overheat (above 102°C) while engine
trouble is running.
Action of • Indicate the coolant temperature monitor of the machine monitor in red.
controller • When coolant temperature drops below 102°C, it returns to normal.
Problem that
appears on • If the machine is operated in such a condition, engine may be damaged.
machine
• Signal of coolant temperature sensor is inputted into the engine controller and that information is
Related
transmitted to the machine monitor through communication system.
information
• Coolant temperature can be checked with monitoring function (code: 04104 and 04105).

Coolant overheat a Investigate the cause and irregular condition of engine, and
1
(When system is normal) carry out the repair.
Defective coolant tem TWTR (male) Coolant temperature Resistance
2 perature sensor
(internal short circuit) Between (A) – (B) 90 – 3.5 kz
Between (A) – 10 – 100°C
Possible causes Min. 1 Mz
ground
and standard
value in normal a Prepare with starting switch OFF and troubleshooting with
state starting switch still OFF.
3 Defective harness grounding Between ground and wiring harness
Resis-
between TWTR (female) (A) – ENG Min. 1 Mz
tance
(female) (15)
4 Defective engine controller ENG (male) Coolant temperature Resistance
Between (15) –
10 – 100°C 90 – 3.5 kz
ground
84 HD325-7, HD405-7
Failure code [B@GAZK] (Battery electrolyte level: Lowering of level) 1

Action code Failure code Battery electrolyte level: Lowering of level
Trouble
E01 B@GAZK (Retarder controller system)
Contents of
• While engine speed is below 100 rpm, input signal is closed (disconnected from ground circuit).
trouble
Action of
controller
Problem that
appears on • If machine is used as it is, battery is deteriorated.
machine
Related
information

Check battery electrolyte level. If it is low, add new electrolyte.
1 Low battery electrolyte level
(If this trouble occurs frequently, check for overcharging.)
2) Connect T-adapter to connector BTL (male).
Defective battery electrolyte Battery electrolyte Resis-
2 BTL (male)
level switch level tance
Possible causes When normal Max. 1 z
and standard Between (1) – ground
value in normal When low Min. 1 Mz
Disconnection in wiring 2) Connect T-adapter to connectors BTC2 (female) and BTL
harness (female).
3
(Disconnection in wiring or
defective contact in connector) Wiring harness between BRC2 (female) Resis-
Max. 1 z
(38) – BTL (female) (1) tance
4 Defective pump controller 2) Connect T-adapter to connector BTC2 (female).
Between BRC2 (female) (38) – ground Voltage 20 – 30 V
HD325-7, HD405-7 85
Failure code [B@JANS] (Steering oil: Overheat) 1

Action code Failure code Steering oil: Overheat
Trouble
E02 B@JANS (Transmission controller system)
Contents of • Voltage of steering temperature sensor circuit has become below 1.61 V (oil temperature is above
trouble 120°C).
• No particular action
Action of
• Turn on steering oil temperature caution lamp.
controller
• Turns on centralized warning lamp and sounds alarm buzzer.
Problem that
appears on • If machine is operated in such a condition, it may cause an oil leakage.
machine
Related
• Steering oil temperature can be checked with monitoring function (code: 32701 and 32702).
information

Steering oil temperature is
overheated. Since the overheat of the steering oil can be suspected, if there is
Possible causes 1
(When the system is operat- an overheat, repair the cause of the failure.
and standard
ing normally)
value in normal
state If no problem is found in cause 1, the steering oil temperature
Defective steering oil sensor system can be suspected to be defective. Carry out the
2
temperature sensor troubleshooting of [Steering oil temperature does not indicate
correctly] in E mode.
86 HD325-7, HD405-7
HD325-7, HD405-7 87

© 2007 KOMATSU
All Rights Reserved
88 HD325-7, HD405-7
SEN01188-01
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up
40 Troubleshooting
Failure code [CA111] (Abnormality in engine controller) ................................................................................. 3
Failure code [CA115] (Abnormal engine Ne and Bkup sensors) .................................................................... 4
Failure code [CA122] (Charge pressure sensor too high) .............................................................................. 6
Failure code [CA123] (Charge pressure sensor too low)................................................................................ 8
Failure code [CA131] (Throttle sensor too high) ........................................................................................... 10
Failure code [CA132] (Throttle sensor too low) ............................................................................................ 12
Failure code [CA135] (Oil pressure sensor too high).................................................................................... 14
Failure code [CA141] (Oil pressure sensor too low) ..................................................................................... 16
Failure code [CA144] (Coolant temperature sensor too high) ...................................................................... 18
Failure code [CA145] (Coolant temperature sensor too low)........................................................................ 20
Failure code [CA153] (Charge temperature sensor too high) ....................................................................... 22
Failure code [CA154] (Charge temperature sensor too low) ........................................................................ 24
Failure code [CA187] (Sensor power source 2 too low) ............................................................................... 24
Failure code [CA221] (Atmospheric pressure sensor too high) .................................................................... 26
Failure code [CA222] (Atmospheric pressure sensor too low)...................................................................... 28
Failure code [CA227] (Sensor power source 2 too high) .............................................................................. 30
HD325-7, HD405-7 1
Failure code [CA234] (Engine over speed) ................................................................................................... 32

Failure code [CA238] (Abnormal power source for engine Ne speed sensor).............................................. 34
Failure code [CA263] (Fuel temperature sensor too high) ............................................................................ 36
Failure code [CA265] (Fuel temperature sensor too low) ............................................................................. 38
Failure code [CA271] (PCV1 short circuit) .................................................................................................... 39
Failure code [CA272] (PCV1 disconnection)................................................................................................. 40
Failure code [CA273] (PCV2 short circuit) .................................................................................................... 41
Failure code [CA274] (PCV2 disconnection)................................................................................................. 42
Failure code [CA322] (Injector No. 1 system disconnection or short circuit)................................................. 44
Failure code [CA342] (Abnormal engine controller data consistency) .......................................................... 56
Failure code [CA351] (Abnormal injector drive circuit).................................................................................. 57
Failure code [CA352] (Sensor power source 1 too low)................................................................................ 58
Failure code [CA386] (Sensor power source 1 too high) .............................................................................. 60
Failure code [CA431] (Abnormal idle validation switch)................................................................................ 62
Failure code [CA432] (Abnormal process with idle validation switch)........................................................... 64
Failure code [CA441] (Power source voltage too low) .................................................................................. 65
Failure code [CA442] (Power source voltage too high)................................................................................. 65
Failure code [CA449] (Common rail pressure too high 2)............................................................................. 66
Failure code [CA451] (Common rail pressure sensor too high) .................................................................... 68
Failure code [CA452] (Common rail pressure sensor too low) ..................................................................... 70
Failure code [CA553] (Common rail pressure too high 1)............................................................................. 70
Failure code [CA554] (In-range error of common rail pressure sensor)........................................................ 71
Failure code [CA559] (Loss of pressure feed from supply pump abnormal 1).............................................. 72
Failure code [CA689] (Abnormal engine Ne speed sensor).......................................................................... 76
Failure code [CA731] (Abnormal engine Bkup speed sensor phase) ........................................................... 78
Failure code [CA757] (Loss of all engine controller data) ............................................................................. 78
Failure code [CA778] (Abnormal engine Bkup speed sensor) ...................................................................... 80
Failure code [CA1228] (Abnormal EGR valve servo 1)................................................................................. 82
Failure code [CA1625] (Abnormal EGR valve servo 2)................................................................................. 83
Failure code [CA1626] (Short circuit of bypass valve solenoid drive) ........................................................... 84
Failure code [CA1627] (Disconnection in bypass valve solenoid drive)........................................................ 86
Failure code [CA1628] (Abnormal bypass valve servo 1) ............................................................................. 87
Failure code [CA1629] (Abnormal bypass valve servo 2) ............................................................................. 88
2 HD325-7, HD405-7
Failure code [CA111] (Abnormality in engine controller) 1

Action code Failure code Abnormality in engine controller
Trouble
E03 CA111 (Engine controller system)
Contents of
• Abnormality has occurred in engine controller.
trouble
Action of
controller
Problem that
• Though the engine can operate normally, it may stall during the operation and may not start when
appears on
the engine is stopped.
machine
Related
information

Fuse may be broken or circuit breaker may be turned OFF. Check
Defective circuit breaker them directly.
1
FUA1 or fuse BT3 (21) – (22) (If fuse is broken or circuit breaker is turned OFF, circuit has proba-
bly has ground fault.)
Disconnection in wiring starting switch still OFF.
harness Wiring harness between J3P (female) (3), Resis-
2 Max. 1 z
(Disconnection or defective (4) – battery relay B terminal tance
Possible causes
contact of connectors) Wiring harness between J3P (female) (1), Resis-
and standard Max. 1 z
value in normal (2) – ground tance
state a Prepare with starting switch OFF and troubleshooting with
Defective harness grounding
3
(Contact with ground circuit) Between ground and wiring harness Resis-
between J3P (female) (3), (4) – battery relay Min. 1 Mz
tance
B terminal
starting switch ON.
J3P Voltage
Between (3), (4) – (1), (2) 20 – 30 V
HD325-7, HD405-7 3
Failure code [CA115] (Abnormal engine Ne and Bkup sensors) 1

Action code Failure code Abnormal engine Ne and Bkup speed sensors
Trouble
Contents of • Abnormality has occurred at the same time in Ne speed sensor circuit and Bkup speed sensor
trouble circuit.
Action of
controller
Problem that
• Engine does not start (during engine stop).
appears on
machine • Engine stops (during engine running).
Related
information

Defective Ne speed sensor
1 Carry out troubleshooting of the failure code [CA689].
circuit
Defective Bkup speed sen-
2 Carry out troubleshooting of failure code [CA778].
sor circuit
Since a mounting section of Ne speed sensor can be suspected to
Defective Ne speed sensor
Possible causes 3 be defective, directly check the mounting section. (Defective instal-
mounting section
and standard lation of sensor itself, internal defect of flywheel, etc.)
value in normal Since a mounting section of Bkup speed sensor can be suspected
state Bkup speed sensor mounting
4 to be defective, directly check the mounting section. (Defective
section
installation of sensor itself, internal defect of supply pump, etc.)
Defective connection of sen- The defective (wrong) connections of Ne speed sensor and Bkup
5
sor (wrong connection) speed sensor can be suspected. Directly check them.
Engine controller can be suspected to be defective if no problem is
6 Defective engine controller found in causes 1 – 5 (since this is an internal defect, it cannot be
diagnosed).
4 HD325-7, HD405-7
HD325-7, HD405-7 5
Failure code [CA122] (Charge pressure sensor too high) 1

Action code Failure code Charge pressure sensor too high
Trouble
Contents of
• Excessively high voltage has occurred in charge pressure sensor circuit.
trouble
Action of
• Operate with a fixed charge pressure (400 kPa {4.1 kg/cm²}).
controller
Problem that
appears on • Engine acceleration performance lowers or more black smoke is produced during acceleration.
machine
Related
information

Defective sensor power If failure code [CA187] or [CA227] is displayed, carry out
1
source circuit troubleshooting for it first.
Prepare with starting switch OFF and troubleshooting with starting
switch ON or with engine started.
PIM Voltage
Defective charge pressure
2 sensor Between (1) – (3) Power source 4.75 – 5.25 V
(internal defect) Since voltage of sensor is measured with the harness connected,
troubleshooting the harness and the controller if the voltage is
abnormal, and then make judgment after it is determined that there
is no other cause of the abnormality.
Disconnection in wiring Wiring harness between ENG (female) (37) Resis-
Max. 1 z
harness – PIM (female) (1) tance
3
(Disconnection or defective Wiring harness between ENG (female) (44) Resis-
contact of connectors) Max. 1 z
– PIM (female) (2) tance
Max. 1 z
– PIM (female) (3) tance
Possible causes a Prepare with starting switch OFF and troubleshooting with
and standard starting switch still OFF.
value in normal Between ground and wiring harness between Resis-
state Min. 1 Mz
Defective harness grounding ENG (female) (37) – PIM (female) (1) tance
4
(Contact with ground circuit) Between ground and wiring harness between Resis-
Min. 1 Mz
ENG (female) (44) – PIM (female) (2) tance
Between ground and wiring harness between Resis-
Min. 1 Mz
ENG (female) (47) – PIM (female) (3) tance
Between wiring harness from ENG (female)
Resis-
(37) – PIM (female) (1) and wiring harness Min. 1 Mz
tance
from ENG (female) (44) – PIM (female) (2)
Harness short
5 Between wiring harness from ENG (female)
(Harness internal short) Resis-
tance
Resis-
tance
a Prepare with starting switch OFF, and troubleshooting with
starting switch ON or with engine started.
ENG Voltage
Between (37) – (47) Power source 4.75 – 5.25 V
6 HD325-7, HD405-7
HD325-7, HD405-7 7
Failure code [CA123] (Charge pressure sensor too low) 1

Action code Failure code Charge pressure sensor too low
Trouble
Contents of
• Excessively low voltage has occurred in charge pressure sensor circuit.
trouble
Action of
• Operate with a fixed charge pressure (400 kPa {4.1 kg/cm²}).
controller
Problem that
appears on • Engine acceleration performance lowers or more black smoke is produced during acceleration.
machine
Related
information

and standard
value in normal Carry out troubleshooting of failure code [CA122].
state
8 HD325-7, HD405-7
HD325-7, HD405-7 9
Failure code [CA131] (Throttle sensor too high) 1

Action code Failure code Throttle sensor too high
Trouble
Contents of
• Signal voltage of throttle sensor has become above 4.5 V.
trouble
Action of • Sets the throttle to low idle position when pedal is released and sets to a medium speed position
controller when pedal is depressed according to idle validation switch.
Problem that
• Even if the accelerator pedal is depressed, the engine speed does not increase above medium
appears on
speed.
machine
Related
information

1
starting switch ON.
AS1 Accelerator pedal Voltage
At any position
Between (1) – (3) 4.75 – 5.25 V
(power source)
Defective accelerator pedal (13 ± 2 % of power
2 When released
(internal defect) source)
Between (2) – (3)
(77 ± 2 % of power
When depressed
source)
Since voltage of sensor is measured with the harness connected,
Disconnection in wiring Wiring harness between J2P (female) (22) – Resis-
Possible causes Max. 1 z
harness AS1 (female) (1) tance
and standard 3
(Disconnection or defective Wiring harness between J2P (female) (9) – Resis-
value in normal contact of connectors) Max. 1 z
AS1 (female) (2) tance
state
Wiring harness between J2P (female) (23) – Resis-
Max. 1 z
Min. 1 Mz
Defective harness grounding J2P (female) (22) – AS1 (female) (1) tance
4
Min. 1 Mz
J2P (female) (9) – AS1 (female) (2) tance
Min. 1 Mz
starting switch ON.
J2P Accelerator pedal Voltage
At any position
Between (22) – (23) 4.75 – 5.25 V
5 Defective engine controller (power source)
(13 ± 2 % of power
When released
source)
Between (9) – (23)
(77 ± 2 % of power
When depressed
source)
10 HD325-7, HD405-7
HD325-7, HD405-7 11
Failure code [CA132] (Throttle sensor too low) 1

Action code Failure code Throttle sensor too low
Trouble
Contents of
• Signal voltage of throttle sensor has become below 0.3 V.
trouble
Action of • Sets the throttle to low idle position when pedal is released and sets to a medium speed position
controller when pedal is depressed according to idle validation switch.
Problem that
• Even if the accelerator pedal is depressed, the engine speed does not increase above medium
appears on
speed.
machine
Related
information

and standard
state
12 HD325-7, HD405-7
HD325-7, HD405-7 13
Failure code [CA135] (Oil pressure sensor too high) 1

Action code Failure code Oil pressure sensor too high
Trouble
Contents of
• Excessively high voltage has occurred in oil pressure sensor circuit.
trouble
Action of
• Operates with oil pressure at default value (250 kPa {2.5 kg/cm²})
controller
Problem that
appears on
machine
Related
information

1
Prepare with starting switch OFF and troubleshooting with starting
switch ON or with engine started.
POIL Voltage
Defective oil pressure sensor Between (1) – (2) Power source 4.75 – 5.25 V
2
(internal defect)
Max. 1 z
harness – POIL (female) (1) tance
3
Max. 1 z
state Min. 1 Mz
Defective harness grounding ENG (female) (37) – POIL (female) (1) tance
4
Min. 1 Mz
ENG (female) (47) – POIL (female) (2) tance
Min. 1 Mz
ENG (female) (13) – POIL (female) (3) tance
Resis-
(37) – POIL (female) (1) and wiring harness Min. 1 Mz
tance
from ENG (female) (47) – POIL (female) (2)
Harness short
tance
Resis-
tance
ENG Voltage
Between (37) – (47) Power source 4.75 – 5.25 V
14 HD325-7, HD405-7
HD325-7, HD405-7 15
Failure code [CA141] (Oil pressure sensor too low) 1

Action code Failure code Oil pressure sensor too low
Trouble
Contents of
• Excessively low voltage has occurred in oil pressure sensor circuit.
trouble
Action of
• Operates with oil pressure at default value (250 kPa {2.5 kg/cm²})
controller
Problem that
appears on
machine
Related
information

and standard
state
16 HD325-7, HD405-7
HD325-7, HD405-7 17
Failure code [CA144] (Coolant temperature sensor too high) 1

Action code Failure code Coolant temperature sensor too high
Trouble
Contents of
• Excessively high voltage has occurred in coolant temperature sensor circuit.
trouble
Action of
• Operates with a fixed coolant temperature (90 °C).
controller
Problem that
appears on • Engine does not start easily at low temperature.
machine
Related
information

Defective coolant starting switch still OFF.
1 temperature sensor
TWTR (male) Coolant temperature Resistance
(internal defect)
Between (A) – (B) 10 – 100 °C 0.6 – 20 kz
harness Wiring harness between ENG (female) (15) Resis-
2 Max. 1 z
Possible causes (Disconnection or defective – TWTR (female) (A) tance
and standard contact of connectors) Wiring harness between ENG (female) (38) Resis-
value in normal Max. 1 z
– TWTR (female) (B) tance
state
Defective harness grounding
3
between ENG (female) (15) – TWTR Min. 1 Mz
tance
(female) (A)
ENG (female) Coolant temperature Resistance
Between (15) – (38) 10 – 100 °C 0.6 – 20 kz
18 HD325-7, HD405-7
HD325-7, HD405-7 19
Failure code [CA145] (Coolant temperature sensor too low) 1

Action code Failure code Coolant temperature sensor too low
Trouble
Contents of
• Excessively low voltage has occurred in coolant temperature sensor circuit.
trouble
Action of
• Operates with a fixed coolant temperature (90 °C).
controller
Problem that
machine
Related
information

and standard
state
20 HD325-7, HD405-7
HD325-7, HD405-7 21
Failure code [CA153] (Charge temperature sensor too high) 1

Action code Failure code Charge temperature sensor too high
Trouble
Contents of
• Excessively high voltage has occurred in charge temperature sensor circuit.
trouble
Action of
• Operates with a fixed charge temperature (intake air temperature) (70 °C).
controller
Problem that
machine
Related
information

Defective charge Intake air tempera-
TIM (male) Resistance
1 temperature sensor ture
(internal defect) Between (A) – (B) 10 – 100 °C 0.5 – 20 kz
Between (A) –
Any condition Min. 1 Mz
ground
Possible causes
and standard 2 Max. 1 z
(Disconnection or defective – TIM (female) (A) tance
value in normal
contact of connectors) Wiring harness between ENG (female) (47) Resis-
state Max. 1 z
– TIM (female) (B) tance
Defective harness grounding starting switch still OFF.
3
Min. 1 Mz
ENG (female) (23) – TIM (female) (A) tance
4 Defective engine controller Intake air tempera-
ENG (female) Resistance
ture
Between (23) – (47) 10 – 100 °C 0.5 – 20 kz
22 HD325-7, HD405-7
HD325-7, HD405-7 23
Failure code [CA154] (Charge temperature sensor too low) 1

Action code Failure code Charge temperature sensor too low
Trouble
Contents of
• Excessively low voltage has occurred in charge temperature sensor circuit.
trouble
Action of
• Operates with a fixed charge temperature (intake air temperature) (70 °C).
controller
Problem that
machine
Related infor-
mation

and standard
state
Failure code [CA187] (Sensor power source 2 too low) 1

Action code Failure code Sensor power source 2 too low
Trouble
Contents of
• Excessively low voltage has occurred in sensor power source 2 (5 V) circuit.
trouble
• Operates using Ne speed sensor signal instead of Bkup speed sensor signal.
• Operate oil pressure sensor with oil pressure at default value (250 kPa {2.5kg/cm²})
• Operates with atmospheric pressure sensor value defaulted to (52.44 kPa {0.534 kg/cm²})
Action of • Operates with charge pressure sensor at fixed value (400 kPa {4.1 kg/cm²}).
controller • Operates with EGR inlet pressure sensor value defaulted to (102 kPa {1.0 kg/cm²}) and runs by
limiting output.
• Restricts the EGR valve lift sensor output and closes EGR valve and bypass valve.
• Restricts the bypass valve lift sensor output and closes EGR valve and bypass valve.
Problem that
appears on • Output decreases.
machine
Related
information

and standard
state
24 HD325-7, HD405-7
HD325-7, HD405-7 25
Failure code [CA221] (Atmospheric pressure sensor too high) 1

Action code Failure code Atmospheric pressure sensor too high
Trouble
Contents of
trouble • Excessively high voltage has occurred in atmospheric pressure sensor circuit.
Action of
• Operates with atmospheric pressure value defaulted to (52.44 kPa {0.534 kg/cm²}).
controller
Problem that
machine
Related
information

Defective sensor power If failure code [CA187] or [CA227] is displayed, carry out trouble-
1
source circuit shooting for it first.
starting switch ON.
PAMB Voltage
Defective atmospheric Between (1) – (2) Power source 4.75 – 5.25 V
2 pressure sensor Between (3) – (2) Signal
(internal defect)
Max. 1 z
harness – PAMB (female) (1) tance
3
(Disconnection or defective Wiring harness between ENG (female) (3) – Resis-
PAMB (female) (3) tance
Max. 1 z
– PAMB (female) (2) tance
state Min. 1 Mz
Defective harness grounding ENG (female) (37) – PAMB (female) (1) tance
4
Min. 1 Mz
ENG (female) (3) – PAMB (female) (3) tance
Min. 1 Mz
ENG (female) (38) – PAMB (female) (2) tance
Resis-
(37) – PAMB (female) (1) and wiring harness Min. 1 Mz
tance
from ENG (female) (3) – PAMB (female) (3)
Harness short
tance
Resis-
tance
6 Defective engine controller ENG Voltage
Between (37) – (38) 4.75 – 5.25 V
Between (3) – (38)
26 HD325-7, HD405-7
HD325-7, HD405-7 27
Failure code [CA222] (Atmospheric pressure sensor too low) 1

Action code Failure code Atmospheric pressure sensor too low
Trouble
Contents of
• Excessively low voltage has occurred in atmospheric pressure sensor circuit.
trouble
Action of
• Operates with atmospheric pressure value defaulted to (52.44 kPa {0.534 kg/cm²}).
controller
Problem that
machine
Related
information

and standard
state
28 HD325-7, HD405-7
HD325-7, HD405-7 29
Failure code [CA227] (Sensor power source 2 too high) 1

Action code Failure code Sensor power source 2 too high
Trouble
Contents of
trouble • Excessively high voltage has occurred in sensor power source 2 (5 V) circuit.
• Operates using Ne speed sensor signal instead of Bkup speed sensor signal.
• Operate oil pressure sensor with oil pressure at default value (250 kPa {2.5 kg/cm²})
• Operates with atmospheric pressure sensor value defaulted to (52.44 kPa {0.534 kg/cm²})
Action of • Operates with charge pressure sensor at fixed value (400 kPa {4.1 kg/cm²}).
controller • Operates with EGR inlet pressure sensor value defaulted to (102 kPa {1.0 kg/cm²}) and runs by
limiting output.
• Restricts the EGR valve lift sensor output and closes EGR valve and bypass valve.
• Restricts the bypass valve lift sensor output and closes EGR valve and bypass valve.
Problem that
machine
Related
information

Check the codes that are displayed at the same time. If any other
1 Defective related circuits
codes are displayed, carry out troubleshooting for those codes.
starting switch ON.
Bkup speed sensor G connector
Oil pressure sensor POIL connector
Atmospheric
PAMB connector
Disconnect the pressure sensor
Defective sensor (internal devices on the right Charge pressure
2 PIM connector
defect) one at a time. sensor
If the code disap- EGR inlet pressure
pears, that device is PEVA connector
sensor
internally defective.
EGR valve
SEGR connector
lift sensor
Bypass valve
SBP connector
lift sensor
Possible causes
and standard
value in normal harness Wiring harness between ENG (female) (37) Resis-
3 Max. 1 z
state (Disconnection or defective – each sensor (female) tance
Max. 1 z
– each sensor (female) tance
Defective harness grounding Between ground and wiring harness between Resis-
4 Min. 1 Mz
(Contact with ground circuit) ENG (female) (37) – each sensor (female) tance
Min. 1 Mz
ENG (female) (47) – each sensor (female) tance
Harness short Between wiring harness from ENG (female)
5
(Harness internal short) (37) – each sensor (female) and wiring Resis-
Min. 1 Mz
harness from ENG (female) (47) – each tance
sensor (female)
starting switch ON.
ENG Voltage
Between (37) – (47) 4.75 – 5.25 V
30 HD325-7, HD405-7
HD325-7, HD405-7 31
Failure code [CA234] (Engine over speed) 1

Action code Failure code Engine over speed
Trouble
Contents of
• Engine speed has exceeded the normal operating range.
trouble
Action of
• Limits fuel injection rate until the speed drops within operating range.
controller
Problem that
appears on • Engine speed fluctuates.
machine
Related
information

Check the failure codes that are displayed at the same time.
1 Defective related circuits If any other codes are displayed, carry out troubleshooting for
Possible causes those codes.
and standard
value in normal Machine may be used improperly. Teach operator proper using
2 Improper usage
state method.
diagnosed).
32 HD325-7, HD405-7
HD325-7, HD405-7 33
Failure code [CA238] (Abnormal power source for engine Ne speed

sensor) 1
Action code Failure code Abnormal power source for engine Ne speed sensor
Trouble
Contents of
• An abnormality has occurred in Ne speed sensor power supply (5 V) circuit.
trouble
Action of
• Controls using Bkup speed sensor signal.
controller
Problem that
• Engine stops during operation (when Bkup speed sensor is defective at the same time).
appears on
machine • Engine cannot be started while stopping (when Bkup speed sensor is defective at the same time).
Related
information

Disconnect a device
Defective Ne speed sensor shown on the right.
1
(internal defect) If the failure code
Ne speed sensor NE connector
disappears, that
device is internally
defective.
2 Max. 1 z
(Disconnection or defective – NE (female) (1) tance
Max. 1 z
– NE (female) (2) tance
Possible causes
and standard a Prepare with starting switch OFF and troubleshooting with
value in normal starting switch still OFF.
state Between ground and wiring harness
Resis-
Defective harness grounding between ENG (female) (16) – NE (female) Min. 1 Mz
3 tance
(Contact with ground circuit) (1)
Between ground and wiring harness
Resis-
between ENG (female) (48) – NE (female) Min. 1 Mz
tance
(2)
Harness short
(16) – NE (female) (1) and wiring harness Min. 1 Mz
tance
from ENG (female) (48) – NE (female) (2)
starting switch ON.
ENG Voltage
Between (16) – (48) 4.75 – 5.25 V
34 HD325-7, HD405-7
HD325-7, HD405-7 35
Failure code [CA263] (Fuel temperature sensor too high) 1

Action code Failure code Fuel temperature sensor too high
Trouble
Contents of
• Excessively high voltage has occurred in fuel temperature sensor circuit.
trouble
Action of
• Operates with a fixed fuel temperature (95 °C).
controller
Problem that
appears on
machine
Related
information

Defective fuel temperature starting switch still OFF.
1 sensor
TFUEL (male) Fuel temperature Resistance
(internal defect)
Between (A) – (B) 10 – 100 °C 0.6 – 20 kz
2 Max. 1 z
Possible causes (Disconnection or defective – TFUEL (female) (A) tance
and standard contact of connectors) Wiring harness between ENG (female) (47) Resis-
– TFUEL (female) (B) tance
state
Defective harness grounding Resis-
3 between ENG (female) (30) – TFUEL Min. 1 Mz
(Contact with ground circuit) tance
(female) (A)
ENG (female) Fuel temperature Resistance
Between (30) – (47) 10 – 100 °C 0.6 – 20 kz
36 HD325-7, HD405-7
HD325-7, HD405-7 37
Failure code [CA265] (Fuel temperature sensor too low) 1

Action code Failure code Fuel temperature sensor too low
Trouble
Contents of
• Excessively low voltage has occurred in fuel temperature sensor circuit.
trouble
Action of
• Operates with a fixed fuel temperature (95 °C).
controller
Problem that
appears on
machine
Related
information

and standard
state
38 HD325-7, HD405-7
Failure code [CA271] (PCV1 short circuit) 1

Action code Failure code PCV1 short circuit
Trouble
Contents of
• Short circuit has occurred in supply pump PCV1 circuit.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Defective supply pump
1 PCV1 PCV1 (male) Resistance
(internal short circuit) Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) – ground Min. 1 Mz
2 Min. 1 Mz
(Contact with ground circuit) ENG (female) (4) – PCV1 (female) (1) tance
Possible causes
ENG (female) (5) – PCV1 (female) (2) tance
value in normal
starting switch ON.
Hot short of wiring harness Between ground and wiring harness between
3 Voltage Max. 1 V
(a contact with 24 V circuit) ENG (female) (4) – PCV1 (female) (1)
Between ground and wiring harness between
Voltage Max. 1 V
ENG (female) (5) – PCV1 (female) (2)
4 Defective engine controller ENG (female) Resistance
Between (4) – (5) 2.3 – 5.3 z
HD325-7, HD405-7 39
Failure code [CA272] (PCV1 disconnection) 1

Action code Failure code PCV1 disconnection
Trouble
Contents of
• A disconnectiont has occurred in the supply pump PCV1 circuit.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

(internal disconnection) Between (1) – (2) 2.3 – 5.3 z
harness Wiring harness between ENG (female) (4) – Resis-
2 Max. 1 z
(Disconnection or defective PCV1 (female) (1) tance
Possible causes contact of connectors) Wiring harness between ENG (female) (5) – Resis-
PCV1 (female) (2) tance
value in normal
3 Min. 1 Mz
Min. 1 Mz
Between (4) – (5) 2.3 – 5.3 z
40 HD325-7, HD405-7
Failure code [CA273] (PCV2 short circuit) 1
Action code Failure code PCV2 short circuit

Trouble
Contents of
• Short circuit has occurred in supply pump PCV2 circuit.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

(internal short circuit) Between (1) – (2) 2.3 – 5.3 z
2 Min. 1 Mz
Possible causes
value in normal
starting switch ON.
3 Voltage Max. 1 V
(a contact with 24 V circuit) ENG (female) (9) – PCV2 (female) (1)
Voltage Max. 1 V
ENG (female) (10) – PCV2 (female) (2)
Between (9) – (10) 2.3 – 5.3 z
HD325-7, HD405-7 41
Failure code [CA274] (PCV2 disconnection) 1

Action code Failure code PCV2 disconnection
Trouble
Contents of
• A disconnection has occurred in the supply pump PCV2 circuit.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Defective supply pump starting switch still OFF.
1 PCV2
PCV2 (male) Resistance
(internal disconnection)
Between (1) – (2) 2.3 – 5.3 z
harness Wiring harness between ENG (female) (9) – Resis-
2 Max. 1 z
(Disconnection or defective PCV2 (female) (1) tance
and standard – PCV2 (female) (2) tance
3 Min. 1 Mz
Min. 1 Mz
Between (9) – (10) 2.3 – 5.3 z
42 HD325-7, HD405-7
HD325-7, HD405-7 43
Failure code [CA322] (Injector No. 1 system disconnection or short

circuit) 1
Action code Failure code Injector No. 1 system disconnection or short circuit
Trouble
Contents of
• A disconnection or short has occurred in injector No. 1 circuit.
trouble
Action of
controller
Problem that
• Output decreases.
appears on
machine • Speed is not stable.
Related
information

Defective injector No. 1 CN1 (male) Resistance
1
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
(Disconnection or defective – CN1(female) (1) tance
Max. 1 z
Possible causes – CN1(female) (2) tance
state
3 Min. 1 Mz
(Contact with ground circuit) ENG (female) (45) – CN1 (female) (1) tance
Min. 1 Mz
ENG (female) (53) – CN1 (female) (2) tance
Between (45) – (53) 0.4 – 1.1 z
Defective injector of another
If another failure code of injector trouble is displayed, carry out
5 cylinder or defective wiring
troubleshooting for it, too.
harness
44 HD325-7, HD405-7
HD325-7, HD405-7 45

circuit) 1
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
Related
information

1
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
(Disconnection or defective – CN5 (female) (1) tance
Max. 1 z
Possible causes – CN5 (female) (2) tance
state
3 Min. 1 Mz
(Contact with ground circuit) ENG (female) (46) – CN5 (female) (1) tance
Min. 1 Mz
ENG (female) (60) – CN5 (female) (2) tance
Between (46) – (60) 0.4 – 1.1 z
harness
46 HD325-7, HD405-7
HD325-7, HD405-7 47

circuit) 1
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
Related
information

1
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
Max. 1 z
value in normal
state Resis-
Defective harness grounding between ENG (female) (55) – CN3 (female) Min. 1 Mz
3 tance
Resis-
between ENG (female) (52) – CN3 (female) Min. 1 Mz
tance
(2)
Between (55) – (52) 0.4 – 1.1 z
harness
48 HD325-7, HD405-7
HD325-7, HD405-7 49

circuit) 1
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
Related
information

1
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
Max. 1 z
value in normal
state Resis-
3 tance
Resis-
tance
(2)
Between (57) – (59) 0.4 – 1.1 z
harness
50 HD325-7, HD405-7
HD325-7, HD405-7 51

circuit) 1
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
Related
information

1
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
Max. 1 z
value in normal
state Resis-
3 tance
Resis-
tance
(2)
Between (54) – (51) 0.4 – 1.1 z
harness
52 HD325-7, HD405-7
HD325-7, HD405-7 53

circuit) 1
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
Related
information

1
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
Disconnection in wiring har- starting switch still OFF.
ness Wiring harness between ENG (female) (56) Resis-
2 Max. 1 z
Max. 1 z
value in normal
state Resis-
3 tance
Resis-
tance
(2)
Between (56) – (58) 0.4 – 1.1 z
harness
54 HD325-7, HD405-7
HD325-7, HD405-7 55
Failure code [CA342] (Abnormal engine controller data consistency) 1

Action code Failure code Abnormal engine controller data consistency
Trouble
Contents of
• Abnormal data consistency has occurred in engine controller.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

and standard
value in normal Carry out troubleshooting of [CA111].
state
56 HD325-7, HD405-7
Failure code [CA351] (Abnormal injector drive circuit) 1

Action code Failure code Abnormal injector drive circuit
Trouble
Contents of
• Abnormality has occurred in injector drive circuit.
trouble
Action of
• Operates with limited output.(Limits common rail pressure.)
controller
Problem that
machine
Related
information

Check the failure codes (codes for injector system trouble) that are
1 Defective related circuits displayed at the same time. If any other codes are displayed, carry
out troubleshooting for those codes.
Since a defect of the fuse or circuit breaker can be suspected,
Defective fuse BT3 (21 – 22)
directly check it.
2 or defective circuit breaker
(If fuse is blown, or circuit breaker is shut off, it is highly possible
FUA1
that a defective grounding, etc. has occurred in the circuit.)
harness Wiring harness between J3P (female) (3), Resis-
3 Max. 1 z
Possible causes (Disconnection or defective (4) – Battery relay B terminal tance
and standard contact of connectors) Wiring harness between J3P (female) (1), Resis-
(2) – ground tance
state
4 between J3P (female) (3), (4) – Battery Min. 1 Mz
relay B terminal
Wiring harness between J3P (female) (1), Resis-
Min. 1 Mz
(2) – ground tance
starting switch ON.
J3P Voltage
Between (3), (4) – (1), (2) 20 – 30 V
HD325-7, HD405-7 57
Failure code [CA352] (Sensor power source 1 too low) 1

Action code Failure code Sensor power source 1 too low
Trouble
Contents of
• Excessively low voltage has occurred in sensor power source 1 (5V) circuit.
trouble
Action of
• Common rail pressure sensor functions with limited output. (Limits common rail pressure.)
controller
Problem that
machine
Related
information

and standard
state
58 HD325-7, HD405-7
HD325-7, HD405-7 59
Failure code [CA386] (Sensor power source 1 too high) 1

Action code Failure code Sensor power source 1 too high
Trouble
Contents of
• Excessively high voltage has occurred in sensor power source 1 (5 V) circuit.
trouble
Action of
• Common rail pressure sensor functions with limited output. (Limits common rail pressure.)
controller
Problem that
machine
Related
information

those codes.
starting switch ON.
Defective sensor (internal Disconnect a device

2 shown on the right.
defect) Common rail
If the failure code dis- PFUEL connector
pressure sensor
appears, that device
is internally defective.
3 Max. 1 z
(Disconnection or defective – PFUEL (female) (1) tance
– PFUEL (female) (3) tance
and standard
value in normal
state
Resis-
Defective harness grounding between ENG (female) (33) – PFUEL Min. 1 Mz
4 tance
(Contact with ground circuit) (female) (1)
Resis-
between ENG (female) (47) – PFUEL Min. 1 Mz
tance
(female) (3)
5
(Harness internal short) (33) – PFUEL (female) (1) and wiring Resis-
Min. 1 Mz
harness from ENG (female) (47) – PFUEL tance
(female) (3)
starting switch ON.
ENG Voltage
Between (33) – (47) 4.75 – 5.25 V
60 HD325-7, HD405-7
HD325-7, HD405-7 61
Failure code [CA431] (Abnormal idle validation switch) 1

Action code Failure code Abnormal idle validation switch
Trouble
Contents of • Open circuits of both idle validation switch signals 1 and 2 or abnormality in their ground circuit has
trouble occurred.
Action of
• Operates normally in accordance with the throttle sensor (E01 Testing and maintenance).
controller
Problem that
appears on • No particular abnormality appears.
machine
Related
information

starting switch ON.
AS1 Signal name Voltage
Between (5) – (4) Signal 1
Defective accelerator pedal See figure 1.
1 Between (6) – (4) Signal 2
(internal defect)
Disconnection in wiring Wiring harness between J2P (female) (32) – Resis-
Max. 1 z
harness AS1 (female) (4) tance
2
(Disconnection or defective Wiring harness between J2P (female) (11) – Resis-
Wiring harness between J2P (female) (1) – Resis-
Max. 1 z
value in normal
state Between ground and wiring harness between Resis-
Min. 1 Mz
Defective harness grounding J2P (female) (32) – AS1 (female) (4) tance
3
Min. 1 Mz
Min. 1 Mz
starting switch ON.
Voltage Max. 1V
Hot short of wiring harness J2P (female) (32) – AS1 (female) (4)
4
(a contact with 24 V circuit) Between ground and wiring harness between
Voltage Max. 1V
J2P (female) (11) – AS1 (female) (5)
Voltage Max. 1V
J2P (female) (1) – AS1 (female) (6)
starting switch ON.
5 Defective engine controller J2P Signal name Voltage
See figure 1.
62 HD325-7, HD405-7
Fig. 1
Pedal: Stroke of accelerator pedal

Output voltage: Output voltage (%)
Sig1: Signal voltage of throttle sensor
Sig2: Signal voltage of idle validation switch 1
Sig3: Signal voltage of idle validation switch 2
Lo: Switch circuit is closed
Hi: Switch circuit is open
Switch gap: Overlap between signals of switch 1 and switch 2
HD325-7, HD405-7 63
Failure code [CA432] (Abnormal process with idle validation switch) 1

Action code Failure code Abnormal process with idle validation
Trouble
Contents of • Throttle potentiometer signal of accelerator pedal is inconsistent with idle validation switch signal 1
trouble and 2.
• Turns on a warning lamp and sounds an alarm buzzer.
Action of
controller • Fixes throttle at low idle or fixes engine speed at idle when the pedal is released and at a medium
speed when the pedal is depressed.
Problem that
• Even if accelerator pedal is depressed, the engine speed stays at low idle or does not increase
appears on
above medium speed.
machine
Related
information

and standard
state
64 HD325-7, HD405-7
Failure code [CA441] (Power source voltage too low) 1

Action code Failure code Power source voltage too low
Trouble
Contents of
• Excessively low voltage has occurred in power source voltage circuit.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

and standard
state
Failure code [CA442] (Power source voltage too high) 1

Action code Failure code Power source voltage too high
Trouble
Contents of
• Excessively high voltage has occurred in power source voltage circuit.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

and standard
state
HD325-7, HD405-7 65
Failure code [CA449] (Common rail pressure too high 2) 1

Action code Failure code Common rail pressure too high 2
Trouble
Contents of
• Excessively high pressure (level 2) has been detected with common rail pressure sensor circuit.
trouble
Action of
controller
Problem that
machine
Related
information

and standard
state
66 HD325-7, HD405-7
HD325-7, HD405-7 67
Failure code [CA451] (Common rail pressure sensor too high) 1

Action code Failure code Common rail pressure sensor too high
Trouble
Contents of
• Excessively high voltage has occurred in common rail pressure sensor circuit.
trouble
Action of
controller
Problem that
machine
Related
information

1
PFUEL Voltage
Defective common rail Between (1) – (3) Power source 4.75 – 5.25 V
2 pressure sensor Between (2) – (3) Signal 0.25 – 4.6 V
(internal defect)
Max. 1 z
harness – PFUEL (female) (1) tance
3
Max. 1 z
state Min. 1 Mz
Defective harness grounding ENG (female) (33) – PFUEL (female) (1) tance
4
Min. 1 Mz
ENG (female) (25) – PFUEL (female) (2) tance
Min. 1 Mz
ENG (female) (47) – PFUEL (female) (3) tance
Resis-
(33) – PFUEL (female) (1) and wiring harness Min. 1 Mz
tance
from ENG (female) (25) – PFUEL (female) (2)
Harness short
tance
Resis-
tance
6 Defective engine controller ENG Voltage
Between (33) – (47) 4.75 – 5.25 V
Between (25) – (47) 0.25 – 4.6 V
68 HD325-7, HD405-7
HD325-7, HD405-7 69
Failure code [CA452] (Common rail pressure sensor too low) 1

Action code Failure code Common rail pressure sensor too low
Trouble
Contents of
• Excessively low voltage has occurred in common rail pressure sensor circuit.
trouble
Action of
controller
Problem that
machine
Related
information

and standard
state
Failure code [CA553] (Common rail pressure too high 1) 1

Action code Failure code Common rail pressure too high 1
Trouble
Contents of
• Excessively high pressure (level 1) has been detected with common rail pressure sensor circuit.
trouble
Action of
controller
Problem that
machine
Related
information

those codes.
Since the use of improper fuel can be suspected, check the fuel.
2 Improper fuel has been used.
(Viscosity is too high)
Defective electrical system of Since an electrical defect of common rail pressure sensor is sus-
Possible causes 3
common rail pressure sensor pected, carry out troubleshooting for the following code. [CA451]
and standard
value in normal Defective mechanical system
Since a mechanical defect of common rail pressure sensor is sus-
state 4 of common rail pressure sen-
pected, directly check the sensor.
sor
Since a damage of spring, wear of seat or sticking of ball is sus-
5 Defective overflow valve
pected, directly check them.
Since an over flow piping is suspected to be clogged, directly
6 Clogged over flow piping
check it.
Since a mechanical defect of pressure limiter is suspected, directly
7 Defective pressure limiter
check the limiter.
70 HD325-7, HD405-7
Failure code [CA554] (In-range error of common rail pressure sensor) 1

Action code Failure code In-range error in common rail pressure sensor
Trouble
Contents of
• In-range error has occurred in common rail pressure sensor circuit.
trouble
Action of
controller
Problem that
machine
Related
information

and standard
state
HD325-7, HD405-7 71
Failure code [CA559] (Loss of pressure feed from supply pump

abnormal 1) 1
Action code Failure code Loss of pressure feed from supply pump abnormal 1
Trouble
Contents of
• Loss of pressure feed (level 1) from supply pump has occurred.
trouble
Action of
• Limits common rail pressure.
controller
Problem that
machine
Related
information

those codes.
2 Improper fuel has been used. Since the use of improper fuel is suspected, directly check the fuel.
a See "Note 1" for the contents of diagnosis. See Testing and
adjusting "Testing fuel pressure" for the pressure inspection of
Defective low pressure the fuel low pressure circuit.
3
circuit device Pressure in fuel low-pressure circuit
Min. 0.15 MPa
(High idle or rated load (torque converter
{Min. 1.5 kg/cm²}
relief))
4 Clogged filter or strainer a See "Note 2" for the contents of diagnosis.
Defective electrical system of Since an electrical defect of supply pump PCV is suspected, carry
5 supply pump PCV out troubleshooting for the following codes.
[CA271], [CA272], [CA273], and [CA274]
Possible causes Defective common rail Since a defect of common rail pressure sensor is suspected, check
6
and standard pressure sensor for a damage in harnesses.
value in normal a As for testing an amount of pressure limiter leak, see testing
state and adjusting “Testing fuel return and leak amount“.
7 Defective pressure limiter
Pressure limiter leak Max. 10 cc/min
amount (Rated load (Torque converter relief))
a As for the test relating to return (spill) limit amount of injector,
see testing and adjusting “Testing fuel return and leak amount“.
Speed under the conditions
Injector return (spill)
which is equivalent to rated
limit amount
operation
8 Defective injector 1,600 rpm 960 cc/min
1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
Supply pump can be suspected to be defective if no problem is
9 Defective supply pump
found in causes 1 – 8.
<How to use the check sheet>

Carry out the above diagnosis as well as record the results for the contents of diagnosis using the attached
"Check sheet for loss of pressure feed".
72 HD325-7, HD405-7
Note 1: When low-pressure circuit is defective, check the following:

1) Fuel level
2) Clogged hydraulic tank breather
3) Stuck or worn feed pump, clogged filter
4) Leaked or clogged low-pressure fuel pipe
5) Bypass valve malfunction, defective assembly of other parts (See Fig.1.)
6) Clogged fuel filter
7) Fuel in oil pan (fuel leakage in head cover)
Fig. 1: Locations of overflow valve [1], bypass valve [2], and fuel inlet joint [3]
q Overflow valve [1]: Spring is seen through both holes.
q Bypass valve [2]: Spring is seen through hole on nut side.
q Fuel inlet joint [3]: Gauze filter is seen through both holes.
Note 2: Follow the procedure below to check, clean, and replace filter and strainer.
1) Gauze filter: Disassemble this filter for checking. If clogged, clean it.
2) Gauze filter upstream strainer: Clean upstream strainer if gauze filter is clogged.
3) Fuel filter: If failure is not remedied after steps 1) and 2) above were executed, replace fuel filter.
HD325-7, HD405-7 73
Check sheet for no-pressure feed
Machine model Working No.

Model serial No. Checked on / /
Engine Service meter h
Engine serial No. Worker name
A. Visual check Good Bad

1 Fuel leakage to outside
2 Clogged fuel tank breather
B. Check with machine monitor (Abnormality record, monitoring, cylinder cut-out operation) Good Bad
3 Checking failure code / / / /
Checking monitoring information
Standard value
Measured
Code Display item Check conditions Unit (Reference Good Bad
value
value)
Low idle rpm 1,930 ± 50
*1 Engine Speed High idle rpm 1,000 ± 25
Rating or equivalent rpm 1,850
Low idle % 0
*2 Throttle speed
High idle % 100
Injection rate
*3 Rating or equivalent mm³ — — —
command
4
Common rail
*4 Rating or equivalent MPa
pressure command
Common rail fuel
*5 Rating or equivalent MPa
pressure
Low idle CA — — —
Injection timing com-
*6 High idle CA — — —
mand
Rating or equivalent CA — — —
*7 Boost Pressure Rating or equivalent kPa — — —
Engine coolant
*8 Low idle °C — — —
temperature
*9 Fuel temperature Low idle °C — — —
Checking cylinder cut-out operation (Engine speed)
Standard value
Func- Measured
Cut-out cylinder Check conditions Unit (Reference Good Bad
tion value
value)
Cylinder 1 Low idle rpm — — —
5 Cylinder 2 Low idle rpm — — —
*10
74 HD325-7, HD405-7
Standard value
C. Checking fuel circuit Measured
Check conditions Unit (Reference Good Bad
pressure value
value)
Pressure in fuel High idle or rated load MPa Min. 0.15
6
low-pressure circuit (torque converter relief) {kg/cm²} {Min. 1.5}
D. Checking strainer filter Good Bad

7 Visual check of strainer
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve
Standard value
E. Checking leakage and fuel Measured
Check conditions Unit (Reference Good Bad
return rate value
value)
Leakage through pressure At rated load
11 cc/min Max. 10
limiter (torque converter relief)
Rating or equivalent
cc/min 960
1600 rpm
cc/min 1,020
1,700 rpm
Speed:
12 Return rate from injector cc/min 1,080
1,800 rpm
Return rate:
cc/min 1,140
1,900 rpm
cc/min 1,200
2,000 rpm
*1 to *10:
When using the monitoring function for checking, see Monitoring Code List.
Equivalent to rating:
1) Engine at full throttle, 2) Torque converter is relieved.
HD325-7, HD405-7 75
Failure code [CA689] (Abnormal engine Ne speed sensor) 1

Action code Failure code Abnormal engine Ne speed sensor
Trouble
Contents of
• An abnormality has occurred in engine Ne speed sensor circuit.
trouble
Action of
• Operates using Bkup speed sensor signal.
controller
Problem that
• Engine stops during operation (when Bkup speed sensor is defective at the same time).
appears on
machine • Engine cannot be started while stopping (when Bkup speed sensor is defective at the same time).
Related
information

Defective sensor power If failure code [CA238] is displayed at the same time, carry out
1
Max. 1 z
harness – NE (female) (1) tance
2
Max. 1 z
Min. 1 Mz
Defective harness grounding ENG (female) (16) – NE (female) (1) tance
3
Min. 1 Mz
ENG (female) (48) – NE (female) (2) tance
Possible causes Between ground and wiring harness between Resis-
Min. 1 Mz
and standard ENG (female) (27) – NE (female) (3) tance
Resis-
tance
Harness short
tance
Resis-
tance
Defective mounting of sensor Since defective mounting of Ne speed sensor (improper gap) or
5 or defective parts for speed defective parts for speed detection (flywheel) can be suspected,
detection directly check it.
Engine Ne speed sensor can be suspected to be defective if no
Defective engine Ne speed
6 problem is found in causes 1 – 5 (since this is an internal defect, it
sensor
cannot be diagnosed).
diagnosed).
76 HD325-7, HD405-7
HD325-7, HD405-7 77
Failure code [CA731] (Abnormal engine Bkup speed sensor phase) 1

Action code Failure code Abnormal engine Bkup speed sensor phase
Trouble
Contents of
• Abnormal phase has been detected in the engine Bkup sensor circuit.
trouble
Action of
• Operates using engine Ne speed sensor signal.
controller
Problem that
• Engine stops during operation (when Ne speed sensor is defective at the same time).
appears on
machine • Engine cannot be started while stopping (when Ne speed sensor is defective at the same time).
Related
information

Possible causes
Defective engine Ne speed Since a defect of engine Ne speed sensor can be suspected, carry
and standard 1
sensor circuit out troubleshooting for the following code. [CA689]
value in normal
state Defective engine Bkup Since a defect of engine Bkup speed sensor can be suspected,
2
speed sensor system carry out troubleshooting for the following code. [CA778]
Failure code [CA757] (Loss of all engine controller data) 1

Action code Failure code Loss of all engine controller data
Trouble
Contents of
• Loss of all data in engine controller has been detected.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

and standard
state
78 HD325-7, HD405-7
HD325-7, HD405-7 79
Failure code [CA778] (Abnormal engine Bkup speed sensor) 1

Action code Failure code Abnormal engine Bkup speed sensor
Trouble
Contents of
• An abnormality has occurred in engine Bkup speed sensor circuit.
trouble
Action of
• Operates using Ne speed sensor signal.
controller
Problem that
• Engine stops during operation (when Ne speed sensor is defective at the same time).
appears on
machine • Engine cannot be started while stopping (when Ne speed sensor is defective at the same time).
Related
information

1
Max. 1 z
harness – G (female) (1) tance
2
– G (female) (2) tance
Max. 1 z
– G (female) (3) tance
Between ground and wiring harness Resis-
Min. 1 Mz
Defective harness grounding between ENG (female) (37) – G (female) (1) tance
3
Min. 1 Mz
between ENG (female) (47) – G (female) (2) tance
Possible causes Between ground and wiring harness Resis-
Min. 1 Mz
and standard between ENG (female) (26) – G (female) (3) tance
Resis-
(37) – G (female) (1) and wiring harness Min. 1 Mz
tance
from ENG (female) (47) – G (female) (2)
Harness short
tance
Resis-
tance
Defective mounting of sensor Since defective mounting of Bkup speed sensor (improper gap) or
5 or defective parts for speed defective parts for speed detection (in supply pump) can be
detection suspected, directly check it.
Engine Bkup speed sensor can be suspected to be defective if no
Defective engine Bkup
6 problem is found in causes 1 – 5 (since this is an internal defect, it
speed sensor
cannot be diagnosed).
diagnosed).
80 HD325-7, HD405-7
HD325-7, HD405-7 81
Failure code [CA1228] (Abnormal EGR valve servo 1) 1

Action code Failure code Abnormal EGR valve servo 1
Trouble
Contents of
• An abnormality has occurred in EGR valve servo (level 1).
trouble
Action of
• Executes open loop control.
controller
Problem that
appears on
machine
Related
information

those codes.
a See Testing and adjusting “Measuring engine oil pressure“ for
engine oil pressure inspection.
Engine Engine oil pressure
Defective engine hydraulic
2 Low idle 0.08 MPa {0.8 kg/cm²}
system (main circuit)
High idle 0.21 MPa {2.1 kg/cm²}
Possible causes If engine oil pressure is out of range, carry out troubleshooting for
and standard mechanical system (S-12 Oil pressure drops)
value in normal
Defective oil pump for EGR Since the oil pump relief valve for the EGR valve circuit can be
state 3
valve suspected to be defective, directly check it.
Defective hydraulic feed Since the hydraulic feed piping for EGR valve circuit can be
4
piping for EGR valve suspected to be defective, directly check it.
Defective hydraulic return Since hydraulic return piping for EGR valve circuit can be sus-
5
piping for EGR valve pected to be defective, directly check it.
Since a mechanical defect of EGR valve can be suspected, directly
6 Defective EGR valve
check it.
diagnosed).
82 HD325-7, HD405-7
Failure code [CA1625] (Abnormal EGR valve servo 2) 1

Action code Failure code Abnormal EGR valve servo 2
Trouble
Contents of
• An abnormality has occurred in EGR valve servo (level 2).
trouble
Action of • Operates by limiting output.
controller • Closes EGR valve and bypass valve.
Problem that
machine
Related infor-
mation

and standard
state
HD325-7, HD405-7 83
Failure code [CA1626] (Short circuit of bypass valve solenoid drive) 1

Action code Failure code Short circuit of bypass valve solenoid drive
Trouble
Contents of
• Short circuit has occurred in the bypass valve solenoid drive circuit.
trouble
Problem that
machine
Related
• Connector No. may vary depending on the equipped model.
information

Defective bypass valve starting switch still OFF.
1 solenoid
BP (male) Resistance
(Internal defect)
Between (1) – (2) 10 – 21 z
2 Max. 1 z
(Disconnection or defective – BP (female) (1) tance
Max. 1 z
– BP (female) (2) tance
Possible causes starting switch still OFF.
and standard
value in normal Defective harness grounding Between ground and wiring harness between Resis-
3 Min. 1 Mz
state (Contact with ground circuit) ENG (female) (31) – BP (female) (1) tance
Min. 1 Mz
ENG (female) (11) – BP (female) (2) tance
starting switch ON.
4 Voltage Max. 1 V
(a contact with 24 V circuit) ENG (female) (31) – BP (female) (1)
Voltage Max. 1 V
ENG (female) (11) – BP (female) (2)
Between (31) – (11) 10 – 21 z
84 HD325-7, HD405-7
HD325-7, HD405-7 85
Failure code [CA1627] (Disconnection in bypass valve solenoid drive) 1

Action code Failure code Disconnection in bypass valve solenoid drive
Trouble
Contents of
• An disconnection has occurred in the bypass valve solenoid drive circuit.
trouble
Problem that
machine
Related
information

and standard
state
86 HD325-7, HD405-7
Failure code [CA1628] (Abnormal bypass valve servo 1) 1

Action code Failure code Abnormal bypass valve servo 1
Trouble
Contents of
• An abnormality has occurred in the bypass valve servo (level 1).
trouble
Action of
• Executes open loop control.
controller
Problem that
appears on
machine
Related
information

those codes.
a See Testing and adjusting "Measuring engine oil pressure" for
engine oil pressure inspection.
Engine Engine oil pressure
Defective engine hydraulic
2 Low idle 0.08 MPa {0.8 kg/cm²}
system (main circuit)
High idle 0.21 MPa {2.1 kg/cm²}
Possible causes If engine oil pressure is out of range, carry out troubleshooting for
and standard mechanical system (S-12 Oil pressure drops)
value in normal
Defective oil pump for Since the oil pump relief valve for the bypass valve circuit can be
state 3
bypass valve suspected to be defective, directly check it.
Defective hydraulic feed Since hydraulic feed piping for bypass valve circuit can be
4
piping for bypass valve suspected to be defective, directly check it.
Defective hydraulic return Since hydraulic return piping for bypass valve circuit can be
5
piping for bypass valve suspected to be defective, directly check it.
Since a mechanical defect of bypass valve can be suspected,
6 Defective bypass valve
directly check it.
diagnosed).
HD325-7, HD405-7 87
Failure code [CA1629] (Abnormal bypass valve servo 2) 1

Action code Failure code Abnormal bypass valve servo 2
Trouble
Contents of
• An abnormality has occurred in the bypass valve servo (level 2).
trouble
Problem that
machine
Related
information

and standard
state
88 HD325-7, HD405-7
HD325-7, HD405-7 89

© 2007 KOMATSU
All Rights Reserved
90 HD325-7, HD405-7
SEN01189-01
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up
40 Troubleshooting
Failure code [CA1631] (Bypass valve lift sensor too high).............................................................................. 4
Failure code [CA1632] (Bypass valve lift sensor too low) ............................................................................... 6
Failure code [CA1633] (Abnormal KOMNET) ................................................................................................. 8
Failure code [CA1642] (EGR inlet pressure sensor too low) ........................................................................ 10
Failure code [CA1653] (EGR inlet pressure sensor too high)....................................................................... 12
Failure code [CA2185] (Throttle sensor power source too high) .................................................................. 14
Failure code [CA2186] (Throttle sensor power source too low) .................................................................... 16
Failure code [CA2249] (Loss of pressure feed from supply pump abnormal 2)............................................ 16
Failure code [CA2271] (EGR valve lift sensor too high) ............................................................................... 18
Failure code [CA2272] (EGR valve lift sensor too low) ................................................................................. 20
Failure code [CA2351] (EGR valve solenoid drive short circuit) ................................................................... 22
Failure code [CA2352] (EGR valve solenoid drive disconnection) ............................................................... 24
Failure code [CA2555] (Intake air heater relay disconnection) ..................................................................... 24
Failure code [CA2556] (Intake air heater relay short circuit)......................................................................... 26
Failure code [D19HKB] (Stop lamp relay output system: Short circuit)......................................................... 28
Failure code [D5ZKKZ] (Front brake cut-off solenoid valve: Disconnection or short circuit)......................... 30
HD325-7, HD405-7 1
Failure code [DAFRKR] (Abnormal CAN communication (machine monitor): Abnormal communication) ...... 32
Failure code [DAQ0KK] (Transmission controller direct power supply: Lowering of source voltage) ........... 34
Failure code [DAQ0KT] (Transmission controller nonvolatile memory: Abnormality in controller)................ 36
Failure code [DAQ2KK] (Transmission controller solenoid power source:
Power source voltage too low)............................................................................................................... 37
Failure code [DAQ9KQ] (Transmission controller: Disagreement of model selection).................................. 38
Failure code [DAQRMA] (Transmission controller option setting: Malfunction) ............................................ 39
Failure code [DB10KT] (Retarder controller nonvolatile memory: Abnormality in controller) ........................ 39
Failure code [DB12KK] (Retarder controller solenoid power source: Power source voltage too low)........... 40
Failure code [DB13KK] (Retarder controller direct power source: Power source voltage too low) ............... 42
Failure code [DB1RKR] (CAN communication (retarder controller): Communication disabled) ................... 44
Failure code [DB1SKQ] (Model selection: Wrong information) ..................................................................... 46
Failure code [DB2RKR] (CAN communication (engine controller): Communication disabled) ..................... 48
Out of input signal range) (If equipped) ................................................................................................. 50
Failure code [DDD8KA] (ARSC system switch system: Disconnection) ....................................................... 52
Failure code [DDD8KB] (ARSC system switch system: Short circuit)........................................................... 54
Failure code [DDDAKA] (ASR system switch: Disconnection) (If equipped) ................................................ 56
Failure code [DDDAKB] (ASR system switch: Short circuit) ......................................................................... 58
Failure code [DDTHKA] (Hi clutch fill switch: Disconnection) ....................................................................... 60
Failure code [DDTJKA] (Lo clutch fill switch: Disconnection)........................................................................ 62
Failure code [DDTKKA] (1st clutch fill switch: Disconnection) ...................................................................... 64
Failure code [DDTLKA] (2nd clutch fill switch: Disconnection) ..................................................................... 66
Failure code [DDTMKA] (3rd clutch fill switch: Disconnection) ..................................................................... 68
Failure code [DDTNKA] (R clutch fill switch: Disconnection) ........................................................................ 70
Failure code [DDTPKA] (4th clutch fill switch : Disconnection) ..................................................................... 72
Failure code [DF10KA] (Gear shift lever: Disconnection) ............................................................................. 74
Failure code [DF10KB] (Gear shift lever: Short circuit) ................................................................................. 77
Failure code [DGF1KX] (Transmission oil temperature sensor: Out of input signal range) .......................... 80
Failure code [DGR2KZ] (Retarder oil temperature sensor : Disconnection or short circuit) ......................... 82
Failure code [DGR6KX] (Steering oil temperature sensor: Input signal out of range)................................... 84
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range) ..................... 86
2 HD325-7, HD405-7
HD325-7, HD405-7 3
Failure code [CA1631] (Bypass valve lift sensor too high) 1

Action code Failure code Bypass valve lift sensor too high
Trouble
Contents of
• Excessively high voltage has occurred in the bypass valve lift sensor circuit.
trouble
Problem that
machine
Related
information

1
SBP Voltage
Defective bypass valve lift
(internal defect) Since the sensor voltage is measured with the harness being
connected, if the voltage is abnormal, first check the harness and
the controller to make it sure if there is no other cause of the trou-
ble, and then judge the sensor voltage.
Max. 1 z
harness – SBP (female) (1) tance
3
– SBP (female) (2) tance
– SBP (female) (3) (4) tance
state
Min. 1 Mz
Defective harness grounding ENG (female) (37) – SBP (female) (1) tance
4
Min. 1 Mz
ENG (female) (38) – SBP (female) (2) tance
Min. 1 Mz
ENG (female) (29) – SBP (female) (3) (4) tance
Resis-
(37) – SBP (female) (1) and wiring harness Min. 1 Mz
tance
from ENG (female) (38) – SBP (female) (2)
5 (37) – SBP (female) (1) and wiring harness Resis-
(Harness internal short) Min. 1 Mz
from ENG (female) (29) – SBP (female) (3) tance
(4)
(38) – SBP (female) (2) and wiring harness Resis-
Min. 1 Mz
from ENG (female) (29) – SBP (female) (3) tance
(4)
4 HD325-7, HD405-7

Possible causes
and standard starting switch ON or with engine started.
value in normal 6 Defective engine controller
ENG Voltage
state
Between (37) – (38) 4.75 – 5.25 V
HD325-7, HD405-7 5
Failure code [CA1632] (Bypass valve lift sensor too low) 1

Action code Failure code Bypass valve lift sensor too low
Trouble
Contents of
• Excessively low voltage has occurred in the bypass valve lift sensor circuit.
trouble
Problem that
machine
Related
information

and standard
state
6 HD325-7, HD405-7
HD325-7, HD405-7 7
Failure code [CA1633] (Abnormal KOMNET) 1

Action code Failure code Abnormal KOMNET
Trouble
Contents of
• An abnormality has occurred in the KOMNET communication circuit to the machine monitor.
trouble
Action of
• Operates in a default mode or keeps the conditions when the abnormality has occurred.
controller
Problem that
appears on
machine
Related
information

Disconnection in wiring Wiring harnesses between DPC4 (female)
Resis-
harness (8) – J2P (female) (47) – ATC2 (female) (22) Max. 1 z
1 tance
(Disconnection or defective – BRC2 (female) (22)
contact of connectors) Wiring harnesses between DPC4 (female)
Resis-
(3) – J2P (female) (46) – ATC2 (female) (32) Max. 1 z
tance
– BRC2 (female) (32)
Between ground and wiring harnesses
between DPC4 (female) (8) – J2P (female) Resis-
Min. 1 Mz
Defective harness grounding (47) – ATC2 (female) (22) – BRC2 (female) tance
2
(Contact with ground circuit) (22) – other related circuits.
between DPC4 (female) (3) – J2P (female) Resis-
Min. 1 Mz
(46) – ATC2 (female) (32) – BRC2 (female) tance
Possible causes (32) – other related circuits.
and standard
state starting switch ON.
between DPC4 (female) (8) – J2P (female)
Voltage Max. 1 V
Hot short in wiring harness (47) – ATC2 (female) (22) – BRC2 (female)
3
(a contact with 24 V circuit) (22) – other related circuits.
between DPC4 (female) (3) – J2P (female)
Voltage Max. 1 V
(46) – ATC2 (female) (32) – BRC2 (female)
(32) – other related circuits.
Defective CAN terminal Resis-
4 Between CAN 1(male) (A) – (B) 120 ± 12 z
resistance tance
Resis-
Between CAN2 (male) (A) – (B) 120 ± 12 z
tance
Defective machine monitor,
If causes 1 – 4 are not detected, machine monitor, engine control-
engine controller, transmis-
5 ler, transmission controller or retarder controller may be defective.
sion controller or retarder
(Since trouble is in system, troubleshooting cannot be carried out.)
controller
8 HD325-7, HD405-7
HD325-7, HD405-7 9
Failure code [CA1642] (EGR inlet pressure sensor too low) 1

Action code Failure code EGR inlet pressure sensor too low
Trouble
Contents of
• Excessively low pressure has occurred in the EGR inlet pressure sensor circuit.
trouble
Action of • Operates with the EGR inlet pressure value defaulted to (102 kPa {1.0 kg/cm²})
controller • Operates by limiting output.
Problem that
machine
Related
information

and standard
state
10 HD325-7, HD405-7
HD325-7, HD405-7 11
Failure code [CA1653] (EGR inlet pressure sensor too high) 1

Action code Failure code EGR inlet pressure sensor too high
Trouble
Contents of
• Excessively high pressure has occurred in the EGR inlet pressure sensor circuit.
trouble
Action of • Operates with the EGR inlet pressure value defaulted to (102 kPa {1.0 kg/cm²})
controller • Operates by limiting output.
Problem that
machine
Related
information

1
PEVA Voltage
Defective EGR inlet pressure
Max. 1 z
harness – PEVA (female) (1) tance
3
– PEVA (female) (2) tance
Max. 1 z
– PEVA (female) (3) tance
value in normal Between ground and wiring harness ENG Resis-
state Min. 1 Mz
Defective harness grounding (female) (37) – PEVA (female) (1) tance
4
(Contact with ground circuit) Between ground and wiring harness ENG Resis-
Min. 1 Mz
(female) (47) – PEVA (female) (2) tance
Between ground and wiring harness ENG Resis-
Min. 1 Mz
(female) (20) – PEVA (female) (3) tance
Resis-
(37) – PEVA (female) (1) and wiring harness Min. 1 Mz
tance
from ENG (female) (47) – PEVA (female) (2)
Harness short
tance
Resis-
tance
ENG Voltage
Between (37) – (47) 4.75 – 5.25 V
12 HD325-7, HD405-7
HD325-7, HD405-7 13
Failure code [CA2185] (Throttle sensor power source too high) 1

Action code Failure code Throttle sensor power source too high
Trouble
Contents of
• Excessively high voltage has occurred in the throttle sensor power source (5 V) circuit.
trouble
Action of • Establishes the throttle opening using signals other than throttle sensor signal in order to operate
controller engine. (depends on an equipped machine)
Problem that
appears on • Depends on an equipped machine.
machine
Related
information

starting switch ON.
Defective accelerator pedal Disconnect a device

1 shown on the right.
(internal defect)
If the failure code dis- Accelerator pedal AS1 connector
appears, that device
is internally defective.
harness Wiring harness between J2P (female) (22) – Resis-
2 Max. 1 z
(Disconnection or defective AS1 (female) (1) tance
contact of connectors) Wiring harness between J2P (female) (23) – Resis-
Max. 1 z
value in normal
Resis-
Defective harness grounding between J2P (female) (22) – AS1 (female) Min. 1 Mz
3 tance
Resis-
between J2P (female) (23) – AS1 (female) Min. 1 Mz
tance
(3)
Harness short
4 Between wiring harness from J2P (female)
(22) – AS1 (female) (1) and wiring harness Min. 1 Mz
tance
from J2P (female) (23) – AS1 (female) (3)
starting switch ON.
J2P Voltage
Between (22) – (23) 4.75 – 5.25 V
14 HD325-7, HD405-7
HD325-7, HD405-7 15
Failure code [CA2186] (Throttle sensor power source too low) 1

Action code Failure code Throttle sensor power source too low
Trouble
Contents of
• Excessively low voltage has occurred in the throttle sensor power source (5 V) circuit.
trouble
Action of • Establishes the throttle opening using signals other than throttle sensor signal in order to operate
controller engine.
Problem that
appears on
machine
Related
information

and standard
state
Failure code [CA2249] (Loss of pressure feed from supply pump

abnormal 2) 1
Action code Failure code Loss of pressure feed from supply pump abnormal 2
Trouble
Contents of
• Loss of pressure feed (level 2) from supply pump has occurred.
trouble
Action of
• Limits common rail pressure.
controller
Problem that
machine
Related
information

and standard
state
16 HD325-7, HD405-7
HD325-7, HD405-7 17
Failure code [CA2271] (EGR valve lift sensor too high) 1

Action code Failure code EGR valve lift sensor too high
Trouble
Contents of
• Excessively high voltage has occurred in the EGR valve lift sensor circuit.
trouble
Problem that
machine
Related
information

1
SEGR Voltage
Defective EGR valve lift
Max. 1 z
harness – SEGR (female) (1) tance
3
– SEGR (female) (2) tance
Max. 1 z
– SEGR (female) (3) (4) tance
and standard Between ground and wiring harness ENG Resis-
value in normal Min. 1 Mz
Defective harness grounding (female) (37) – SEGR (female) (1) tance
state 4
(Contact with ground circuit) Between ground and wiring harness ENG Resis-
Min. 1 Mz
(female) (47) – SEGR (female) (2) tance
Min. 1 Mz
ENG (female) (19) – SEGR (female) (3) (4) tance
Resis-
(37) – SEGR (female) (1) and wiring harness Min. 1 Mz
tance
from ENG (female) (47) – SEGR (female) (2)
5 (37) – SEGR (female) (1) and wiring Resis-
(Harness internal short) Min. 1 Mz
harness from ENG (female) (19) – SEGR tance
(female) (3) (4)
(47) – SEGR (female) (2) and wiring Resis-
Min. 1 Mz
harness from ENG (female) (19) – SEGR tance
(female) (3) (4)
ENG Voltage
Between (37) – (47) 4.75 – 5.25 V
18 HD325-7, HD405-7
HD325-7, HD405-7 19
Failure code [CA2272] (EGR valve lift sensor too low) 1

Action code Failure code EGR valve lift sensor too low
Trouble
Contents of
• Excessively low voltage has occurred in the EGR valve lift sensor circuit.
trouble
Problem that
machine
Related
information

and standard
state
20 HD325-7, HD405-7
HD325-7, HD405-7 21
Failure code [CA2351] (EGR valve solenoid drive short circuit) 1

Action code Failure code EGR valve solenoid drive short circuit
Trouble
Contents of
• Short circuit has occurred in the drive circuit of EGR valve solenoid.
trouble
Problem that
machine
Related
information

Defective EGR valve sole- starting switch still OFF.
1 noid
EGR (male) Resistance
(internal defect)
Between (1) – (2) 10 – 21 z
2 Max. 1 z
(Disconnection or defective – EGR (female) (1) tance
Max. 1 z
– EGR (female) (2) tance
and standard
value in normal Defective harness grounding Between ground and wiring harness ENG Resis-
3 Min. 1 Mz
state (Contact with ground circuit) (female) (22) – EGR (female) (1) tance
Between ground and wiring harness ENG Resis-
Min. 1 Mz
(female) (11) – EGR (female) (2) tance
starting switch ON.
Hot short of wiring harness Between ground and wiring harness ENG
4 Voltage Max. 1 V
(a contact with 24V circuit) (female) (22) – EGR (female) (1)
Between ground and wiring harness ENG
Voltage Max. 1 V
(female) (11) – EGR (female) (2)
Between (22) – (11) 10 – 21 z
22 HD325-7, HD405-7
HD325-7, HD405-7 23
Failure code [CA2352] (EGR valve solenoid drive disconnection) 1

Action code Failure code EGR valve solenoid drive disconnection
Trouble
Contents of
• Disconnection has occurred in the drive circuit of EGR valve solenoid.
trouble
Problem that
machine
Related
information

and standard
state
Failure code [CA2555] (Intake air heater relay disconnection) 1

Action code Failure code Disconnection in intake air heater relay
Trouble
Contents of
• Disconnection has occurred in intake air heater relay circuit.
trouble
Action of
controller
Problem that
appears on • Startability of engine deteriorates in low temperature.
machine
Related
information

and standard
state
24 HD325-7, HD405-7
HD325-7, HD405-7 25
Failure code [CA2556] (Intake air heater relay short circuit) 1

Action code Failure code Intake air heater relay short circuit
Trouble
Contents of
• Short circuit has occurred in intake air heater relay circuit.
trouble
Action of
controller
Problem that
appears on • Startability of engine deteriorates in low temperature.
machine
Related
• The drive condition of heater relay varies depending on an equipped model.
information

Defective intake air heater starting switch still OFF.
1 relay
R07 (male) Resistance
(internal defect)
Between (1) – (2) 200 – 400 z
harness Wiring harness between J2P (female) (40) – Resis-
2 Max. 1 z
(Disconnection or defective R37 (female) (1) tance
contact of connectors) Wiring harness between J2P (female) (42) – Resis-
and standard R37 (female) (2) tance
3 Min. 1 Mz
(Contact with ground circuit) J2P (female) (40) – R37 (female) (1) tance
Min. 1 Mz
J2P (female) (42) – R37 (female) (2) tance
starting switch ON.
4 Defective engine controlle J2P Heater relay Voltage
At working condition Max. 1 V
Between (40) – (42)
At stopping condition 20 – 30 V
26 HD325-7, HD405-7
HD325-7, HD405-7 27
Failure code [D19HKB] (Stop lamp relay output system: Short circuit) 1
Action code Failure code Stop lamp relay output system: Short circuit
Trouble
E01 D19HKB (Retarder controller system)
Contents of
• When signal was output to stop lamp relay, abnormal current flowed.
trouble
Action of • Turns output to stop lamp relay OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Stop lamp does not light up.
machine
Related
information

2) Connect T-adapter to connector R08 (male).
R08 (male) Resistance
1 Defective stop lamp relay Between (1) – (2) 250 – 350 z
Between (1) – ground Min. 1 Mz
Relay may be checked by exchanging it with another relay
(5-pole relay).
Possible causes
value in normal Ground fault in wiring har- 2) Disconnect connectors BRC2 and R08.
state 2 ness 3) Connect T-adapter to BRC2 (female).
(Contact with GND circuit) Wiring harness between BRC2 (female) Resis-
Min. 1 Mz
(18) – R08 (female) (2) tance
2) Insert T-adapter in connector BRC2 (female).
3 Defective retarder controller BRC2 Brake pedal Voltage
Between (18) – When pressed Max. 1 V
ground When in neutral 20 – 30 V
28 HD325-7, HD405-7
HD325-7, HD405-7 29
Failure code [D5ZKKZ] (Front brake cut-off solenoid valve: Disconnec-

tion or short circuit) 1
Action code Failure code Front brake cut-off solenoid valve: Disconnection, short circuit
Trouble
E01 D5ZKKZ (Retarder controller system)
Contents of
• No current or overcurrent flowed in front brake cut-off solenoid valve circuit.
trouble
Action of • If wiring harness has disconnection, no current flows.
controller • If wiring harness has short circuit, controller stops output to solenoid.
Problem that
appears on • Front brake cannot be cut off.
machine
Related
information

2) Connect T-adapter to connector FB (male).
Defective front brake cut-off FB (male) Resistance
1
solenoid valve
Between (1) – (2) –z
(1), (2) – ground Min. 1 Mz
Disconnection in wiring har- 2) Connect T-adapter to connector BRC3 (female) and FB (female).
ness
Wiring harness between BRC3 (female) Resis-
2 (Disconnection in wiring or Max. 1 z
(28) – FB (female) (1) tance
defective contact in connec-
tor) Wiring harness between BRC3 (female) Resis-
Max. 1 z
(13) – FB (female) (2) tance
and standard 2) Disconnect connectors BRC3 and FB.
value in normal 3) Connect T-adapter to BRC3 (female).
state
Ground fault in wiring har- Wiring harness between BRC3 (female) Resis-
Min. 1 Mz
3 ness (28) – FB (female) (1) tance
(Contact with GND circuit) Contact of wiring harness between BRC3
(female) (28) – FB (female) (1) and wiring Resis-
Min. 1 Mz
harness between BRC3 (female) (13) – FB tance
(female) (2)
4 Defective retarder controller Front brake cut-off
BRC3 Voltage
switch
When operated (cut) 20 – 30 V
Between (28) – (13)
When not operated Max. 1 V
30 HD325-7, HD405-7
HD325-7, HD405-7 31
Failure code [DAFRKR] (Abnormal CAN communication

(machine monitor): Abnormal communication) 1
Action code Failure code Abnormal CAN communication (machine monitor): Abnormal com-
Trouble munication
E03 DAFRKR (Machine monitor system)
Contents of
• Transmission controller stops updating the data received from the machine monitor.
trouble
Action of • Keep the information at the time when abnormality occurred.
controller • Turns on centralized warning lamp and sounds alarm buzzer.
Problem that
• When the network is abnormal, the machine monitor can not correctly display the data from each
appears on
controller.
machine
Related
• Check that the power source circuit of machine monitor is normal.
information

2) Disconnect related connectors (See circuit diagram).
3) Connect T-adapter to connector of circuit to be measured.
Wiring harnesses between J2P (female)
(46) – CJE4 (female) (2), (8) – CAN1 Resis-
Max. 1 z
(female) (A) – CJE4 (female) (1) – CAN2 tance
(female) (A)
Wiring harnesses between J2P (female)
Disconnection in wiring
(47) – CJE4 (female) (4), (6) – CAN1 Resis-
harness Max. 1 z
1 (female) (B) – CJE4 (female) (3) – CAN2 tance
(Disconnection or defective
(female) (B)
contact)
Wiring harnesses between CJE4 (female)
(1) – DPC4 (female) (3) – ATC2 (female) Resis-
Max. 1 z
(32) – BRC2 (female) (32) – DL (female) (3) tance
– CAN2 (female) (A)
Wiring harnesses between CJE4 (female)
(3) – DPC4 (female) (8) – ATC2 (female) Resis-
Max. 1 z
(22) – BRC2 (female) (22) – DL (female) tance
Possible causes (10) – CAN2 (female) (B)
and standard
value in normal
state
Resis-
between J2P (female) (46) – CJE4 (female) Min. 1 Mz
Short circuit of harness tance
2 (2), (8) – CAN1 (female) (A)
(Contact with ground circuit)
between CJE4 (female) (1) – DPC4
Resis-
(female) (3) – ATC (female) (32) – BRC2 Min. 1 Mz
tance
(female) (32) – DL (female) (4) – CAN2
(female) (A)
2) Connect T-adapter to connectors CAN1 (male) and CAN2 (male).
Defective CAN terminal Resis-
3 Between CAN1 (male) (A) – (B) 120 ± 12 z
resistance tance
Resis-
tance
Defective machine monitor, If no problem is found in causes 1 – 3, machine monitor, engine
engine controller, controller, transmission controller or retarder controller can be
4
transmission controller or suspected to be defective (since this is an internal defect, it cannot
retarder controller be diagnosed).
32 HD325-7, HD405-7
HD325-7, HD405-7 33
Failure code [DAQ0KK] (Transmission controller direct power supply:

Lowering of source voltage) 1
Action code Failure code Transmission controller direct power supply: Lowering of source
Trouble voltage
E03 DAQ0KK (Transmission controller system)
Contents of
• While engine was running, controller direct power supply circuit voltage lowered below 18 V.
trouble
Action of
• The controller sets the gear in Neutral.
controller
Problem that
• The gear is set in Neutral suddenly during travel and the machine cannot start again until the volt-
appears on
age rises to the normal level.
machine
• If failure code "AB00MA" (Malfunction of alternator) is indicated, perform troubleshooting for it first.
Related
information • If the fuse is broken, check the line between the fuse and ATC3 (female) (1) and (11) for grounding
fault.

1) Test the battery voltage and specific gravity of the battery fluid.
Battery voltage Voltage Min. 24 V
1 Battery defective
Specific
Specific gravity of battery fluid Min. 1.26
gravity
2) Disconnect negative (–) terminal of battery and insert T-adapter
in ATC3.
3) Connect negative (–) terminal of battery.
Between battery relay terminal B – ground Voltage 20 – 30 V
Disconnection in wiring har- Between ATC3 (1), (11) – ground Voltage 20 – 30 V
Possible causes ness
2 If there is voltage between battery relay terminal B and ground and
and standard (Disconnection or defective there is not voltage between ATC3 (1) and (2), wiring harness
value in normal contact) between them has disconnection.
state
2) Disconnect negative (–) terminal of battery and connect T-
adapter to ATC3 (female)
Wiring harness between ATC3 (female) Resis-
Max. 1 z
(21), (31), (33) – ground tance
in ATC3.
Defective transmission con- 3) Connect negative (–) terminal of battery.
3
troller • Voltage can be measured with starting switch turned OFF.
Between ATC3 (1), (11) – (21), (31), (32),
Voltage 20 – 30 V
(33)
34 HD325-7, HD405-7
HD325-7, HD405-7 35
Failure code [DAQ0KT] (Transmission controller nonvolatile memory:

Abnormality in controller) 1
Action code Failure code Transmission controller nonvolatile memory: Abnormality in con-
Trouble
E01 DAQ0KT troller (Transmission controller system)
• An abnormality has occurred in the nonvolatile memory inside the controller.

Contents of
trouble • Just after starting switch was turned OFF, there was not battery direct power supply and finishing
operation was not carried out normally.
• Control the model selection and option setting with default value.
Action of
controller • Even if the cause of the failure has been eliminated automatically, the machine does not return to
normal unless once resetting the starting switch OFF.
Problem that
• Machine control parameter may change and transmission gear shift shock and hoist seating shock
appears on
may get worse.
machine
Related
• Perform initial setting and initial adjustment as when transmission controller is replaced.
information

and standard Since this is an internal defect, it cannot be diagnosed.
value in normal Defective transmission
1 (It is no problem to keep using controller unless any visible trouble
state controller
symptom appears on machine.)
36 HD325-7, HD405-7
Failure code [DAQ2KK] (Transmission controller solenoid power

source: Power source voltage too low) 1
Action code Failure code Transmission controller solenoid power source: Power source volt-
Trouble
E03 DAQ2KK age too low (Transmission controller system)
Contents of • Battery direct power source voltage of transmission controller has dropped to above 20 V, and
trouble solenoid power source voltage has dropped to below 18 V.
Action of • Holds the gear speed.
controller • Keeps neutral with shift lever neutral.
Problem that
• Suddenly shifts to neutral while traveling, and the machine cannot move off again.
appears on
machine • Body does not operate.
Related
• When the fuse is blown, check for ground fault of line from fuse – ATC3 (female) (2), (12), (22).
information

in ATC3.
Disconnection in wiring 3) Connect negative (–) terminal of battery.
harness Between battery relay terminal M – ground Voltage 20 – 30 V
1
contact) Between ATC3 (2), (12), (22) – ground Voltage 20 – 30 V
Possible causes
and standard If there is voltage between battery relay terminal M and ground and
value in normal there is not voltage between ATC3 (2), (12), (22) and ground, wir-
state ing harness between them has disconnection.
in ATC3.
Defective transmission 3) Connect negative (–) terminal of battery.
2
controller 4) Turn starting switch ON.
Between ATC3 (2), (12), (22) – (21), (31),
Voltage 20 – 30 V
(32), (33)
HD325-7, HD405-7 37
Failure code [DAQ9KQ] (Transmission controller: Disagreement of

model selection) 1
Action code Failure code Transmission controller: Disagreement of model selection
Trouble
E03 DAQ9KQ (Transmission controller system)
Contents of
trouble
Action of
• Lights up central warning lamp and sounds alarm buzzer.
controller
Problem that
appears on • If machine travels as it is, transmission may be broken.
machine
Related
information

Failure code [DAQ9KQ] is not displayed (Code is not displayed).
Possible causes Setting of model with
1 a When machine monitor or transmission controller is replaced,
and standard machine monitor
set them according to Testing and adjusting.
value in normal
state Controller of correct part No. is mounted.
2 Transmission controller a Check part No. If it is wrong, replace transmission controller
with correct one.
38 HD325-7, HD405-7
Failure code [DAQRMA] (Transmission controller option setting:

Malfunction) 1
Action code Failure code Transmission controller option setting: Malfunction
Trouble (Machine monitor-transmission controller)
E03 DAQRMA (Machine monitor system)
Contents of • Option setting signals inputted from machine monitor with the starting switch ON are different from
trouble the option settings that controller memorizes.
• Holds the gear speed in neutral.
Action of
• Controls with the option setting that the controller memorizes.
controller
• It does not return normal unless the starting switch is turned OFF.
Problem that
appears on • The gear speed becomes neutral and the machine cannot move off again.
machine
Related
• Perform initial setting and initial adjustment as when transmission controller is replaced.
information

and standard
value in normal Defective option setting of machine monitor or internal defect of
1 Defective machine monitor
state monitor
Failure code [DB10KT] (Retarder controller nonvolatile memory:

Abnormality in controller) 1
Action code Failure code Retarder controller nonvolatile memory: Abnormality in controller
Trouble
E01 DB10KT (Retarder controller system)
Contents of
• An abnormality has occurred in the nonvolatile memory inside the controller.
trouble
• Control the model selection and option setting with default value.
Action of
controller • Even if the cause of the failure has been eliminated automatically, the machine does not return to
normal unless once resetting the starting switch OFF.
Problem that
appears on • Machine parameter may change and power may increase or decrease.
machine
Related
information

and standard
value in normal Since this is an internal defect, it cannot be diagnosed.
1 Defective retarder controller
state Replace to controller.
HD325-7, HD405-7 39
Failure code [DB12KK] (Retarder controller solenoid power source:

Power source voltage too low) 1
Action code Failure code Retarder controller solenoid power source: Power source voltage
Trouble too low
E03 DB12KK (Retarder controller system)
Contents of • While controller direct power source voltage is normal, solenoid power source voltage has become
trouble below 18 V.
Action of • Turn OFF all of output circuits.
controller • Turn OFF sensor 24 V power source.
Problem that • All systems of retarder controller do not operate. (retarder, dump, automatic suspension, ARSC and
appears on ASR)
machine • Failure code (DHU2KX and DHU3KX) are displayed at the same time.
• If the fuse is blown, check for ground fault of line from fuse – BRC3 (female) (2), (12), (22).
Related
information • If failure code "DAQ0KK" or "DAQ2KK" (transmission controller power source) is displayed, carry
out troubleshooting for it first.

in BRC3.
3) Connect negative (–) terminal of battery.
Between battery terminal M – ground Voltage 20 – 30 V
Disconnection in wiring Between BRC3 (2), (12), (22) – ground Voltage 20 – 30 V
harness
1 If voltage at fuse BT3 (12) is normal and voltage at BRC3 (2), (12),
Possible causes contact) (22) is abnormal, wiring harness between fuse (12) – BRC3
and standard (female) (2), (12), (22) has disconnection.
value in normal 1) Turn starting switch OFF.
state 2) Disconnect negative (–) terminal of battery and connect T-
adapter to BRC3 (female).
Max. 1 z
(21), (31), (32), (33) – ground tance
in BRC3.
2 Defective retarder controller 3) Connect negative (–) terminal of battery.
Between BRC3 (2), (12), (22) – ground Voltage 20 – 30 V
40 HD325-7, HD405-7
HD325-7, HD405-7 41
Failure code [DB13KK] (Retarder controller direct power source: Power

source voltage too low) 1
Action code Failure code Retarder controller direct power source: Power source voltage
Trouble too low
E03 DB13KK (Retarder controller system)
Contents of
• Controller source voltage is below 18 V.
trouble
Action of
• Turns all output OFF.
controller
Problem that
appears on • Retarder does not operate.
machine
• When the fuse is blown, check the short circuit of line from fuse – BRC3 (female) (1), (11), (2), (12),
Related (22).
information • If failure code "DAQ0KK" or "DAQ2KK" (transmission controller power source) is displayed, carry
out troubleshooting for it first.

a Check battery voltage and electrolyte specific gravity.
Battery voltage Voltage Min. 24 V
1 Defective battery
Specific
Battery electrolyte specific gravity Min. 1.26
gravity
2) Disconnect battery (–) terminal and insert T-adapter in BRC3.
3) Connect battery (–) terminal.
Between battery relay terminal R – ground Voltage 20 – 30 V
Possible causes
and standard Disconnection in wiring har- Between BRC (1), (11) – ground Voltage 20 – 30 V
value in normal ness 1) Turn starting switch OFF.
state 2 (Disconnection in wiring or 2) Disconnect battery (–) terminal and connect T-adapter to BRC3
defective contact in connec- (female).
tor)
Max. 1 z
(21), (31), (32), (33) – ground tance
If there is voltage between battery relay terminal B and ground but
not between ATC3 (1), (11) and ground, wiring harness or fuse is
broken.
Defective transmission con- and carry out troubleshooting.
3
troller
Between BRC3 (1), (11) – ground Voltage 20 – 30 V
42 HD325-7, HD405-7
HD325-7, HD405-7 43
Failure code [DB1RKR] (CAN communication (retarder controller):

Communication disabled) 1
Action code Failure code Abnormal CAN communication (retarder controller): Communica-
tion disabled
Trouble
E03 DB1RKR (Between retarder controller – transmission controller)
(Retarder controller system)
Contents of
trouble • Updating of received data from retarder controller has stopped.
• AISS is locked in LOW or Hi.(until starting switch is turned OFF.)
Action of
controller • Keep the information at the time when abnormality occurred.
Problem that
appears on • The information and special functions which are retrieved from retarder controller do not work or
machine display.
Related
information

Defective CAN terminal
1 Resis-
resistance Between CAN1 (male) (A) – (B) 120 ± 12 z
tance
Resis-
tance
Wiring harness between DPC4 (female) (3), Resis-
Max. 1 z
(8) – CAN2 (female) (A), (B) tance
Max. 1 z
(8) – BRC2 (female) (32), (22) tance
Disconnection in wiring Wiring harness between DPC4 (female) (3), Resis-
Max. 1 z
harness (8) – ATC2 (female) (32), (22) tance
2
(Disconnection or defective Wiring harness between DPC4 (female) (3), Resis-
contact) Max. 1 z
(8) – J2P (female) (46), (47) tance
Max. 1 z
Possible causes (8) – DL (female) (4), (10) tance
and standard Wiring harness between DPC4 (female) (3), Resis-
state Wiring harness between J2P (female) (46),
Resis-
(47) – CAN1 (female) (A), (B) – CAN2 Max. 1 z
tance
(female) (A), (B)
Min. 1 Mz
DPC4 (female) (3) – CAN2 (female) (A) tance
Min. 1 Mz
DPC4 (female) (3) – BRC2 (female) (32) tance
Min. 1 Mz
Short circuit of harness DPC4 (female) (3) – ATC2 (female) (32) tance
3
Min. 1 Mz
DPC4 (female) (3) – J2P (female) (46) tance
Min. 1 Mz
Min. 1 Mz
DPC4 (female) (3) – DL (female) (4) tance
Resis-
J2P (female) (46) – CAN1 (female) (A) – Min. 1 Mz
tance
CAN2 (female) (A)
44 HD325-7, HD405-7

and standard Defective machine monitor, If no problem is found in causes 1 – 3, machine monitor, engine
engine controller, controller ,transmission controller and retarder controller can be
value in normal 4
state
HD325-7, HD405-7 45
Failure code [DB1SKQ] (Model selection: Wrong information) 1

Action code Failure code Model selection: Wrong information
(Internal save value disagrees with model information from
Trouble
E03 DB1SKQ machine monitor)
Contents of • Model selection information cannot be received because of error in communication with monitoring
trouble mode or model selection information out of setting was received.
Action of
controller
Problem that
appears on • This failure does not have a serious effect on the machine.
machine
Related
• Other failures are detected, too. (Failure codes [DAFRKR], [DB1RKR], [DB2RKR] are displayed.)
information

Possible causes
Transmission controller a If the failure is not repaired by replacing the retarder controller,
and standard 1
defective the transmission controller is defective.
value in normal
state a If the failure is repaired by replacing the transmission controller,
the retarder controller is defective.
46 HD325-7, HD405-7
HD325-7, HD405-7 47
Failure code [DB2RKR] (CAN communication (engine controller):

Communication disabled) 1
Action code Failure code CAN communication (engine controller): Communication disabled
Trouble (Between engine controller – transmission controller)
E03 DB2RKR
(Engine controller system)
Contents of
• Updating of received data from engine controller has stopped.
trouble
• Holds the gear speed.
Action of
• Keep the neutral with gear shift lever N.
controller
Problem that
• The information and special functions which are retrieved from engine controller do not work or
appears on
display.
machine
Related
information

2) Connect T-adapter to connectors CAN1 (male) and CAN2
(male).
Defective CAN terminal
1 Resis-
resistance Between CAN1 (male) (A) – (B) 120 ± 12 z
tance
Resis-
tance
Max. 1 z
Max. 1 z
(8) – J2P (female) (46), (47) tance
Max. 1 z
Possible causes (8) – ATC2 (female) (32), (22) tance
and standard Wiring harness between DPC4 (female) (3), Resis-
harness Max. 1 z
value in normal 2 (8) – BRC2 (female) (32), (22) tance
state Wiring harness between DPC4 (female) (3), Resis-
contact) Max. 1 z
Max. 1 z
(8) – DL (female) (3), (10) tance
Wiring harness between J2P (female) (46),
Resis-
(47) – CAN1 (female) (A), (B) – CAN2 Max. 1 z
tance
(female) (A), (B)
Wiring harness between J2P (female) (39) –
Resis-
BT3 (22) – (21) – starting switch (terminal Min. 1 Mz
tance
ACC)
Short circuit of harness
3 Between ground and wiring harness between Resis-
(Contact with ground circuit) Min. 1 Mz
Min. 1 Mz
DPC4 (female) (3) – J2P (female) (46) tance
48 HD325-7, HD405-7

Min. 1 Mz
DPC4 (female) (3) – ATC2 (female) (32) tance
Min. 1 Mz
DPC4 (female) (3) – BRC2 (female) (32) tance
Min. 1 Mz
Short circuit of harness Between ground and wiring harness between Resis-
3 Min. 1 Mz
(Contact with ground circuit) DPC4 (female) (3) – DL (female) (3) tance
Possible causes
and standard Resis-
J2P (female) (46) – CAN1 (female) (A) – Min. 1 Mz
value in normal tance
state CAN2 (female) (A)
Wiring harness between J2P (female) (39) –
Resis-
BT3 (22) – (21) – starting switch (terminal Max. 1 z
tance
ACC)
Defective engine controller If engine cannot be started, engine controller power supply may be
4
power supply defective. Carry out troubleshooting for "Failure code CA111".
Defective machine monitor, If no problem is found in causes 1 – 3, machine monitor, engine
engine controller, controller ,transmission controller and retarder controller can be
5
HD325-7, HD405-7 49

Out of input signal range) (If equipped) 1
Action code Failure code Trouble in travel speed setting switch system: Out of input signal
range (If equipped)
Trouble
E03 DDD7KX (When ARSC is set and ARSC system switch is ON)
Contents of
trouble • The input signal circuit voltage of the travel speed set switch is below 0.15 V.
Action of
controller • When ARSC operates, the controller releases the brake gradually.
Problem that
machine
Related
information • None in particular.

Travel speed set switch 2) Replace the travel speed set switch (ARSC SET switch).
1 (ARSC SET switch) defec- Replace the travel Failure is not
Switch is normal
tive speed set switch repaired.
(ARSC SET switch). Failure is repaired. Switch is defective
2) Disconnect connector RE3.
2 Register (250 z) defective 3) Connect T-adapter.
Resis-
Between RE3 (female) (1) – (2) 250 ± 25 z
tance
3 Resistor (1,020 z) defective 3) Connect T-adapter.
Resis- 1,020 ±
Between RE4 (female) (1) – (2)
tance 102 z
2) Disconnect connectors BRC1, ARC, RE3, and RE4.
Possible causes Disconnection in wiring har- Max. 1 z
(22) – RE3 (male) (1) tance
and standard ness
value in normal 4 Wiring harness between BRC1 (female) Resis-
state (13) – RE3 (male) (2) – ARC (female) (1) tance
contact)
Wiring harness between RE4 (male) (1) – Resis-
Max. 1 z
ARC (female) (3) tance
Wiring harness between RE4 (male) (2) – Resis-
Max. 1 z
ARC (female) (2) tance
2) Disconnect connectors BRC1.
Between BRC1 (22) – (21) Voltage Approx. 5 V
2) Disconnect connectors BRC1.
When set switch is Resis- 1,020 ±
ON tance 102 z
When set switch is Resis-
68 ± 6.8 z
Between BRC1 TOUCH UP tance
(female) (13) – (21) When set switch is Resis- 198 ±
TOUCH DOWN tance 19.8 z
When set switch is Resis- 418 ±
CANCEL tance 41.8 z
50 HD325-7, HD405-7
HD325-7, HD405-7 51
Failure code [DDD8KA] (ARSC system switch system: Disconnection) 1

Action code Failure code ARSC system switch system: Disconnection
Trouble (When ARSC is set and ARSC system switch is ON)
E03 DDD8KA (Machine moniter system)
Contents of
• The ON input of the ARSC system switch is ON and the OFF input of the system switch is ON.
trouble
Action of
• When ARSC operates, the controller releases the brake gradually.
controller
Problem that
machine
Related
• Condition of ARSC switch can be checked with monitoring function (Code: 37701).
information

Disconnection in wiring har- 2) Disconnect connectors ARSC and DPC2B.
ness 3) Connect T-adapter.
1
contact) Wiring harness between DPC2B (female) Resis-
Max. 1 z
(1) – ARSC (female) (3) tance
2) Replace the ARSC system switch with normal one.
ARSC system switch defec-
2 System switch is nor-
Possible causes tive When the ARSC system switch No
mal
and standard is replaced with normal one, is
value in normal failure repaired? System switch is
Yes
state defective
2) Disconnect connector DPC2B.
Turn the ARSC sys-
3 Machine monitor defective
tem switch ON Voltage 20 – 30 V
Between DPC2B (1) (Press it up).
– ground Turn the ARSC sys-
tem switch OFF Voltage Max. 1 V
(Press it down).
52 HD325-7, HD405-7
HD325-7, HD405-7 53
Failure code [DDD8KB] (ARSC system switch system: Short circuit) 1

Action code Failure code ARSC system switch system: Short circuit
Trouble (When ARSC is set and ARSC system switch is ON)
E03 DDD8KB (Machine monitor system)
Contents of
• The ON input of the ARSC system switch is ON and the OFF input of the system switch is ON.
trouble
Action of
• When ARSC operates, the controller releases the brake gradually.
controller
Problem that
machine
Related
• Condition of ARSC switch can be checked with monitoring function (Code: 37701).
information

2) Disconnect connectors ARSC and DPC2B.
1 Hot short in wiring harness Wiring harness between DPC2B (female)
Voltage Max. 1 V
(1) – ARSC (female) (3)
Wiring harness between DPC2B (female)
Voltage Max. 1 V
(7) – ARSC (female) (2)
2) Replace the ARSC system switch with normal one.
Possible causes ARSC system switch defec-
and standard 2 System switch is nor-
tive When the ARSC system switch No
value in normal mal
is replaced with normal one, is
state failure repaired? System switch is
Yes
defective
Turn the ARSC sys-
3 Machine monitor defective
tem switch ON Voltage 20 – 30 V
Between DPC2B (1) (Press it up).
– ground Turn the ARSC sys-
tem switch OFF Voltage Max. 1 V
(Press it down).
54 HD325-7, HD405-7
HD325-7, HD405-7 55
Failure code [DDDAKA] (ASR system switch: Disconnection) (If

equipped) 1
Action code Failure code ASR system switch: Disconnection (If equipped)
Trouble
E01 DDDAKA (Machine monitor system)
Contents of
• The ON input of the ARSC system switch is OFF and the OFF input of the system switch is OFF.
trouble
Action of
• Resets ASR control.
controller
Problem that
• Machine is not affected seriously.
appears on
machine • ASR control cannot be continued.
Related
• Condition of ASR switch can be checked with monitoring function (Code: 37900).
information

2) Disconnect connectors ASR and DPC2B.
Disconnection in wiring har- Wiring harness between DPC2B (female) Resis-
ness Max. 1 z
(3) – ASR (female) (3) tance
1 (Disconnection in wiring or
defective contact in connec- 1) Turn starting switch OFF.
tor) 2) Disconnect connectors ASR and DPC2B.
Wiring harness between DPC2B (female) Resis-
Max. 1 z
(9) – ASR (female) (2) tance
2) Replace ASR system switch with normal switch.
Possible causes 3) Turn starting switch ON.
Defective ASR system
and standard 2 System switch is nor-
switch When ASR system switch is No
value in normal mal
state replaced with normal switch,
does condition become normal? System switch is
Yes
abnormal
ASR system switch
Voltage 20 – 30 V
Between DPC2B (3) "ON"
3 Defective machine monitor – chassis ground ASR system switch
Voltage Max. 1 V
"OFF"
ASR system switch
Voltage Max. 1 V
– chassis ground ASR system switch
Voltage 20 – 30 V
"OFF"
56 HD325-7, HD405-7
HD325-7, HD405-7 57
Failure code [DDDAKB] (ASR system switch: Short circuit) 1

Action code Failure code ASR system switch system: Short circuit
Trouble
E01 DDDAKB (Machine monitor system)
Contents of
• ASR system switch ON input is turned ON and system switch OFF input is turned ON.
trouble
Action of
• Resets ASR control.
controller
Problem that
• Machine is not affected particularly.
appears on
Related
information

2) Disconnect connectors ASR and DPC2B.
1 Hot short in wiring harness
Voltage Max. 1 V
(3) – ASR (female) (3)
Voltage Max. 1 V
(9) – ASR (female) (2)
2) Replace ASR system switch with normal switch.
Defective ASR system
Possible causes 2 System switch is nor-
switch When ASR system switch is No
and standard mal
replaced with normal switch, is
value in normal System switch is
condition normal? Yes
state defective
ASR system switch
Voltage 20 – 30 V
3 Defective machine monitor – chassis ground ASR system switch
Voltage Max. 1 V
"OFF"
ASR system switch
Voltage Max. 1 V
– chassis ground ASR system switch
Voltage 20 – 30 V
"OFF"
58 HD325-7, HD405-7
HD325-7, HD405-7 59
Failure code [DDTHKA] (Hi clutch fill switch: Disconnection) 1

Action code Failure code Hi clutch fill switch: Disconnection
(Command is Holding pressure, fill switch is OFF, and slip is not
Trouble
E03 DDTHKA sensed)
Contents of • When the output to the Hi clutch ECMV is turned ON, the clutch is engaged but the signal from the
trouble fill switch is not turned ON.
Action of • The controller keeps the current gear speed.
controller • If the shift lever is set in the "N" position, the controller keeps the gear in Neutral.
Problem that
• The gear cannot be shifted.
appears on
machine • If the shift lever is set in the "N" position, the machine cannot start until it is stopped.
Related
information

1 Hi clutch fill switch defective When dis- Resis-
Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
and standard Disconnection in wiring har- 2) Disconnect connectors ATC3 and CN20.
value in normal ness 3) Connect T-adapter.
2
state (Disconnection or defective
contact) Wiring harness between ATC3 (female) (30) Resis-
Max. 1 z
Transmission controller
3 When dis- Resis-
defective Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
60 HD325-7, HD405-7
HD325-7, HD405-7 61
Failure code [DDTJKA] (Lo clutch fill switch: Disconnection) 1

Action code Failure code Lo clutch fill switch: Disconnection
Trouble
E03 DDTJKA sensed)
Contents of • When the output to the Lo clutch ECMV is turned ON, the clutch is engaged but the signal from the
Problem that
appears on
Related
information

1 Lo clutch fill switch defective When dis- Resis-
Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
2
Max. 1 z
3 When dis- Resis-
defective Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
62 HD325-7, HD405-7
HD325-7, HD405-7 63
Failure code [DDTKKA] (1st clutch fill switch: Disconnection) 1

Action code Failure code 1st clutch fill switch: Disconnection
Trouble
E03 DDTKKA sensed)
Contents of • When the output to the 1st clutch ECMV is turned ON, the clutch is engaged but the signal from the
controller • If the shift lever is set in the "N" position, the controller keeps the gear in neutral.
Problem that
appears on
Related
information

1 1st clutch fill switch defective When dis- Resis-
Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
2
Max. 1 z
3 When dis- Resis-
defective Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
64 HD325-7, HD405-7
HD325-7, HD405-7 65
Failure code [DDTLKA] (2nd clutch fill switch: Disconnection) 1

Action code Failure code 2nd clutch fill switch: Disconnection (KA)
Trouble
E03 DDTLKA sensed)
Contents of • When the output to the 2nd clutch ECMV is turned ON, the clutch is engaged but the signal from the
Problem that
appears on
Related
information

2nd clutch fill switch defec-
1 When dis- Resis-
tive Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
2
Max. 1 z
3 When dis- Resis-
defective Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
66 HD325-7, HD405-7
HD325-7, HD405-7 67
Failure code [DDTMKA] (3rd clutch fill switch: Disconnection) 1

Action code Failure code 3rd clutch fill switch: Disconnection
Trouble
E03 DDTMKA sensed)
Contents of • When the output to the 3rd clutch ECMV is turned ON, the clutch is engaged but the signal from the
Problem that
appears on
Related
information

1 3rd clutch fill switch defective When dis- Resis-
Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
2
Max. 1 z
3 When dis- Resis-
defective Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
68 HD325-7, HD405-7
HD325-7, HD405-7 69
Failure code [DDTNKA] (R clutch fill switch: Disconnection) 1

Action code Failure code R clutch fill switch: Disconnection
Trouble
E03 DDTNKA sensed)
Contents of • When the output to the R clutch ECMV is turned ON, the clutch is engaged but the signal from the
Problem that
appears on
Related
information

1 R clutch fill switch defective When dis- Resis-
Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
2
Max. 1 z
3 When dis- Resis-
defective Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
70 HD325-7, HD405-7
HD325-7, HD405-7 71
Failure code [DDTPKA] (4th clutch fill switch : Disconnection) 1

Action code Failure code 4th clutch fill switch : Disconnection
Trouble
E03 DDTPKA sensed)
Contents of • When the output to the 4th clutch ECMV is turned ON, the clutch is engaged but the signal from the
Problem that
appears on
Related
information

1 4th clutch fill switch defective When dis- Resis-
Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
2
Max. 1 z
3 When dis- Resis-
defective Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
72 HD325-7, HD405-7
HD325-7, HD405-7 73
Failure code [DF10KA] (Gear shift lever: Disconnection) 1

Action code Failure code Gear shift lever: Disconnection (No lever signal input)
Trouble
E03 DF10KA (Transmission controller system)
Contents of
• Gear shift lever signal is not input at all.
trouble
Action of
• Controls according to previous gear shift lever information before abnormality occurs.
controller
Problem that • Gear speed is still in neutral and cannot start vehicle.
appears on • Cannot shift between forward and reverse positions.
machine • All gear shift lever position lamps go out.
Related infor-
• Nothing particular.
mation

• Gear shift lever is being pushed even though it is not operated.
1 Operational error • Gear shift lever has been stopped at the midway point between
each of the gear positions.
2) Connect T-adapter to connector SF1 (male), ATC1 (female) and
ATC2 (female).
Resis-
Harness between BT3 (14) – SF1 (male) (1) Max. 1 z
tance
Max. 1 z
– SF1 (male) (3) tance
Max. 1 z
Max. 1 z
Disconnection in wiring Wiring harness between ATC2 (female) (15) Resis-
harness Max. 1 z
2 – SF1 (male) (6) tance
contact of connectors) Wiring harness between ATC2 (female) (5) Resis-
Max. 1 z
Possible causes Wiring harness between ATC2 (female) (36) Resis-
Max. 1 z
and standard – SF1 (male) (8) tance
value in normal Wiring harness between ATC2 (female) (26) Resis-
Max. 1 z
state – SF1 (male) (9) tance
Max. 1 z
Max. 1 z
Max. 1 z
(31) (32) (33) – SF1 (male) (2) tance
2) Connect T-adapter to connectors ATC1 (female), ATC2 (female),
and SF1 (male).
Min. 1 Mz
ATC2 (female) (35) – SF1 (male) (3) tance
3 Min. 1 Mz
(Contact with ground circuit) ATC2 (female) (25) – SF1 (male) (5) tance
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
74 HD325-7, HD405-7

Min. 1 Mz
Min. 1 Mz
Defective harness grounding ATC2 (female) (26) – SF1 (male) (9) tance
3
Min. 1 Mz
Min. 1 Mz
2) Insert T-adapter in connector SF1.
In shift range "R" Voltage 20 – 30 V
Between SF1 (3) –
ground In shift range other
Voltage Max. 1 V
than "R"
In shift range "N" Voltage 20 – 30 V
Between SF1 (4) –
Voltage Max. 1 V
than "N"
In shift range "D" Voltage 20 – 30 V
Between SF1 (5) –
Voltage Max. 1 V
than "D"
In shift range "6" Voltage 20 – 30 V
Between SF1 (6) –
Voltage Max. 1 V
than "6"
Possible causes 4 Defective gear shift lever
and standard Between SF1 (7) –
value in normal Voltage Max. 1 V
than "5"
state
Between SF1 (8) –
Voltage Max. 1 V
than "4"
Between SF1 (9) –
Voltage Max. 1 V
than "3"
Between SF1 (10) –
Voltage Max. 1 V
than "2"
Voltage Max. 1 V
than "1"
2) Insert T-adapter in connectors ATC1 and ATC2.
Between ATC2 (35) –
Voltage Max. 1 V
Defective transmission than "R"
5
controller In shift range "D" Voltage 20 – 30 V
Voltage Max. 1 V
than “D“
Voltage Max. 1 V
than "N"
HD325-7, HD405-7 75

Voltage Max. 1 V
than "6"
Voltage Max. 1 V
than "5"
Possible causes Between ATC2 (36) –
and standard Voltage Max. 1 V
Defective transmission than "4"
value in normal 5
state controller In shift range "3" Voltage 20 – 30 V
Voltage Max. 1 V
than "3"
Voltage Max. 1 V
than "2"
Voltage Max. 1 V
than "1"
76 HD325-7, HD405-7
Failure code [DF10KB] (Gear shift lever: Short circuit) 1

Action code Failure code Gear shift lever: Short circuit
Trouble (Input of multiple lever signach)
E03 DF10KB (Transmission controller system)
Contents of
• Gear shift lever signals have been inputted at the same time from 2 or more systems.
trouble
• Controls according to high priority signal.
(1): N > D > 6> 5 > 4 > 3 > 2 > 1
Action of
(2): N > R1
controller
• Shifts gear speed to neutral when signals have been inputted from system (1) and system (2) at the
same time.
• There are cases where the gear speed is shifted to a higher gear speed than that which has been
Problem that
set by the gear shift lever.
appears on
• Gear speed is still in neutral and cannot start vehicle.
machine
• Gear shift lever position lamp does not indicate actual gear shift lever position.
Related
• Nothing particular.
information

2) Connect T-adapter to connectors ATC1 (female), ATC2
(female), and SF1 (male).
When not
Voltage at R2,
ATC2 (female) (35) – SF1 (male) (3)
Max. 1 V
When not
Voltage at R1,
Max. 1 V
When not
Voltage at N, Max.
1V
When not
Voltage at D, Max.
Hot short in wiring harness ATC2 (female) (15) – SF1 (male) (6)
1 1V
(a contact with 24 V circuit)
Possible causes When not
and standard Voltage at 5, Max.
value in normal 1V
state When not
Voltage at 4, Max.
1V
When not
Voltage at 3, Max.
1V
When not
Voltage at 2, Max.
1V
When not
Voltage at 1, Max.
1V
2) Insert T-adapter in connector SF1.
2 Defective gear shift lever
Between SF1 (3) –
Voltage Max. 1 V
than "R"
HD325-7, HD405-7 77

Between SF1 (4) –
Voltage Max. 1 V
than "N"
In shift range"D" Voltage 20 – 30 V
Between SF1 (5) –
Voltage Max. 1 V
than "D"
Between SF1 (6) –
Voltage Max. 1 V
than "6"
Between SF1 (7) –
Voltage Max. 1 V
than "5"
2 Defective gear shift lever
Between SF1 (8) –
Voltage Max. 1 V
than "4"
Between SF1 (9) –
Voltage Max. 1 V
than "3"
Voltage Max. 1 V
than "2"
Voltage Max. 1 V
than "1"
Possible causes a Turn the starting switch OFF.
and standard
value in normal In shift range "R" Voltage 20 – 30 V
state ground In shift range other
Voltage Max. 1 V
than "R"
In shift range "D" Voltage 20 – 30 V
Voltage Max. 1 V
than "D"
In shift range"N" Voltage 20 – 30 V
Voltage Max. 1 V
than “N“
Voltage Max. 1 V
than "6"
Defective transmission In shift range "5" Voltage 20 – 30 V
3 Between ATC2 (5) –
controller In shift range other
ground Voltage Max. 1 V
than "5"
Voltage Max. 1 V
than "4"
Voltage Max. 1 V
than "3"
Voltage Max. 1 V
than "2"
Voltage Max. 1 V
than "1"
78 HD325-7, HD405-7
HD325-7, HD405-7 79
Failure code [DGF1KX] (Transmission oil temperature sensor: Out of

input signal range) 1
Action code Failure code Transmission oil temperature sensor: Out of input signal range
Trouble
E03 DGF1KX (Transmission controller system)
Contents of • The voltage of the signal circuit of the transmission oil temperature sensor is below 0.97 V (above
trouble 150°C) or very different from the torque converter oil temperature signal.
Action of
• The controller controls the clutch oil pressure, fixing the sensed oil temperature high.
controller
Problem that
appears on • Gear shift shocks become large.
machine
Related
information • After repairing the failure and confirming resetting of the machine, perform the initial learning of the
transmission controller, referring to TESTING AND ADJUSTING, "Inspection of machine monitor".

Transmission oil temperature
1 Between Oil temperature: 25°C Resis-
sensor defective 37 – 50 kz
CN23 tance
(male) (1) Resis-
– (2) Oil temperature: 100°C 3.5 – 4.0 kz
tance
2) Disconnect connectors ATC1, and CN23.
Disconnection in wiring har- 3) Connect T-adapter.
ness
contact)
Max. 1 z

Ground fault in wiring har- 3) Connect T-adapter.
value in normal 3
ness
state Between ground and wiring harness ATC1 Resis-
Min. 1 Mz
(female) (3) – CN23 (female) (1) tance
4 Hot short in wiring harness 4) Turn the starting switch ON.
Between ground and wiring harness ATC1
Voltage Max. 1 V
(female) (3) – CN23 (female) (1)
2) Disconnect connectors ATC1.
4) Connect the connector.
5
defective
Between Resis-
Oil temperature: 25°C 37 – 50 kz
ATC1 tance
(female) Resis-
(3) – (2) Oil temperature: 100°C 3.5 – 4.0 kz
tance
80 HD325-7, HD405-7
HD325-7, HD405-7 81
Failure code [DGR2KZ] (Retarder oil temperature sensor :

Disconnection or short circuit) 1
Action code Failure code Retarder oil temperature sensor: Disconnection or short circuit
Trouble
E01 DGR2KZ (Retarder controller system)
Contents of
• Signal circuit voltage of retarder oil temperature sensor has become below 0.96 V.
trouble
Action of
controller
Problem that
appears on • Oil temperature gauge does not work because of failure mode of sensor.
machine
Related • Input signal from oil temperature sensor can be checked with monitoring function (codes: 30211
information and 30212).

a Prepare with starting switch OFF, disconnect connector RTR
(meal) and troubleshooting with starting switch still OFF.
Retarder oil tempera-
RTR (male) Resistance (kz)
ture (°C)
Defective retarder oil temper- 25 42.7
1
ature sensor
30 35.13
Between (1) – (2) 80 6.556
90 4.925
100 3.75
a Prepare with starting switch OFF, disconnect connector BRC1
(femeal) and troubleshooting with starting switch still OFF.
Retarder oil tempera-
BRC1 (female) Resistance (kz)
Disconnection in wiring ture (°C)
harness 25 42.7
2
Possible causes (Disconnection or defective
30 35.13
and standard contact)
value in normal Between (3) – (21) 80 6.556
state 90 4.925
100 3.75
a Prepare with starting switch OFF, disconnect connector BRC1
(femeal) and troubleshooting with starting switch still OFF.
retarder oil tempera-
BRC1 (female) Resistance (kz)
ture (°C)
3 (Contact with GND circuit or 25 42.7
contact between harnesses) 30 35.13
Between (3) – (21) 80 6.556
90 4.925
100 3.75
starting switch still ON.
Defective retarder controller
4 Check with monitor-
(In normal system) Oil tem- Actual oil temperature and dis-
ing function
perature played temperature are same.
(Code: 30203).
82 HD325-7, HD405-7
HD325-7, HD405-7 83
Failure code [DGR6KX] (Steering oil temperature sensor: Input signal

out of range) 1
Action code Failure code Steering oil temperature sensor: Input signal out of range
Trouble
E01 DGR6KX (Transmission controller system)
• Signal circuit voltage of steering oil temperature sensor has reached 0.97 V (more than 150 °C) or
only steering oil temperature is low (signal circuit voltage of steering oil temperature sensor is above
Contents of
4.56 V (less than 15 °C)).
trouble
• Oil temperature sensor voltages of torque converter and brake are below 3.7 V (more than 55 °C )
and normal.
Action of
controller
Problem that
appears on • Steering oil temperature gauge does not indicate properly.
machine
• Input signal from oil temperature sensor can be checked with monitoring function.
Related 1) Steering oil temperature sensor (codes: 32701 and 32702)
information 2) Torque converter oil temperature sensor (codes: 30100 and 30101)
3) Retarder oil temperature sensor (codes: 30211 and 30212)

2) Connect T-adapter to connector STR (male).
Defective steering oil Between Oil temperature: Resis-
1 37 – 50 kz
temperature sensor STR 25 °C tance
(male) (1) Oil temperature: Resis-
– (2) 3.5 – 4.0 kz
100 °C tance
2) Connect T-adapter to connectors ATC1 (female) and STR
Disconnection in wiring (female).
harness
– STR (female) (1) tance
contact)
Max. 1 z
– STR (female) (2) tance

and standard 2) Disconnect connectors ATC1 and STR.
value in normal Defective harness grounding 3) Connect T-adapter to connector ATC1 (female).
3
Resis- Min. 1
between ATC1 (female) (20) – STR (female)
tance Mz
(1)
2) Disconnect connectors ATC1 and STR.
Hot short in wiring harness 4) Turn starting switch ON.
4
between ATC1 (female) (20) – STR (female) Voltage Max. 5V
(1)
Defective transmission Between Oil temperature: Resis-
5 37 – 50 kz
controller ATC1 25 °C tance
(female) Oil temperature: Resis-
(20) – (21) 3.5 – 4.0 kz
100 °C tance
84 HD325-7, HD405-7
HD325-7, HD405-7 85
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of

Trouble Torque converter oil temperature sensor: Out of input signal range
E01 DGT1KX
Contents of • The voltage of the signal circuit of the torque converter oil temperature sensor is below 0.97 V
trouble (above 150°C) or very different from the transmission valve oil temperature signal.
Action of
• Takes no particlar action.
controller
Problem that
appears on • The torque converter oil temperature gauge does not indicate normally.
machine
Related
information

Torque converter oil temper- Between Resis-
1 Oil temperature: 25°C 37 – 50 kz
ature sensor defective CN22 (T/ tance
C-T)
(male) (1) Oil temperature: 100°C Resis-
3.5 – 4.0 kz
– (2) tance

2) Disconnect connectors ATC1, ATC3B, and CN22.
Disconnection in wiring har- 3) Connect T-adapter.
ness
contact)
Max. 1 z
Possible causes
and standard
value in normal Ground fault in wiring har-
3 3) Connect T-adapter.
state ness
Between ground and wiring harness ATC1 Resis-
Min. 1 Mz
(female) (9) – CN22 (female) (1) tance
Between ground and wiring harness ATC1
Voltage Max. 1 V
(female) (9) – CN22 (female) (1)
5
defective Between Oil temperature: 25°C Resis-
37 – 50 kz
AT1 tance
(female) Resis-
(9) – (21) Oil temperature: 100°C tance
3.5 – 4.0 kz
86 HD325-7, HD405-7
HD325-7, HD405-7 87

© 2007 KOMATSU
All Rights Reserved
88 HD325-7, HD405-7
SEN01190-01
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up
Failure code [DHP6KA] (Suspension pressure sensor system (Rear right): Disconnection).......................... 4
Failure code [DHP6KX] (Failure in suspension pressure sensor system trouble (Rear right):
Out of input signal range) ........................................................................................................................ 6
Failure code [DHP7KA] (Suspension pressure sensor system (Rear left): Disconnection) ............................ 8
Failure code [DHP7KX] (Failure in suspension pressure sensor system trouble (Rear left):
Out of input signal range) ...................................................................................................................... 10
Failure code [DHT5KX] (Torque converter oil pressure sensor: Out of input signal range) .......................... 12
Disagreement of run and stop condition with signal) ............................................................................. 14
Failure code [DHU2KX] (Front accumulator oil pressure sensor: Out of input signal range)........................ 16
Failure code [DHU3KX] (Rear accumulator oil pressure sensor: Out of input signal range) ........................ 18
Failure code [DJF1KA] (Fuel level sensor: Disconnection)........................................................................... 20
Failure code [DK51L5] (Retarder lever potentiometer:
Potentiometer signal is inconsistent with swich signal) ......................................................................... 21
Failure code [DK52KX] (Failure in hoist lever potentiometer 1: Out of input signal range)........................... 24
Failure code [DK53L8] (Failure in hoist lever potentiometer 2: Disagreement of analog signal) .................. 26
HD325-7, HD405-7 1
Failure code [DK54KX] (Body positioner sensor: Out of input signal range) ................................................ 28
Failure code [DKD0L6] (Failure in steering speed sensor:
Disagreement of run and stop condition with signal) (If equipped) ........................................................ 30
Failure code [DKH0KX] (Pitch angle sensor: Out of input signal range) (If equipped).................................. 32
Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection) ........................................ 34
Disagreement of revolution speed signal).............................................................................................. 36
Failure code [DLF2KA] (Transmission intermediate shaft speed sensor: Disconnection) ............................ 38
Disagreement of revolution speed signal).............................................................................................. 40
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection) ...................................... 42
Disagreement of revolution speed signal) (If equipped) ........................................................................ 44
Failure code [DLT4KA] (Transmission output shaft speed sensor: Disconnection) (If equipped) ................. 46
Disagreement of revolution speed signal) (If equipped) ........................................................................ 48
Disconnection or short circuit) (If equipped) .......................................................................................... 50
Disconnection or short circuit) (If equipped) .......................................................................................... 52
Disconnection or short circuit)................................................................................................................ 54
Failure code [DW78KZ] (Failure in rear brake BCV command output system:
Failure code [DX11K4] (Rear brake proportional pressure reducing solenoid valve:
Out of control) ........................................................................................................................................ 60
Failure code [DX11KA] (Rear brake proportional pressure reducing solenoid valve output circuit:
Disconnection) ....................................................................................................................................... 62
Failure code [DX11KB] (Rear brake proportional pressure reducing solenoid valve: Short circuit) .............. 63
Failure code [DX11KY] (Rear brake proportional pressure reducing solenoid valve:
Short circuit to power source line).......................................................................................................... 64
Failure code [DX11MA] (Rear brake proportional pressure reducing solenoid valve: Malfunction) .............. 66
Failure code [DX13KA] (Output circuit of hoist EPC valve: Disconnection) .................................................. 68
Failure code [DX13KB] (Output circuit of hoist EPC valve: Short circuit)...................................................... 70
Failure code [DX13KY] (Output circuit of hoist EPC valve: Short circuit with power source line) ................. 72
2 HD325-7, HD405-7
HD325-7, HD405-7 3
Failure code [DHP6KA] (Suspension pressure sensor system (Rear

right): Disconnection) 1
Action code Failure code Suspension pressure sensor system (Rear right): Disconnection
Trouble
E01 DHP6KA (Retarder controller system)
Contents of • The voltage of the signal circuit of the suspension pressure sensor (Rear right) is below 1.0 V or
trouble above 4.6 V.
Action of
controller
Problem that
appears on • The payload is not indicated and saved correctly.
machine
• The suspension pressure (Rear left) signal can be checked with the monitoring function (Code:
Related
32816).
information
• This failure occurs only when the built-in PLM function is installed.

2) Disconnect connectors PM6, BRC1, and SURR.
Disconnection in wiring Wiring harness between PM6 (female) (7) – Resis-
harness Max. 1 z
1 SURR (female) (C) tance
contact) Wiring harness between PM6 (female) (2) – Resis-
Max. 1 z
SURR (female) (B) tance
Wiring harness between PM6 (female) (3) – Resis-
Max. 1 z
Possible causes SURR (female) (A) tance
value in normal 2) Disconnect connector SURR.
state Defective suspension 3) Insert T-adapter.
2
pressure sensor (Rear right) 4) Turn starting switch ON.
Between SURR (B) – (A) Voltage 18 ± 3 V
Between SURR (B) – (A) Voltage 1.0 – 4.6 V
2) Disconnect connector PM6.
Defective payload meter 3) Insert T-adapter.
3 4) Turn starting switch ON.
controller
Between PM6 (2) – (3) Voltage 18 ± 3 V
Between PM6 (7) – (3) Voltage 1.0 – 4.6 V
4 HD325-7, HD405-7
HD325-7, HD405-7 5
Failure code [DHP6KX] (Failure in suspension pressure sensor system

trouble (Rear right): Out of input signal range) 1
Action code Failure code Failure in suspension pressure sensor system trouble (Rear right):
Out of input signal range
Trouble
E03 DHP6KX (When ARSC is not set or ARSC system switch is "OFF")
Contents of • The voltage of the signal circuit of the suspension pressure sensor (right) is below 1.0 V or above
trouble 4.6 V.
Action of
• Does not operate auto suspension.
controller
Problem that
appears on • There is no great influence of machine.
machine
Related • This trouble can be checked with monitoring function (Code: 32816, 32817).
information • If ARSC is set and ARSC system switch is turned ON, failure code "DHP7KX" is displayed.

2) Disconnect connectors BRC1, SURR, and PM6.
harness Max. 1 z
1 SURR (female) (C) tance
Max. 1 z
SURR (female) (A) tance
Max. 1 z
SURR (female) (B) tance
2) Disconnect connectors BRC1, SURR, PM6.
3) Connect T-adapter to PM6 (female).
Ground fault in wiring Wiring harness between PM6 (female) (7) – Resis-
2 Min. 1 Mz
harness SURR (female) (C) tance
Resis-
Possible causes between PM6 (female) (2) – SURR (female) Min. 1 Mz
tance
and standard (B)
state 2) Disconnect connectors PM6, BRC1, and SURR.
3) Connect T-adapter to PM6 (female).
3 Hot short in wiring harness 4) Turn starting switch ON.
between PM6 (female) (7) – SURR Voltage Max. 1 V
(female) (C)
2) Disconnect connector SURR.
Defective suspension 3) Insert T-adapter.
4
pressure sensor (Rear right) 4) Turn starting switch ON.
Between SURR (B) – (A) Voltage 18 ± 3 V
Between SURR (C) – (A) Voltage 1.0 – 4.6 V
Defective retarder 3) Insert T-adapter.
5
controller 4) Turn starting switch ON.
6 HD325-7, HD405-7
HD325-7, HD405-7 7
Failure code [DHP7KA] (Suspension pressure sensor system (Rear

left): Disconnection) 1
Action code Failure code Suspension pressure sensor system (Rear left): Disconnection
Trouble
E01 DHP7KA (Retarder controller system)
Contents of • The voltage of the signal circuit of the suspension pressure sensor (Rear left) is below 1.0 V or
trouble above 4.6V.
Action of
controller
Problem that
appears on • The payload is not indicated and saved correctly.
machine
• The suspension pressure (Rear left) signal can be checked with the monitoring function (Code:
Related
32814).
information
• This failure occurs only when the built-in PLM function is installed.

2) Disconnect connectors BRC1, PM6, and SURL.
harness Max. 1 z
1 SURL (female) (C) tance
Max. 1 z
SURL (female) (B) tance
Max. 1 z
Possible causes SURL (female) (A) tance
value in normal 2) Disconnect connector SURL.
state Defective suspension 3) Insert T-adapter.
pressure sensor (Rear left)
Between SURL (B) – (A) Voltage 18 ± 3 V
Between SURL (C) – (A) Voltage 1.0 – 4.6 V
Defective VHMS & PLM 3) Insert T-adapter.
controller
Between PM6 (2) – (3) Voltage 18 ± 3 V
8 HD325-7, HD405-7
HD325-7, HD405-7 9
Failure code [DHP7KX] (Failure in suspension pressure sensor system

trouble (Rear left): Out of input signal range) 1
Action code Failure code Failure in suspension pressure sensor system trouble (Rear left):
Out of input signal range
Trouble
E03 DHP7KX (When ARSC is not set or ARSC system switch is "OFF")
Contents of • The voltage of the signal circuit of the suspension pressure sensor (left) is below1.0 V or above 4.6
trouble V.
Action of
• Does not operate ARSC.
controller
Problem that
appears on • There is no great influence of machine.
machine
Related • This trouble can be checked with monitoring function (Code: 32814, 32815).
information • If ARSC is set and ARSC system switch is turned ON, failure code "DHP6KX" is displayed.

2) Disconnect connectors BRC1, SURL, and PM6.
harness Max. 1 z
1 SURL (female) (C) tance
Max. 1 z
SURL (female) (A) tance
Max. 1 z
SURL (female) (B) tance
2) Disconnect connectors BRC1, SURL, and PM6.
3) Connect T-adapter to connector PM6 (female).
Ground fault in wiring Resis-
2 between PM6 (female) (8) – SURL (female) Min. 1 Mz
harness tance
(C)
Possible causes Resis-
between PM6 (female) (2) – SURL (female) Min. 1 Mz
and standard tance
(B)
value in normal
2) Disconnect connectors BRC1,PM6, and SURL.
3) Connect T-adapter to connector PM6 (female).
3 Hot short in wiring harness 4) Turn starting switch ON.
between PM6 (female) (8) – SURL (female) Voltage Max. 1 V
(C)
2) Disconnect connector SURL.
Defective suspension 3) Insert T-adapter.
pressure sensor (Rear left)
Between SURL (B) – (A) Voltage 18 ± 3 V
Between SURL (C) – (A) Voltage 1.0 – 4.6 V
5 Defective retarder controller 3) Insert T-adapter.
10 HD325-7, HD405-7
HD325-7, HD405-7 11
Failure code [DHT5KX] (Torque converter oil pressure sensor: Out of

Action code Failure code Torque converter oil pressure sensor: Out of input signal range
Trouble
E01 DHT5KX (Transmission controller system)
Contents of • The voltage of the signal circuit of the torque converter oil pressure sensor is below 0.5 V or above
trouble 4.5 V.
Action of • The controller controls the machine, fixing the torque converter oil pressure to the set pressure in
controller itself.
Problem that
appears on • Large shocks are made when the lockup system is operated.
machine
Related
information

2) Disconnect connectors ATC1, ATC3, and CN21.
Disconnection in wiring Wiring harness between ATC3(female) (8) – Resis-
harness Max. 1 z
1 CN21 (female) (B) tance
contact) Wiring harness between ATC1(female) (21) Resis-
Max. 1 z
– CN21 (female) (A) tance
Max. 1 z
– CN21 (female) (C) tance
Ground fault in wiring Resis-
2 between ATC3A (female) (8) – CN21 Min. 1 Mz
harness tance
(female) (B)
Resis-
Possible causes between ATC1 (female) (1) – CN21 (female) Min. 1 Mz
tance
and standard (C)
value in normal 1) Turn the starting switch OFF.
state 2) Disconnect connectors ATC3 and CN21.
Between ground and wiring har-
ness between ATC3 (female) (8) Voltage 0.8 – 2.0 V
– CN21 (female) (B)
Torque converter oil pressure 3) Insert T-adapter.
sensor defective
Between CN21 (B) – (A) Voltage 20 – 30 V
Between CN21 (C) – (A) Voltage 0.8 – 2.0 V
2) Disconnect connectors ATC1 and ATC3.
Transmission controller 3) Insert T-adapter.
defective
Between ATC1 (1) – (21) Voltage 20 – 30 V
Between ATC3 (8) – ATC1 (21) Voltage 0.8 – 2.0 V
12 HD325-7, HD405-7
HD325-7, HD405-7 13

Disagreement of run and stop condition with signal) 1
Action code Failure code Torque converter oil pressure sensor: Disagreement of run and
Trouble stop condition with signal
E01 DHT5L6 (Transmission controller system)
Contents of • While the engine is stopped, an oil pressure signal is input to the signal circuit of the torque con-
trouble verter oil pressure sensor.
Action of • The controller controls the machine, fixing the torque converter oil pressure to the set pressure init-
controller self.
Problem that
appears on • Large shocks are made when the lockup system is operated.
machine
Related
information

Wiring harness between ATC1 (female) (1)
Voltage Max. 1.2 V
– CN21 (female) (C)
Possible causes 2) Disconnect connector CN21.
and standard
Torque converter oil pressure 3) Insert T-adapter.
value in normal 2 4) Turn the starting switch ON.
sensor defective
state
Between CN21 (B) – (A) Voltage 20 – 30 V
Between CN21 (C) – (A) Voltage 0.8 – 2.0 V
2) Disconnect connectors ATC1 and ATC3.
Transmission controller 3) Insert T-adapter.
defective
Between ATC3 (8) – ATC1 (21) Voltage 20 – 30 V
Between ATC1 (1) – (21) Voltage 0.8 – 2.0 V
14 HD325-7, HD405-7
HD325-7, HD405-7 15
Failure code [DHU2KX] (Front accumulator oil pressure sensor: Out of

Action code Failure code Front accumulator oil pressure sensor: Out of input signal range
Trouble
E01 DHU2KX (Retarder controller system)
Contents of • Signal circuit voltage of front accumulator oil pressure sensor has become below 0.5 V or above 4.5
trouble V.
Action of
controller
Problem that
appears on • There is no great influence on the machine.
machine
Related
• Signal from oil pressure sensor can be checked with monitoring function (codes: 35500 and 35504).
information

2) Connect T-adapter to connectors BRC1 (female) and ACCF
(female).
Disconnection in wiring Wiring harness between BRC1 (female) Resis-
harness Max. 1 z
1 (13) – ACCF (female) (C) tance
(Disconnection or
defective contact) Wiring harness between BRC1 (female) Resis-
Max. 1 z
(21) – ACCF (female) (A) tance
Max. 1 z
(22) – ACCF (female) (B) tance
2) Connect T-adapter to connectors BRC1 (female) and ACCF
(female).
2 between BRC1 (female) (13) – ACCF Min. 1 Mz
(female) (C)
Resis-
between BRC1 (female) (22) – ACCF Min. 1 Mz
tance
(female) (B)
and standard 2) Connect T-adapter to connectors BRC1 (female) and ACCF
value in normal (female).
state 3
between BRC1 (female) (13) – ACCF Voltage Max. 1 V
(female) (C)
2) Connect T-adapter to connector ACCF (male).
3) Carry out troubleshooting while starting switch is OFF and ON.
Resis-
ACCF Brake oil pressure
tance
Defective front accumulator Max. 4.9 MPa
4 Min. 1 Mz
oil pressure sensor {Max. 50 kg/cm²}
Between (A) – (B)
Min. 4.9 MPa
Max. 1 z
{Min. 50 kg/cm²}
Between ACCF (B) – (A) Voltage 20 – 30 V
Between ACCF (C) – (A) Voltage 1.8 – 3.5 V
5 Defective retarder controller 3) Turn starting switch ON.
Between BRC1 (22) – (21) Voltage 20 – 30 V
Between BRC1 (13) – (21) Voltage 0.5 – 4.5 V
16 HD325-7, HD405-7
HD325-7, HD405-7 17
Failure code [DHU3KX] (Rear accumulator oil pressure sensor: Out of

Action code Failure code Rear accumulator oil pressure sensor: Out of input signal range
Trouble
E01 DHU3KX (Retarder controller system)
Contents of • Signal circuit voltage of front accumulator oil pressure sensor has become below 0.5 V or above 4.5
trouble V.
Action of
controller
Problem that
appears on • There is no great influence on the machine.
machine
Related
• Signal from oil pressure sensor can be checked with monitoring function (codes: 35501 and 35505).
information

2) Connect T-adapter to connectors BRC1 (female) and ACCR
(female).
Disconnection in wiring Wiring harness between BRC1 (female) (7) Resis-
harness Max. 1 z
1 – ACCR (female) (C) tance
(Disconnection or
defective contact) Wiring harness between BRC1 (female) Resis-
Max. 1 z
(21) – ACCR (female) (A) tance
Max. 1 z
(22) – ACCR (female) (B) tance
2) Connect T-adapter to connectors BRC1 (female) and ACCR
(female).
2 between BRC1 (female) (7) – ACCR Min. 1 Mz
(female) (C)
Resis-
between BRC1 (female) (22) – ACCR Min. 1 Mz
tance
(female) (B)
and standard 2) Connect T-adapter to connectors BRC1 (female) and ACCR
value in normal (female).
state 3
(a contact with 24V circuit)
between BRC1 (female) (7) – ACCR Voltage Max. 1 V
(female) (C)
2) Connect T-adapter to connector ACCR (male).
3) Carry out troubleshooting while starting switch is OFF and ON.
Resis-
ACCR (male) Brake oil pressure
tance
Defective rear accumulator Max. 4.9 MPa
4 Min. 1 Mz
oil pressure sensor {Max. 50 kg/cm²}
Between (A) – (B)
Min. 4.9 MPa
Max. 1 z
{Min. 50 kg/cm²}
Between ACCR (B) – (A) Voltage 20 – 30 V
Between ACCR (C) – (A) Voltage 1.8 – 3.5 V
5 Defective retarder controller 3) Turn starting switch ON.
Between BRC1 (22) – (21) Voltage 20 – 30 V
18 HD325-7, HD405-7
HD325-7, HD405-7 19
Failure code [DJF1KA] (Fuel level sensor: Disconnection) 1

Action code Failure code Fuel level sensor: Disconnection
Trouble
E01 DJF1KA (Transmission controller system)
Contents of
trouble • The voltage of the signal circuit of the fuel level sensor is higher than 4.0 V.
Action of
controller • None in particular.
Problem that
appears on • The fuel level gauge does not indicate normally.
machine
Related
information • This failure can be checked in the monitoring function (Code: 04200, 04201).

2) Disconnect connector FUEL.
1 Fuel level sensor defective Fuel level: Resis-
Max. 12 z
Between FUEL When FULL tance
(male) (1) – (2) Fuel level: Resis-
74 – 100 z
When EMPTY tance
2) Disconnect connectors ATC1and FUEL.
harness
– FUEL (female) (1) tance
Possible causes contact)
and standard Wiring harness between ATC1 (female) (21) Resis-
Max. 1 z
value in normal – FUEL (female) (2) tance
state 1) Turn the starting switch OFF.
2) Disconnect connectors ATC1and FUEL.
Voltage Max. 1 V
ATC1(female) (8) – FUEL (female) (1)
4
defective Fuel level: Resis-
Max. 12 z
Between ATC1 When FULL tance
(female) (8) – (21) Fuel level: Resis-
74 – 100 z
When EMPTY tance
20 HD325-7, HD405-7
Failure code [DK51L5] (Retarder lever potentiometer: Potentiometer

signal is inconsistent with swich signal) 1
Action code Failure code Retarder lever potentiometer: Potentiometer signal is inconsistent
Trouble with swich signal
E03 DK51L5 (Retarder controller system)
Contents of • The signal voltage of the potentiometer of the retarder lever circuit is below 0.3 V or above 4.7 V. Or,
trouble the potentiometer signal does not agree with the switch signal.
The controller acts as follows, depending on the condition of the failure.
Action of • Controls with the potentiometer signal.
controller • Limits the output for the solenoid to 70%.
• Turns the output for the solenoid OFF.
The following appear, depending on the action of the controller.
Problem that
• This failure does not have a serious effect on the machine.
appears on
• The retarder cannot control finely.
machine
• The retarder does not operate (The foot brake operates, however).
Related
information

2) Disconnect connectors BRC1, BRC3, RE1, and RTL.
Max. 1 z
(22) – RE1 (female) (1) tance
Wiring harness between RE1 (female) (2) – Resis-
Max. 1 z
RTL (female) (1) tance
harness Max. 1 z
1 (21) – RTL (female) (3) tance
contact) Wiring harness between BRC1 (female) Resis-
Max. 1 z
(14) – RTL (female) (2) tance
(24) – RTL (female) (4) tance
and standard
value in normal Wiring harness between BRC1 (female) Resis-
Max. 1 z
state (18) – RTL (female) (5) tance
Wiring harness between RTL (female) (6) – Resis-
Max. 1 z
BRC3 (female) (21) (31) (32) (33) tance
2) Disconnect connectors BRC1, RE1, and RTL.
3) Connect T-adapter to BRC1 (female).
Resis-
Ground fault in wiring between BRC1 (female) (22) – RE1 (female) Min. 1 Mz
tance
2 harness (1)
Min. 1 Mz
between RE1 (female) (2) – RTL (female) (1) tance
Resis-
between BRC1 (female) (14) – RTL (female) Min. 1 Mz
tance
(2)
HD325-7, HD405-7 21

2) Disconnect connectors BRC1 and RTL.
Hot short in wiring Between ground and wiring harness
harness between BR1 (female) (22) – RE1 (female) Voltage Max. 1 V
3 (1)
(Contact with power source
circuit) Between ground and wiring harness
Voltage Max. 1 V
between RE1 (female) (2) – RTL (female) (1)
between BRC1 (female) (14) – RTL (female) Voltage Max. 1 V
(2)
4 Resistor (RE1) defective 3) Connect T-adapter.
Resis-
Between RE1 (male) (1) – (2) 250 ± 5 z
tance
2) Disconnect connector RTL
5) Check the potentiometer.
Between RTL (1) – (3) Voltage 4.1 – 4.8 V
Between RTL (2) – (3) Voltage 0.3 – 4.7 V
2) Disconnect connector RTL
Possible causes 5 Retarder lever defective 3) Connect T-adapter.
and standard 4) Check the switch.
value in normal
Resis-
state Lever at OFF position Max. 1 z
Between RTL (male) tance
(4) – (6) Resis-
Lever at ON position Min. 1 Mz
tance
Resis-
Lever at OFF position Min. 1 Mz
Between RTL (male) tance
(5) – (6) Resis-
Lever at ON position Max. 1 z
tance
2) Disconnect connectors BRC1, and BRC3.
Between BRC1 (22) – BRC3
Voltage 4.1 – 4.8 V
(21) (31) (32) (33)
(21) (31) (32) (33)
2) Disconnect connector RTL.
6 Retarder controller defective 3) Connect T-adapter.
4) Check the switch.
Resis-
Between BRC1 Lever at OFF position Max. 1 z
tance
(female) (24) –
ground Resis-
Lever at ON position Min. 1 Mz
tance
Resis-
Between BRC1 Lever at OFF position Min. 1 Mz
tance
(female) (18) –
ground Resis-
Lever at ON position Max. 1 z
tance
22 HD325-7, HD405-7
HD325-7, HD405-7 23
Failure code [DK52KX] (Failure in hoist lever potentiometer 1: Out of

Action code Failure code Failure in hoist lever potentiometer 1: Out of input signal range
Trouble (Out of input signal range of lever potentiometer 1 or 2)
E03 DK52KX (Retarder controller system)
Contents of • The signal voltage of the signal circuit of hoist lever potentiometer 1 or 2 is below 0.3 V or above 4.7
trouble V.
Action of
• The controller recognizes the hoist lever position as "HOLD".
controller
Problem that
appears on • Body does not operate.
machine
Related
information

2) Disconnect connectors BRC1, BRC3, and HSL.
Disconnection in wiring Max. 1 z
(34) – HSL (female) (4) tance
harness
1 Wiring harness between BRC1 (female) Resis-
contact)
Max. 1 z
Max. 1 z
Possible causes Between ground and wiring harness
and standard Resis-
between BRC3 (female) (34) – HSL (female) Min. 1 Mz
value in normal Ground fault in wiring tance
(4)
state 2 harness
tance
(2)
Resis-
tance
(3)
Hot short in wiring harness Wiring harness between BRC3 (female) (34)
3 (Contact with power source Voltage Max. 1 V
– HSL (female) (4)
circuit)
Wiring harness between BRC1 (female) (20)
Voltage Max. 1 V
Voltage Max. 1 V
24 HD325-7, HD405-7

2) Disconnect connector HSL.
4 Hoist lever defective
Between HSL (4) – (1) Voltage 4.6 – 5.4 V
Possible causes Between HSL (2) – (1) Voltage 0.3 – 4.7 V

and standard Between HSL (3) – (1) Voltage 0.3 – 4.7 V
state 2) Disconnect connectors BRC1, BRC3, and HSL.
4)Turn the starting switch ON.
5 Retarder controller defective Between BRC3 (34) – BRC1
(21)
HD325-7, HD405-7 25
Failure code [DK53L8] (Failure in hoist lever potentiometer 2:

Disagreement of analog signal) 1
Action code Failure code Failure in hoist lever potentiometer 2: Disagreement of analog
signal
Trouble (Out of total range of input signal voltage of lever potentiometer 1
E03 DK53L8 or 2)
Contents of
• The total voltage of the signal circuit of hoist lever potentiometer 1 or 2 is below 4.4 V or above 5.6 V.
trouble
Action of
• The controller recognizes the hoist lever position as "NEUTRAL".
controller
Problem that
machine
Related • This failure can be checked in the monitoring function (Code: 34305).
information • If the failure code "DK52KX" is displayed, perform troubleshooting for it.

2) Disconnect connector HSL.
Possible causes 4) Turn the starting switch ON.
and standard 1 Hoist lever defective
value in normal Between HSL (4) – (1) Voltage 4.6 – 5.4 V
state Between HSL (2) – (1) Voltage 0.3 – 4.7 V
Between HSL (3) – (1) Voltage 0.3 – 4.7 V
• If the failure is not repaired by performing the troubleshooting in
1 above, the retarder controller is defective.
26 HD325-7, HD405-7
HD325-7, HD405-7 27
Failure code [DK54KX] (Body positioner sensor: Out of input signal

range) 1
Action code Failure code Body positioner sensor: Out of input signal range
Trouble
E03 DK54KX (Retarder controller system)
Contents of
• The signal circuit voltage of the body positioner is below 0.3 V or above 4.7 V.
trouble
Action of • The controller controls dumping according to the hoist lever signal.
controller • The controller controls, assuming that the body is not seated.
• Body seating shocks become large.
Problem that
• The hoist lever positioner does not function.
appears on
machine • The maximum gear speed is limited.
• The machine cannot travel in reverse if the hoist lever is not at "FLOAT".
Related
information

2) Disconnect connectors BRC1, BRC3, and B07.
Disconnection in wiring Wiring harness between BRC1 (female) (8) Resis-
harness Max. 1 z
1 – B07 (female) (C) tance
Max. 1 z
(34) – B07 (female) (B) tance
Max. 1 z
(21) – B07 (female) (A) tance
Wiring harness between BRC1 (female) (8) Resis-
2 harness Min. 1 Mz
– B07 (female) (C) tance
Possible causes Between ground and wiring harness
and standard Resis-
between BRC3 (female) (34) – B07 (female) Min. 1 Mz
(B)
state
Hot short in wiring 4) Turn the starting switch ON.
harness Between ground and wiring harness
3
(Contact with power source between BRC1 (female) (8) – B07 (female) Voltage Max. 1 V
circuit) (C)
between BRC3 (female) (34) – B07 (female) Voltage Max. 1 V
(B)
2) Disconnect connector B07.
4 Body positioner defective 4) Turn the starting switch ON.
Between B07 (C) – (A) Voltage 4.6 – 5.4 V
Between B07 (B) – (A) Voltage 0.3 – 4.7 V
28 HD325-7, HD405-7

Possible causes 2) Disconnect connectors BRC1, BRC3, and B07.
and standard 3) Insert T-adapter.
value in normal 5 Retarder controller defective 4) Turn the starting switch ON.
state Between BRC1 (8) – (21) Voltage 4.1 – 4.8 V
(21)
HD325-7, HD405-7 29
Failure code [DKD0L6] (Failure in steering speed sensor: Disagreement

of run and stop condition with signal) (If equipped) 1
Action code Failure code Failure in steering speed sensor: Disagreement of run and stop
condition with signal (If equipped)
Trouble
E01 DKD0L6 (Run and stop condition of engine disagrees with signal)
Contents of • Disconnection, grounding fault, or short circuit occurs in the signal circuit of the steering speed sen-
trouble sor and no signals are input.
Action of
controller • None in particular.
Problem that
machine
Related
information • This failure can be checked in the monitoring function (Code: 35401).

2) Disconnect connectors BRC1, BRC2, and SR2.
harness Max. 1 z
1 (29) – SR3 (female) (2) tance
Max. 1 z
(37) – SR3 (female) (3) tance
Max. 1 z
(16) – SR3 (female) (1) tance
2) Disconnect connectors BRC1, BRC2, and SR3.
2 Between ground and wiring harness between Resis-
harness Min. 1 Mz
BRC2 (female) (37) – SR3 (female) (3) tance
Min. 1 Mz
BRC1 (female) (16) – SR3 (female) (1) tance
Possible causes 2) Disconnect connector SR3.
and standard 3) Insert T-adapter.
value in normal 4) Turn the starting switch ON.
state 5) Turn the steering wheel slowly.
Steering speed sensor Between SR3 (1) – (3) Voltage 10 – 13 V
3
defective
2) Disconnect connector SR3.
Between SR3 (2) – (3) Voltage See FIG-1.
2) Disconnect connectors BRC1, BRC2.
Voltage 10 – 13 V
(29)
5) Turn the steering wheel slowly.
Between BRC2 (37) – (29) Voltage See FIG-1.
30 HD325-7, HD405-7
HD325-7, HD405-7 31
Failure code [DKH0KX] (Pitch angle sensor: Out of input signal range)
(If equipped) 1
Action code Failure code Pitch angle sensor: Out of input signal range (If equipped)
Trouble
E01 DKH0KX (Transmission controller system)
Contents of
trouble • Voltage in signal circuit of Inclination sensor has become below 0.5 V or above 4.5 V.
Action of
controller • No particular action.
Problem that
appears on • Load weight is not displayed or recorded normally.
machine
Related • Signal from Inclination sensor can be checked with monitoring function (Code: 32900 and 32903).
information • Cannot detect tipping over.

2) Connect T-adapter to connector AS3 (male).
1 Defective pitch angle sensor
Between AS3 (C) – (A) Voltage 20 – 30 V
Between AS3 (B) – (A) Voltage 0.5 – 4.5 V
2) Connect T-adapter to connectors ATC1 (female) and AS3
(female).
Disconnection in wiring Wiring harness between ATC1 (female) (19) Resis-
harness Max. 1 z
2 – AS3 (female) (B) tance
Max. 1 z
– AS3 (female) (C) tance
Max. 1 z
– AS3 (female) (A) tance
Possible causes 2) Disconnect ATC1 and AS3.
and standard 3) Connect T-adapter to ATC1 (female).
value in normal
state Defective harness grounding Resis-
3 between ATC1 (female) (19) – AS3 (female) Min. 1 Mz
(B)
Resis-
between ATC1 (female) (16) – AS3 (female) Min. 1 Mz
tance
(C)
2) Disconnect ATC1 and AS3.
Hot short in wiring harness 3) Connect T-adapter to ATC1 (female).
4
(a contact with 24 V circuit) Between ground and wiring harness
between ATC1 (female) (19) – AS3 (female) Voltage Max. 4.6 V
(B)
2) Insert T-adapter in connector ATC1.
Defective transmission 3) Turn starting switch ON.
5
controller
Between ATC1 (female) (16) – (21) Voltage 20 – 30 V
Between ATC1 (female) (19) – (21) Voltage 0.5 – 4.5 V
32 HD325-7, HD405-7
HD325-7, HD405-7 33
Failure code [DLF1KA] (Transmission input shaft speed sensor:

Disconnection) 1
Action code Failure code Transmission input shaft speed sensor: Disconnection
Trouble
E03 DLF1KA (Transmission controller system)
Contents of • The signal circuit of the transmission input shaft speed sensor is disconnected and signals are not
trouble input.
Action of • The controller keeps the current gear speed and turns the lockup operation OFF.
Problem that
• The lockup system is reset and the gear cannot be shifted.
appears on
Related
information

Press the sensor lightly against the revolution pickup gear, and
Wrong adjustment of
then return it by 1/2 – 1 turn.
1 transmission input shaft
a For details, see Testing and adjusting, "Adjustment of transmis-
speed sensor
sion speed sensor".
Transmission input shaft
2 Resis- 500 –
speed sensor defective Between CN3 (male) (1) – (2)
tance 1,000 z
and standard tance
state 2) Disconnect connectors ATC2 and CN3.
harness
contact)
Max. 1 z
4
defective
Resis- 500 –
Between ATC2 (female) (40) – (29)
tance 1,000 z
34 HD325-7, HD405-7
HD325-7, HD405-7 35

Disagreement of revolution speed signal) 1
Action code Failure code Transmission input shaft speed sensor: Disagreement of revolution
Trouble speed signal
E03 DLF1LC (Transmission controller system)
• The speed calculated from the engine speed sensor signal, transmission intermediate shaft speed
Contents of
sensor signal, and transmission output shaft speed sensor signal is different from the signal speed
trouble
of the transmission input shaft speed sensor.
Problem that
appears on
Related
information

Transmission input shaft
1 Resis- 500 –
tance 1,000 z
Resis-
tance
Ground fault in wiring 3) Connect T-adapter.
2
Possible causes harness Between ground and wiring harness
and standard Resis-
(1)
state
between ATC2 (female) (40) – CN3 (female) Voltage Max. 1 V
(1)
4
defective
Resis- 500 –
tance 1,000 z
36 HD325-7, HD405-7
HD325-7, HD405-7 37
Failure code [DLF2KA] (Transmission intermediate shaft speed sensor:

Disconnection) 1
Action code Failure code Transmission intermediate shaft speed sensor: Disconnection
Trouble
E03 DLF2KA (Transmission controller system)
Contents of • The signal circuit of the transmission intermediate shaft speed sensor is disconnected and signals
trouble are not input.
Problem that
appears on
Related
information

Wrong adjustment of
then return it by 1/2 – 1 turn.
1 transmission intermediate
shaft speed sensor
sion speed sensor".
Transmission intermediate
2 Resis- 500 –
shaft speed sensor defective Between CN4 (male) (1) – (2)
tance 1,000 z
and standard tance
state 2) Disconnect connectors ATC2, CN4.
harness
contact)
Max. 1 z
4
defective
Resis- 500 –
tance 1,000 z
38 HD325-7, HD405-7
HD325-7, HD405-7 39

Disagreement of revolution speed signal) 1
Action code Failure code Transmission intermediate shaft speed sensor: Disagreement of
Trouble revolution speed signal
E03 DLF2LC (Transmission controller system)
• The speed calculated from the engine speed sensor signal, transmission input shaft speed sensor
Contents of
signal, and transmission output shaft speed sensor signal is different from the signal speed of the
trouble
transmission intermediate shaft speed sensor.
Problem that
appears on
Related
information

Transmission intermediate
1 Resis- 500 –
shaft speed sensor defective Between CN4 (male) (1) – (2)
tance 1,000 z
Resis-
tance
2) Disconnect connectors ATC2 – CN4.
2
Possible causes harness Between ground and wiring harness
and standard Resis-
(1)
state
(1)
4
defective
Resis- 500 –
tance 1,000 z
40 HD325-7, HD405-7
HD325-7, HD405-7 41
Failure code [DLT3KA] (Transmission output shaft speed sensor:

Disconnection) 1
Action code Failure code Transmission output shaft speed sensor: Disconnection
Trouble (When ARSC is set and ARSC system switch is "ON")
E01 DLT3KA (Transmission controller system)
Contents of • The signal circuit of the transmission output shaft speed sensor is disconnected and signals are not
trouble input.
• Keeps gear speed when trouble occurs.
Action of
• If gearshift lever is set in "N", gear is kept in neutral.
controller
• Turns lockup system OFF.
Problem that
• Gear cannot be shifted.
appears on
machine • If gearshift lever is set in "N", machine cannot restart.
Related • This failure can be checked in the monitoring function (Code: 31400).
information • If ARSC is set and ARSC system switch is turned OFF, failure code "dLT3KA" is displayed.

Wrong adjustment of
then return it by 1/2 - 1 turn.
1 transmission output shaft
speed sensor
sion speed sensor".
Transmission output shaft
2 Resis- 500 –
tance 1,000 z
and standard tance
state 2) Disconnect connectors BRC2, ATC2, CN5.
Disconnection in wiring 3) Connect T-adapter to ATC2 (female) and CN5 (female).
harness
contact)
Max. 1 z
2) Disconnect connectors BRC2, ATC2.
4 Retarder controller defective 3) Connect T-adapter to ATC2 (female).
Resis- 500 –
tance 1,000 z
42 HD325-7, HD405-7
HD325-7, HD405-7 43

Disagreement of revolution speed signal) (If equipped) 1
Action code Failure code Transmission output shaft speed sensor: Disagreement of revolu-
Trouble tion speed signal (If equipped)
E03 DLT3LC (Retarder controller system)
• The speed calculated from the engine speed sensor signal, transmission input shaft speed sensor
Contents of
signal, and transmission intermediate shaft speed sensor signal is different from the signal speed of
trouble
the transmission output shaft speed sensor.
Problem that
appears on
machine • If the shift lever is set in the "N" position, the gear is set in neutral.
Related
information

1 Resis- 500 –
tance 1,000 z
Between CN5 (male) (1), (2) – chassis Resis-
Min. 1 Mz
ground tance
2) Disconnect connectors ATC2, BRC2, and CN5.
Possible causes 2
harness Between ground and wiring harness
and standard Resis-
value in normal between ATC2 (female) (30) – BRC2 Min. 1 Mz
tance
state (female) (30) – CN5 (female) (1)
2) Disconnect connectors ATC2, BRC2, CN5.
Wiring harness between ATC2 (female) (30)
Voltage Max. 1 V
– BRC2 (female) (30) – CN5 (female) (1)
4
defective
Resis- 500 –
tance 1,000 z
44 HD325-7, HD405-7
HD325-7, HD405-7 45
Failure code [DLT4KA] (Transmission output shaft speed sensor:

Disconnection) (If equipped) 1
Action code Failure code Transmission output shaft speed sensor: Disconnection
Trouble (If equipped)
E03 DLT4KA (Retarder controller system)
Contents of • When ARSC, ASR, and auto-suspension are set, signal circuit of transmission output shaft speed
trouble sensor has disconnection and no signals are input.
• Turns output to ASR proportional solenoid OFF.
Action of • Turns output to auto-suspension solenoid OFF.
controller • When ARSC operates, brake is released gradually, then control is stopped until power is turned
OFF.
2) Disconnect emergency escape connectors A1 (female) and A2 (male) and connect them to each
Problem that other to set machine in emergency escape mode.
appears on 3) Operate gearshift lever and start machine again.
machine
• When operating gearshift lever, release accelerator pedal.
• Operate gearshift lever from N to D or from N to R1 – R2.
• Machine is kept in emergency escape mode until starting switch is turned OFF.
Related
information

Wrong adjustment of
then return it by 1/2 - 1 turn.
1 transmission output shaft
speed sensor
sion speed sensor".
Transmission output shaft Resis- 500 –
2 Between CN5 (male) (1) – (2)
speed sensor defective tance 1,000 z
Resis-
Possible causes Between CN5 (male) (1), (2) – ground Min. 1 Mz
tance
and standard
state 2) Disconnect connectors ATC2, BRC2, and CN5.
Disconnection in wiring 3) Connect T-adapter to BRC2 (female) and CN5 (female).
harness
3 Wiring harness between BRC2 (female) (30) Resis-
contact)
Max. 1 z
2) Disconnect connectors BRC2 and ATC2.
Transmission controller 3) Connect T-adapter to BRC2 (female).
4
defective
Resis- 500 –
Between BRC2 (female) (30) – (29)
tance 1,000 z
46 HD325-7, HD405-7
HD325-7, HD405-7 47

Disagreement of revolution speed signal) (If equipped) 1
Action code Failure code Transmission output shaft speed sensor: Disagreement of revolu-
Trouble tion speed signal (If equipped)
E01 DLT4LC (ASR is set and ASR system switch is turned "ON")
Contents of • When ARSC, ASR, and auto-suspension are set, signal circuit of transmission output shaft speed
trouble sensor has disconnection and no signals are input.
• Turns output to ASR proportional solenoid OFF.
Action of • Turns output to auto-suspension solenoid OFF.
controller • When ARSC operates, brake is released gradually, then control is stopped until power is turned
OFF.
Problem that
• Machine is not affected particularly.
appears on
Related • Transmission output shaft speed can be checked with monitoring function (Code: 31400). Wheel
information speed can be also checked with monitoring function (Code: 31403).

1 Resis- 500 –
tance 1,000 z
Between CN5 (male) (1), (2) – chassis Resis-
Min. 1 Mz
ground tance
2) Disconnect connectors ATC2, BRC2, PM5, and CN5.
2 Between ground and wiring harness
harness
Possible causes between BRC2 (female) (30) – ATC2 Resis-
(female) (30) – PM5 (female) (7) – CN5 tance
value in normal (female) (1)
state
2) Disconnect connectors BRC2, ATC2, PM5, and CN5.
3 Hot short in wiring harness
between ATC2 (female) (30) – BRC2
Voltage Max. 1 V
(female) (30) – PM5 (female) (7) – CN5
(female) (1)
4
defective
Resis- 500 –
Between BRC2 (female) (30) – (29)
tance 1,000 z
48 HD325-7, HD405-7
HD325-7, HD405-7 49
Failure code [DW35KZ] (Failure in output system of auto suspension

solenoid 1: Disconnection or short circuit) (If equipped) 1
Action code Failure code Failure in output system of auto suspension solenoid 1: Disconnec-
Trouble tion or short circuit (If equipped)
E01 DW35KZ (Retarder controller system)
Contents of • When the output to the auto suspension solenoid 1 circuit is ON, a too large current flows or any
trouble current does not flow. Or, some current is flowing while the output is OFF.
Action of
• The controller turns the output to auto suspension solenoid 1 OFF.
controller
Problem that
appears on • The auto suspension system does not operate.
machine
Related
information

2) Disconnect connector S04.
Auto suspension solenoid 1
1 Resis-
defective Between S04 (female) (1) – (2) 15 – 35 z
tance
Resis-
Between S04 (female) (1), (2) – ground Min. 1 Mz
tance
2) Disconnect connectors BRC1 and S04.
harness
Possible causes 2 Wiring harness between BRC3 (female) (7) Resis-
and standard – S04 (female) (1) tance
contact)
value in normal Wiring harness between BRC3 (female) (3) Resis-
state Max. 1 z
– S04 (female) (2) tance
2) Disconnect BRC3 and S04.
Hot short in wiring harness 3) Connect T-adapter to BRC3 (female).
3 (Contact with power supply 4) Turn starting switch ON.
circuit)
Voltage Max. 1 V
– S04 (female) (1)
4 Retarder controller defective 3) Insert T-adapter.
Resis-
Between BRC3 (female) (7) – ground 15 – 20 z
tance
50 HD325-7, HD405-7
HD325-7, HD405-7 51
Failure code [DW36KZ] (Failure in output system of auto suspension

solenoid 2: Disconnection or short circuit) (If equipped) 1
Action code Failure code Failure in output system of auto suspension solenoid 2: Disconnec-
Trouble tion or short circuit (If equipped)
Contents of • When the output to the auto suspension solenoid 2 circuit is ON, a too large current flows or any
Action of
• The controller turns the output to auto suspension solenoid 2 OFF.
controller
Problem that
appears on • The auto suspension system does not operate.
machine
Related
information

2) Disconnect connector S05.
Auto suspension solenoid 2
1 Resis-
defective Between S05 (female) (1) – (2) 15 – 35 z
tance
Resis-
Between S05 (female) (1), (2) – ground Min. 1 Mz
tance
2) Disconnect connectors BRC3 and S05.
harness
Possible causes 2 Wiring harness between BRC3 (female) (37) Resis-
and standard – S05 (female) (1) tance
contact)
value in normal Wiring harness between BRC3 (female) (3) Resis-
state Max. 1 z
– S05 (female) (2) tance
2) Disconnect BRC3 and S05.
3 (Contact with power supply 4) Turn starting switch ON.
circuit)
Voltage Max. 1 V
– S05 (female) (1)
Resis-
Between BRC3 (female) (37) – ground 15 – 20 z
tance
52 HD325-7, HD405-7
HD325-7, HD405-7 53

Action code Failure code Failure in kick-out solenoid output system: Disconnection or short
Trouble
E01 DW72KZ circuit
Contents of • When the output to the hoist lever kick-out solenoid circuit is ON, a too large current flows or any
Action of
• The controller turns the output to the hoist lever kick-out solenoid OFF.
controller
Problem that
appears on • Detent lock is not applied to the hoist lever.
machine
Related
information

2) Disconnect connectors BRC3 and LK0.
harness
1 Wiring harness between LK0 (female) (2) – Resis-
ground tance
contact)
Max. 1 z
– LK0 (female) (1) tance
2) Disconnect connectors BRC3 and LK0.
2 (Contact with power supply 4) Turn the starting switch ON.
Possible causes circuit) Between ground and wiring harness
and standard
between BRC3 (female) (27) – LK0 (female) Voltage Max. 1 V
value in normal
(1)
state
2) Disconnect connector LK0.
Hoist lever kick-out solenoid
3 Resis-
defective Between LK0 (male) (1) – (2) 39 z ± 5 %
tance
Resis-
Between LK0 (male) (1), (2) – ground Min. 1 Mz
tance
Resis-
Between BRC3 (female) (27) – ground 39 z ± 5 %
tance
54 HD325-7, HD405-7
HD325-7, HD405-7 55

Action code Failure code Failure in hoist select valve output system: Disconnection or short
Trouble circuit
Contents of • When the output to the hoist lever select valve solenoid circuit is ON, a too large current flows or
trouble any current does not flow. Or, some current is flowing while the output is OFF.
Action of • The controller turns the output to the hoist lever select valve solenoid OFF.
controller • The controller turns the output to the hoist lever EPC valve solenoid OFF.
Problem that
machine
Related
information

2) Disconnect connectors BRC3 and HSOL.
harness
– HSOL (female) (B) tance
contact)
Max. 1 z
– HSOL (female) (A) tance
2) Disconnect connectors BRC3 and HSOL.
Possible causes
and standard
between BRC3 (female) (17) – HSOL Voltage Max. 1 V
value in normal
(female) (A)
state
2) Disconnect connector HSOL.
Hoist lever select valve sole-
3 Resis-
noid defective Between HSOL (male) (A) – (B) 15 – 35 z
tance
Resis-
Between HSOL (male) (A), (B) – ground Min. 1 Mz
tance
2) Disconnect connector HSOL.
Resis-
Between BRC3 (female) (17) – (3) 15 – 35 z
tance
56 HD325-7, HD405-7
HD325-7, HD405-7 57
Failure code [DW78KZ] (Failure in rear brake BCV command output

system: Disconnection or short circuit) 1
Action code Failure code Failure in rear brake BCV command output system: Disconnection
Trouble or short circuit
Contents of
• Current does not flow to rear brake BCV solenoid, or excessive current flows when output is ON.
trouble
Action of • If wiring harness has disconnection, no current flows.
controller • If wiring harness has ground fault or short circuit, controller stops output.
Problem that
appears on • No change is made in machine, or cooling capacity lowers and retarder may overheat.
machine
Related
information

2) Connect T-adapter to connector BCVR (male).
Resis-
1 Defective rear BCV solenoid Between BCVR (male) (1) – (2) Max. 1 z
tance
Resis-
Between BCVR (male) (1), (2) – ground Min. 1 Mz
tance
2) Connect T-adapter to connectors BRC3 (female) and BCVR
harness
(18) – BCVR (female) (1) tance
contact)
Wiring harness between BCVR (female) (2) Resis-
Max. 1 z
Possible causes – ground tance
value in normal 2) Disconnect connectors BRC3 and BCVR.
state 3) Connect T-adapter to BRC3 (female).
(Contact with ground circuit Resis-
3 between BRC3 (female) (18) – BCVR Min. 1 Mz
or contact between tance
(female) (1)
harnesses)
Wiring harness between BRC3 (female)
Resis-
(18) – BCVR (female) (1) – other wiring har- Min. 1 Mz
tance
ness
4 Defective retarder controller When solenoid
Between BRC3 Voltage 20 – 30 V
output is ON
(female) (18) –
ground When solenoid
Voltage Max. 1 V
output is OFF
58 HD325-7, HD405-7
HD325-7, HD405-7 59
Failure code [DX11K4] (Rear brake proportional pressure reducing

solenoid valve: Out of control) 1
Action code Failure code Rear brake proportional pressure reducing solenoid valve: Out of
control
Trouble
E03 DX11K4 (Valve is stuck in operated condition)
Contents of • Rear brake proportional pressure reducing solenoid valve is stuck in operated condition (does not
trouble move).
Action of
• Continues control.
controller
Problem that • If solenoid is defective, rear brake drags.
appears on • If switch is defective or switch input circuit has ground fault, gear shift-up operation becomes difficult
machine and gear shift-down operation becomes easy.
Related
• Retarder oil pressure switch state can be checked with monitoring function (Code: 40932).
information

Defective rear brake • Check rear brake proportional pressure reducing solenoid valve.
1 proportional pressure If there is an abnormality (mechanical failure), repair or replace
reducing solenoid valve it.
2) Connect T-adapter to connector REVR (male).
Oil
Defective rear brake Resis-
pressure Max. 1 z
2 proportional pressure tance
is ON.
reducing solenoid Between REVR (male) (1) – (2)
Oil
Resis-
pressure Min. 1 Mz
tance
is OFF.
2) Insert T-adapter in connector RESW.
3) Start engine.
Possible causes Defective retarder pressure
3 RESW Retarder Voltage
and standard switch
value in normal When not operated 20 – 30 V
state Between (1) – (2)
When operated Max. 1 V
2) Disconnect connectors BRC1 and RESW.
Defective harness grounding 3) Connect T-adapter to BRC1 (female).
4
(Contact with ground circuit) Between ground and wiring harness
Resis-
between BRC1 (female) (5) – RESW Min. 1 Mz
tance
(female) (1)
2) Connect T-adapter to connector BRC3 (female).
Oil
pressure Voltage Max. 1 V
is ON.
Between BRC3 (16) – (13)
Oil
pressure Voltage 20 – 30 V
is OFF.
60 HD325-7, HD405-7
HD325-7, HD405-7 61
Failure code [DX11KA] (Rear brake proportional pressure reducing

solenoid valve output circuit: Disconnection) 1
Action code Failure code Rear brake proportional pressure reducing solenoid valve output
Trouble circuit: Disconnection
E03 DX11KA (Retarder controller system)
Contents of • When output to rear brake proportional pressure reducing valve solenoid circuit is ON, current does
trouble not flow.
Action of
• Turn output to rear brake proportional pressure reducing valve solenoid OFF.
controller
Problem that
appears on • Retarder (rear brake) does not operate.
machine
Related
information

Defective rear brake
Resis-
1 proportional pressure Between REVR (male) (1) – (2) 10 – 30 z
tance
reducing solenoid valve
Resis-
Between REVR (female) (1), (2) – ground Min. 1 Mz
tance
and standard 2) Connect T-adapter to connectors BRC3 (female) and REVR
value in normal Disconnection in wiring (female).
state harness
(16) – REVR (female) (1) tance
contact)
Max. 1 z
(13) – REVR (female) (2) tance
2) Connect T-adapter to connector BRC3 (female).
Resis-
tance
62 HD325-7, HD405-7
Failure code [DX11KB] (Rear brake proportional pressure reducing

solenoid valve: Short circuit) 1
Action code Failure code Rear brake proportional pressure reducing solenoid valve: Short
Trouble circuit
E03 DX11KB (Retarder controller system)
Contents of • When output to solenoid circuit of rear brake proportional pressure reducing valve is turned ON,
trouble much current flows.
Action of
• Turns output to solenoid circuit of rear brake proportional pressure reducing valve OFF.
controller
Problem that
machine
Related
information

Resis-
1 proportional pressure Between REVR (male) (1) – (2) 10 – 30 z
tance
Resis-
Between REVR (male) (1), (2) – ground Min. 1 Mz
tance
2) Disconnect connectors BRC3 and REVR.
Possible causes
and standard
value in normal Between ground and wiring harness
Short circuit of harness Resis-
state between BRC3 (female) (16) – REVR Min. 1 Mz
2 (Contact with GND circuit or tance
(female) (1)
contact between harnesses)
Between wiring harness from BRC3
(female) (16) – REVR (female) (1) and wir- Resis-
Min. 1 Mz
ing harness from BRC3 (female) (13) – tance
REVR (female) (2)
Resis-
tance
HD325-7, HD405-7 63
Failure code [DX11KY] (Rear brake proportional pressure reducing

solenoid valve: Short circuit to power source line) 1
Action code Failure code Rear brake proportional pressure reducing solenoid valve: Short
Trouble circuit to power source line
E03 DX11KY (Retarder controller system)
Contents of • When output to rear brake proportional pressure reducing valve solenoid circuit is OFF, electric cur-
trouble rent flows.
Action of
• Turn output to rear brake proportional pressure reducing valve solenoid OFF.
controller
Problem that
machine
Related
information

2) Connect T-adapter to connector REVE (male).
Resis-
1 proportional pressure Between REVE (male) (1) – (2) 10 – 30 z
tance
Resis-
Between REVE (male) (1), (2) – ground Min. 1 Mz
tance
and standard 2) Disconnect connectors BRC3 and REVE.
value in normal 3) Connect T-adapter to BRC3 (female).
state Hot short in wiring harness 4) Turn starting switch ON.
2
between BRC3 (female) (16) – REVE Voltage Max. 1 V
(female) (1)
Resis-
tance
64 HD325-7, HD405-7
HD325-7, HD405-7 65
Failure code [DX11MA] (Rear brake proportional pressure reducing

solenoid valve: Malfunction) 1
Action code Failure code Rear brake proportional pressure reducing solenoid valve:
Trouble Malfunction
E03 DX11MA (Retarder controller system)
• Front brake proportional pressure reducing solenoid valve and solenoid keep operating and do not
Contents of
return or their condition cannot be judged normally because of defect in sensor switch after they
trouble
return.
Action of
• Continues control.
controller
Problem that
• If solenoid is defective, rear brake drags.
appears on
machine • If switch is defective or switch input circuit has disconnection, condition does not change.
Related
• Condition of retarder oil pressure switch can be checked with monitoring function (Code: 40932).
information

• Check rear brake proportional pressure reducing solenoid valve.
1 proportional pressure
If it is abnormal (has mechanical defect), repair or replace it.
2) Connect T-adapter to connector REVR.
Disconnection in wiring Oil
Resis-
harness pressure Max. 1 z
2 tance
(Disconnection or defective ON
contact) Between REVR (male) (1) – (2)
Oil
Resis-
pressure Min. 1 Mz
tance
OFF
2) Insert T-adapter in connector RESW.
3) Start engine.
Possible causes Defective retarder pressure
3 RESW Retarder Voltage
and standard switch
value in normal When not operated 20 – 30 V
state Between (1) – (2)
When operated Max. 1 V
Ground fault in wiring 2) Disconnect connectors BRC1 and RESW.
4 harness 3) Connect T-adapter to BRC1.
(Contact with ground circuit) Wiring harness between BRC1 (female) (5) Resis-
Min. 1 Mz
– RESW (female) (1) tance
2) Insert T-adapter to connector BRC3.
Oil
5 Defective retarder controller pressure Voltage Max. 1 V
ON
Between BRC3 (16) – (13)
Oil
pressure Voltage 20 – 30 V
OFF
66 HD325-7, HD405-7
HD325-7, HD405-7 67
Failure code [DX13KA] (Output circuit of hoist EPC valve:

Disconnection) 1
Action code Failure code Output circuit of hoist EPC valve: Disconnection
Trouble
E03 DX13KA (Retarder controller system)
Contents of
• When the output to the hoist EPC solenoid circuit is ON, any current does not flow.
trouble
Action of • The controller turns the output to the hoist select valve solenoid OFF.
controller • The controller turns the output to the hoist EPC valve solenoid OFF.
Problem that
machine
Related
information

2) Disconnect connector HEPC.
Hoist EPC valve solenoid
1 Resis-
defective Between HEPC (male) (1) – (2) 15 – 20 z
tance
Resis-
Between HEPC (male) (1), (2) – ground Min. 1 Mz
tance
and standard 2) Disconnect connectors BRC3 and HEPC.
value in normal Disconnection in wiring 3) Connect T-adapter.
state harness
– HEPC (female) (1) tance
contact)
Max. 1 z
(13) – HEPC (female) (2) tance
Resis-
tance
68 HD325-7, HD405-7
HD325-7, HD405-7 69
Failure code [DX13KB] (Output circuit of hoist EPC valve: Short cir-
cuit) 1
Action code Failure code Output circuit of hoist EPC valve: Short circuit
Trouble
E03 DX13KB (Retarder controller system)
Contents of
• When the output to the hoist EPC valve solenoid circuit is ON, a too large current flows.
trouble
Problem that
machine
Related
information

1 Resis-
defective Between HEPC (male) (1) – (2) 15 – 20 z
tance
Resis-
Between HEPC (male) (1), (2) – ground Min. 1 Mz
tance
Possible causes 2) Disconnect connectors BRC3 and HEPC.
and standard 3) Connect T-adapter to BRC3 (female).
value in normal Grounding fault or short
state circuit in wiring harness Resis-
2 between BRC3 (female) (5) – HEPC Min. 1 Mz
(Contact with GND circuit or tance
(female) (1)
another wiring harness)
Resis-
– HEPC (female) (1) and between BRC2 Min. 1 Mz
tance
(female) (13) – HEPC (female) (2)
Resis-
tance
70 HD325-7, HD405-7
HD325-7, HD405-7 71
Failure code [DX13KY] (Output circuit of hoist EPC valve: Short circuit
with power source line) 1
Action code Failure code Output circuit of hoist EPC valve: Short circuit with power source
Trouble line
E03 DX13KY (Retarder controller system)
Contents of
• While the output to the hoist EPC valve solenoid circuit is OFF, some large current is flowing.
trouble
Problem that
machine
Related
information

1 Resis-
defective Between HEPC (female) (1) – (2) 15 – 20 z
tance
Resis-
Between HEPC (female) (1), (2) – ground Min. 1 Mz
tance
2) Disconnect connectors BRC3 and HEPC.
Possible causes
and standard
value in normal Hot short in wiring harness
2 (Contact with power source
between BRC3 (female) (5) – HEPC Voltage Max. 1 V
wiring harness)
(female) (1)
between BRC3 (female) (13) – HEPC Voltage Max. 1 V
(female) (2)
Resis-
tance
72 HD325-7, HD405-7
HD325-7, HD405-7 73

© 2007 KOMATSU
All Rights Reserved
74 HD325-7, HD405-7
SEN01191-01
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up
Failure code [DXH1KA] (Lockup clutch solenoid output circuit: Disconnection) ............................................. 4
Failure code [DXH1KB] (Lock-up clutch solenoid output circuit: Short circuit) ............................................... 6
Failure code [DXH1KY] (Lockup clutch solenoid output circuit: Short circuit to power source line) ............... 8
Failure code [DXH2KA] (Hi clutch solenoid output circuit: Disconnection) ................................................... 10
Failure code [DXH2KB] (Hi clutch solenoid output circuit: Short circuit) ....................................................... 12
Failure code [DXH2KY] (Hi clutch solenoid output circuit: Short circuit to power source line)...................... 14
Failure code [DXH3KA] (Lo clutch solenoid output circuit: Disconnection)................................................... 18
Failure code [DXH3KB] (Lo clutch solenoid output circuit: Short circuit) ...................................................... 20
Failure code [DXH3KY] (Lo clutch solenoid output circuit: Short circuit in power source line) ..................... 22
Failure code [DXH4KA] (1st clutch solenoid output circuit: Disconnection) .................................................. 26
Failure code [DXH4KB] (1st clutch solenoid output circuit: Short circuit) ..................................................... 28
Failure code [DXH4KY] (1st clutch solenoid output circuit: Short circuit to power source line) .................... 30
Failure code [DXH5KA] (2nd clutch solenoid output circuit: Disconnection)................................................. 34
Failure code [DXH5KB] (2nd clutch solenoid output circuit: Short circuit) .................................................... 36
Failure code [DXH5KY] (2nd clutch solenoid output circuit: Short circuit in power source line) ................... 38
Failure code [DXH6KA] (3rd clutch solenoid output circuit: Disconnection) ................................................. 42
HD325-7, HD405-7 1
Failure code [DXH6KB] (3rd clutch solenoid output circuit: Short circuit) ..................................................... 44
Failure code [DXH6KY] (3rd clutch solenoid output circuit: Short circuit to power source line) .................... 46
Failure code [DXH7KA] (R clutch solenoid output circuit: Disconnection) .................................................... 50
Failure code [DXH7KB] (R clutch solenoid output circuit: Short circuit)........................................................ 52
Failure code [DXH7KY] (R clutch solenoid output circuit: Short circuit to power source line)....................... 54
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
2 HD325-7, HD405-7
HD325-7, HD405-7 3
Failure code [DXH1KA] (Lockup clutch solenoid output circuit:

Disconnection) 1
Action code Failure code Lockup clutch solenoid output circuit: Disconnection
Trouble
E03 DXH1KA (Transmission controller system)
Contents of
trouble • When signal is output to lockup clutch solenoid, no current flows.
• Keeps gear speed used for travel.

Action of
controller • Turns lockup operation OFF.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that • Lockup system does not operate.
appears on
machine • If gearshift lever is set in N, machine cannot restart until it stops.
• As solenoid detects disconnection while output is ON, be sure to turn output ON to check operation
after repair.
Related infor- • Output current to lockup solenoid can be checked with monitoring function (Code: 31609).
mation • Since output is turned ON and self-check is performed for 5 seconds after starting switch is turned
ON, wait for 5 seconds without starting the engine.
• If trouble has not been repaired, error is detected again.

1 Between CN16 (male) (1) – (2) 5 – 15 z
solenoid tance
Resis-
tance
and standard 2) Connect T-adapter to connectors ATC3 (female) and CN16
state harness
(Disconnection or improper Max. 1 z
contact)
Max. 1 z
3
controller Resis-
Between ATC3 (female) (35) – (23) 5 – 15 z
tance
4 HD325-7, HD405-7
HD325-7, HD405-7 5
Failure code [DXH1KB] (Lock-up clutch solenoid output circuit: Short

circuit) 1
Action code Failure code Lockup clutch solenoid output circuit: Short circuit
Trouble
E03 DXH1KB (Transmission controller system)
Contents of • When signal is output to lockup clutch solenoid, much current flows, or while signal is OFF, some
trouble current flows.
Action of • Keeps gear speed used for travel and turns lockup operation OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that • Lockup system is kept OFF or ON.
appears on • If gearshift lever is set in N, machine cannot restart until it stops (or cannot start any more, depend-
machine ing on contents of trouble).
Related infor-
mation • Output current to lockup solenoid can be checked with monitoring function (Code: 31609).

1 Between CN16 (male) (1) – (2) 5 – 15 z
solenoid tance
Resis-
tance
value in normal Short circuit of harness
state (Contact with ground circuit Resis-
2 between ATC3 (female) (35) – CN16 Min. 1 Mz
or contact between har- tance
(female) (1)
nesses)
Between wiring harness from ATC3 (female)
Resis-
(35) – CN16 (female) (1) and wiring harness Min. 1 Mz
tance
from ATC3 (female) (23) – CN16 (female) (2)
3
5 – 15 z
– (23) tance
6 HD325-7, HD405-7
HD325-7, HD405-7 7
Failure code [DXH1KY] (Lockup clutch solenoid output circuit: Short

circuit to power source line) 1
Action code Failure code Lockup clutch solenoid output circuit: Short circuit to power source
Trouble line
E03 DXH1KY (Transmission controller system)
Contents of
trouble • While output to lock-up clutch solenoid is OFF, electric current flows.
Action of • Keeps gear speed used for travel and turns lockup operation OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that • Cannot change gear speed.
appears on • Keeps lockup OFF
machine • When gear shift lever is operated to N, machine cannot move off.
Related infor-
mation • Output current to lockup solenoid can be checked with monitoring function (Code: 31609)

1 Between CN16 (male) (1) – (2) 5 – 15 z
solenoid tance
Resis-
tance
value in normal 3) Connect T-adapter to ATC3 (female).
2
between ATC3 (female) (35) – CN16 Voltage Max. 1 V
(female) (1)
3
controller Resis-
tance
8 HD325-7, HD405-7
HD325-7, HD405-7 9
Failure code [DXH2KA] (Hi clutch solenoid output circuit:

Disconnection) 1
Action code Failure code Hi clutch solenoid output circuit: Disconnection
Trouble
Contents of
trouble • No electric current flows when the output to Hi clutch ECMV is ON.
Action of
ure.
controller
Problem that
machine
after repair.
Related infor- • Electric current of output to ECMV can be checked with monitoring function (code: 31600).

Resis-
tance
Resis-
tance
state harness
(Disconnection or Max. 1 z
defective contact)
Max. 1 z
Defective transmission con- 2) Connect T-adapter to connector ATC3 (female).
3
troller Wiring harness between ATC3 (female) (26) Resis-
5 – 15 z
– (3) tance
10 HD325-7, HD405-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R1
Low Low RH R2 OFF
HD325-7, HD405-7 11
Failure code [DXH2KB] (Hi clutch solenoid output circuit: Short circuit)1
Action code Failure code Hi clutch solenoid output circuit: Short circuit
Trouble
Contents of • Abnormally excessive current flows while output to Hi clutch ECMV is ON, or current flows while
trouble output is OFF.
Action of
ure.
controller
Problem that
machine
Related infor-
mation • Electric current of output to ECMV can be checked by monitoring function (code: 31600).

Resis-
tance
Resis-
tance
Possible causes
and standard
3) Connect T-adapter to ATC3 (female).
state Between ground and wiring harness between Resis-
2 (Contact with GND circuit or Min. 1 Mz
ATC3 (female) (26) – CN19 (female) (1) tance
contact between harnesses)
Resis-
tance
3
controller Resis-
tance
12 HD325-7, HD405-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R1
Low Low RH R2 OFF
HD325-7, HD405-7 13
Failure code [DXH2KY] (Hi clutch solenoid output circuit: Short circuit
to power source line) 1
Action code Failure code Hi clutch solenoid output circuit: Short circuit to power source line
Trouble
Contents of
trouble • When output to Hi clutch ECMV is OFF, electric current flows.
Action of
ure.
controller
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
2
between ATC3 (female) (26) – CN19 Voltage Max. 1V
(female) (1)
3
controller Resis-
tance
14 HD325-7, HD405-7
Table 2

3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R2 OFF
HD325-7, HD405-7 15
16 HD325-7, HD405-7
HD325-7, HD405-7 17
Failure code [DXH3KA] (Lo clutch solenoid output circuit:

Disconnection) 1
Action code Failure code Lo clutch solenoid output circuit: Disconnection
Trouble
Contents of
trouble • Current does not flow when output to Lo clutch ECMV is ON.
Action of
ure.
controller
Problem that
machine
after repair.

Resis-
tance
Resis-
tance
state harness
contact)
Max. 1 z
3
5 – 15 z
– (13) tance
18 HD325-7, HD405-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R1
Low Low RH R2 OFF
HD325-7, HD405-7 19
Failure code [DXH3KB] (Lo clutch solenoid output circuit: Short circuit)1
Action code Failure code Lo clutch solenoid output circuit: Short circuit
Trouble
Contents of
trouble • Excessive current flows while output to Lo clutch ECMV is ON, or current flows while output is OFF.
Action of
ure.
controller
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
Possible causes
and standard
value in normal Short circuit of harness Between ground and wiring harness
Resis-
state (Contact with ground circuit between ATC3 (female) (6) – CN17 (female) Min. 1 Mz
2 tance
or contact between har- (1)
nesses) Between wiring harness from ATC3 (female)
(6) – CN17 (female) (1) and wiring harness Resis-
Min. 1 Mz
from ATC3 (female) (13) – CN17 (female) tance
(2)
3
5 – 15 z
– (13) tance
20 HD325-7, HD405-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R1
Low Low RH R2 OFF
HD325-7, HD405-7 21
Failure code [DXH3KY] (Lo clutch solenoid output circuit: Short circuit
in power source line) 1
Action code Failure code Lo clutch solenoid output circuit: Short circuit to power source line
Trouble
Contents of
trouble • When output to Lo clutch ECMV is turned “OFF“, current flows to circuit.
Action of
ure.
controller
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
Possible causes
value in normal 2) Disconnect connectors ATC3 and CN17.
state 3) Connect T-adapter to ATC3 (female).
2
(1)
3 Resis-
controller Between ATC3 (female) (6) – (13) 5 – 15 z
tance
22 HD325-7, HD405-7
Table 2

3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R2 OFF
HD325-7, HD405-7 23
24 HD325-7, HD405-7
HD325-7, HD405-7 25
Failure code [DXH4KA] (1st clutch solenoid output circuit:

Disconnection) 1
Action code Failure code 1st clutch solenoid output circuit: Disconnection
Trouble
Contents of
trouble • Current does not flow when output to 1st clutch ECMV is ON.
Action of
ure.
controller
Problem that
machine
after repair.

Resis-
tance
Resis-
tance
Possible causes
and standard
value in normal
state harness Wiring harness between ATC3 (female) (36) Resis-
2 Max. 1 z
(Disconnection or improper – CN6 (female) (1) tance
Max. 1 z
Defective transmission 2) Connect T-adapter to ATC3 (female).
3
5 – 15 z
– (3) tance
26 HD325-7, HD405-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R1
Low Low RH R2 OFF
HD325-7, HD405-7 27
Failure code [DXH4KB] (1st clutch solenoid output circuit: Short circuit)1
Action code Failure code 1st clutch solenoid output circuit: Short circuit
Trouble
Contents of • Abnormally excessive current flows when output to 1st clutch ECMV is ON, or current flows while
Action of
ure.
controller
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
Possible causes
2) Disconnect connectors to ATC3 (female) and CN6 (female).
and standard
Short circuit of harness 3) Connect T-adapter to connector ATC3 (female).
value in normal
state (Contact with ground circuit Between ground and wiring harness between Resis-
2 Min. 1 Mz
or contact between har- ATC3 (female) (36) – CN6 (female) (1) tance
Resis-
tance
3
5 – 15 z
– (3) tance
28 HD325-7, HD405-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R1
Low Low RH R2 OFF
HD325-7, HD405-7 29
Failure code [DXH4KY] (1st clutch solenoid output circuit: Short circuit
Action code Failure code 1st clutch solenoid output circuit: Short circuit in power source line
Trouble
Contents of
trouble • When output to 1st clutch ECMV is "OFF", current flows to circuit.
Action of
ure.
controller
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
2
(1)
3
controller Resis-
tance
30 HD325-7, HD405-7
Table 2

3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R2 OFF
HD325-7, HD405-7 31
32 HD325-7, HD405-7
HD325-7, HD405-7 33
Failure code [DXH5KA] (2nd clutch solenoid output circuit:

Disconnection) 1
Action code Failure code 2nd clutch solenoid output circuit: Disconnection
Trouble
Contents of
trouble • Current does not flow when output to 2nd clutch ECMV is ON.
Action of
ure.
controller
Problem that
machine
after repair.

Resis-
tance
Resis-
tance
state harness
contact)
Max. 1 z
3
5 – 15 z
– (23) tance
34 HD325-7, HD405-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R1
Low Low RH R2 OFF
HD325-7, HD405-7 35
Failure code [DXH5KB] (2nd clutch solenoid output circuit: Short cir-
cuit) 1
Action code Failure code 2nd clutch solenoid output circuit: Short circuit
Trouble
Contents of • Abnormally excessive current flows while output to 2nd clutch ECMV is ON, or current flows while
Action of
ure.
controller
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
state Resis-
2 (Contact with GND circuit or between ATC3 (female) (5) – CN8 (female) Min. 1 Mz
tance
contact between harnesses) (1)
Resis-
tance
3
5 – 15 z
– (23) tance
36 HD325-7, HD405-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R1
Low Low RH R2 OFF
HD325-7, HD405-7 37
Failure code [DXH5KY] (2nd clutch solenoid output circuit: Short circuit
in power source line) 1
Action code Failure code 2nd clutch solenoid output circuit: Short circuit in power source line
Trouble
Contents of
trouble • When output to 2nd clutch ECMV is "OFF", current flows to circuit.
Action of
ure.
controller
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
2
(a contact with 24V circuit)
(1)
3
controller Resis-
tance
38 HD325-7, HD405-7
Table 2

3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R2 OFF
HD325-7, HD405-7 39
40 HD325-7, HD405-7
HD325-7, HD405-7 41
Failure code [DXH6KA] (3rd clutch solenoid output circuit:

Disconnection) 1
Action code Failure code 3rd clutch solenoid output circuit: Disconnection
Trouble
Contents of
trouble • Current does not flow when output to 3rd clutch ECMV is ON.
Action of
ure.
controller
Problem that
machine
after repair.

Resis-
tance
Resis-
tance
and standard 2) Disconnect T-adapter connectors to ATC3 (female) and CN10
value in normal Disconnection in wiring (male).
state harness
contact)
Max. 1 z
3
5 – 15 z
– (13) tance
42 HD325-7, HD405-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R1
Low Low RH R2 OFF
HD325-7, HD405-7 43
Failure code [DXH6KB] (3rd clutch solenoid output circuit: Short cir-
cuit) 1
Action code Failure code 3rd clutch solenoid output circuit: Short circuit
Trouble
Contents of • Abnormally excessive current flows while output to 3rd clutch ECMV is ON, or current flows while
Action of
ure.
controller
Problem that
machine
Related infor-

Resis-
1 Defective 3rd clutch ECMV Between CN10(male) (1) – (2) 5 – 15 z
tance
Resis-
tance
(female) (1)
nesses)
Resis-
tance
3
5 – 15 z
– (13) tance
44 HD325-7, HD405-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R1
Low Low RH R2 OFF
HD325-7, HD405-7 45
Failure code [DXH6KY] (3rd clutch solenoid output circuit: Short circuit
Action code Failure code 3rd clutch solenoid output circuit: Short circuit to power source line
Trouble
Contents of
trouble • When output to 3rd clutch ECMV is OFF, current flows to circuit.
Action of
ure.
controller
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
2
(female) (1)
3
controller Resis-
tance
46 HD325-7, HD405-7
Table 2

3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R2 OFF
HD325-7, HD405-7 47
48 HD325-7, HD405-7
HD325-7, HD405-7 49
Failure code [DXH7KA] (R clutch solenoid output circuit:

Disconnection) 1
Action code Failure code R clutch solenoid output circuit: Disconnection
Trouble
Contents of
trouble • Current does not flow when output to R clutch ECMV is ON.
Action of
ure.
controller
Problem that
machine
after repair.

Resis-
tance
Resis- Min. 1
Between CN12 (male) (1), (2) – ground
tance Mz
state harness
contact)
Max. 1 z
3
5 – 15 z
– (23) tance
50 HD325-7, HD405-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R1
Low Low RH R2 OFF
HD325-7, HD405-7 51
Failure code [DXH7KB] (R clutch solenoid output circuit: Short circuit)1

Action code Failure code R clutch solenoid output circuit: Short circuit
Trouble
Contents of • Abnormally excessive current flows while output to R clutch ECMV is ON, or current flows while out-
trouble put is OFF.
Action of
ure.
controller
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
Possible causes
and standard
Resis-
state (Contact with ground circuit between ATC3 (female) (25) – CN12 Min. 1 Mz
2 tance
or contact between har- (female) (1)
(25) – CN12 (female) (1) and wiring harness Resis-
Min. 1 Mz
from ATC3 (female) (23) – CN12 (female) tance
(2)
3
5 – 15 z
– (23) tance
52 HD325-7, HD405-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R1
Low Low RH R2 OFF
HD325-7, HD405-7 53
Failure code [DXH7KY] (R clutch solenoid output circuit: Short circuit to

power source line) 1
Action code Failure code R clutch solenoid output circuit: Short circuit to power source line
Trouble
Contents of
trouble • When output to R clutch ECMV is OFF, current flows to circuit.
Action of
ure.
controller
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
2
(female) (1)
3
controller Resis-
tance
54 HD325-7, HD405-7
Table 2

3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R2 OFF
HD325-7, HD405-7 55
56 HD325-7, HD405-7
HD325-7, HD405-7 57
Failure code [DXHHKA] (4th clutch solenoid output circuit:

Disconnection) 1
Action code Failure code 4th clutch solenoid output circuit: Disconnection
Trouble
E03 DXHHKA (Transmission controller system)
Contents of
trouble • Current does not flow when output to 4th clutch ECMV is ON.
Action of
ure.
controller
Problem that
machine
after repair.

Resis-
tance
Resis-
tance
Possible causes
and standard
value in normal
state harness Wiring harness between ATC3 (female) (16) Resis-
2 Max. 1 z
Max. 1 z
3
5 – 15 z
– (3) tance
58 HD325-7, HD405-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R1
Low Low RH R2 OFF
HD325-7, HD405-7 59
Failure code [DXHHKB] (4th clutch solenoid output circuit: Short

circuit) 1
Action code Failure code 4th clutch solenoid output circuit: Short circuit
Trouble
E03 DXHHKB (Transmission controller system)
Contents of • Abnormally excessive current flows while output to 4th clutch ECMV is ON, or current flows while
Action of
ure.
controller
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
(female) (1)
nesses)
Resis-
tance
3
5 – 15 z
– (3) tance
60 HD325-7, HD405-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
R1
Low Low RH R2 OFF
HD325-7, HD405-7 61
Failure code [DXHHKY] (4th clutch solenoid output circuit: Short circuit
Action code Failure code 4th clutch solenoid output circuit: Short circuit to power source line
Trouble
E03 DXHHKY (Transmission controller system)
Contents of
trouble • When output to 4th clutch ECMV is OFF, current flows to circuit.
Action of
ure.
controller
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
2
(female) (1)
3
controller Resis-
tance
62 HD325-7, HD405-7
Table 2

3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R2 OFF
HD325-7, HD405-7 63
64 HD325-7, HD405-7
HD325-7, HD405-7 65

© 2007 KOMATSU
All Rights Reserved
66 HD325-7, HD405-7
SEN01192-01
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up
Troubleshooting of electrical system
(E-mode)
Before troubleshooting of electric system ....................................................................................................... 3
Contents of troubleshooting table ................................................................................................................... 6
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 sound................................................................................................................. 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
HD325-7, HD405-7 1
E-12 Night illumination (lighting) does not work properly .............................................................................. 30

E-13 Emergency steering does not operate.................................................................................................. 39
2 HD325-7, HD405-7
Before troubleshooting of electric system 1

Wiring table for circuit breaker and slow blow fuse
a This wiring table shows the components which are supplied with power by each power source of the cir-
cuit breaker or the slow blow fuse.
(Switched power source refers to the power source supplied with the starting switch ON, and constant
power source refers to the power source supplied with the starting switch OFF.)
a When proceeding to a troubleshooting by failure code, first of all, inspect the circuit breaker or slow blow
fuse to check if the power source is supplied properly.
Type of
Breaker name Content Destinations of electric power distribution
power supply
80 A (3), (5), (7), (9), (11), (13), (15), (17)
80A
(1), (3), (5), (7)
Power source of switch • Fuse (BT1) (inlet terminal No.)

(Terminal M of (1), (3), (5), (7), (13), (15), (19)
battery relay) • Fuse (BT2) (inlet terminal No.)
80 A (7), (9), (11), (15)
80A
(1)
(9), (11), (13), (15), (17), (19)
30 A • Fuse (BT3) (inlet terminal No.)
30A
(FUA1) (21), (23)
Constant power source
(Terminal B of • Fuse (BT2) (inlet terminal No.)
battery relay) 30 A (13), (17), (19), (21), (23), (27), (29)
30A
(FUA2) • Fuse (BT3) (inlet terminal No.)
(29)
Power source of switch
(Terminal M of Slow blow fuse 300A • Engine intake air heater relay
battery relay)
HD325-7, HD405-7 3
Wiring table for fuse box

a This wiring table shows the components which are supplied with power by each power source of the
fuse box.
(Switched power source refers to the power source supplied with the starting switch ON, and constant
power source refers to the power source supplied with the starting switch OFF.)
a When proceeding to a troubleshooting by failure code, first inspect the fuse box to check if the power
source is supplied properly.
Fuse numbers are mentioned in the order of the fuse outlet No. o inlet No.
(6) – (5) 20A Heater
(8) – (7) 20A Heater
(10) – (9) 20A ABS controller
(12) – (11) 20A Retarder controller
BT3
Switched power supply
Gearshift lever
(Battery relay
terminal M) (16) – (15) 10A Automatic emergency steering
(Circuit breaker) P/B relay
(80 A)
(18) – (17) 10A Radio
(SUB2)
(2) – (1) 10A Room lamp 2
Engine compartment lamp
(4) – (3) 10A Engine pre-heat power supply
BT4
(6) – (5) 20A Rotary lamp
Step lamp
(8) – (7) 20A Side lamp
(2) – (1) 10A Main lamp
Small lamp
(4) – (3) 10A Winker lamp
BT1
(8) – (7) 20A Headlamp (High)
(14) – (13) 10A Stop lamp
(16) – (15) 20A Backup lamp
(20) – (19) 20A Spare
Switched power supply (8) – (7) 20A Power window (Left)
(Battery relay (10) – (9) 20A Power window (Right)
terminal M) BT2
(12) – (11) 10A PLM2 controller
(Circuit breaker)
(80 A) (16) – (15) 10A Machine monitor
(SUB1) BT3 (2) – (1) 20A Fog lamp
(10) – (9) 20A Operator's seat heater
Air suspension seat
(12) – (11) 20A PLM external pilot lamp
(14) – (13) 10A Tachograph
BT4
Cigarette lighter
(18) – (17) 20A Spare power supply
(20) – (19) 20A Front wiper
4 HD325-7, HD405-7

Constant power supply (22) – (21) 30A Engine controller
(Battery relay
terminal B)
BT3
(Circuit breaker) (24) – (23) —
(30 A)
(SUA1)
(14) – (13) 10A Horn
(20) – (19) 20A Steering switch terminal B
Constant power supply (22) – (21) 10A Retarder controller
(Battery relay ABS controller
terminal B) BT2
(24) – (23) 20A Hazard lamp
(Circuit breaker)
(30 A) (28) – (27) 10A Room lamp
(SUA2) Radio
KOMTRAX
BT3 (30) – (29) 20A Spare
BT1 (12) – (11) 20A Headlamp (High)
(18) – (17) 10A Small lamp
Fuse in circuit
BT2 PLM2 controller
(26) – (25) 10A Emergency steering power supply
BT3
HD325-7, HD405-7 5

a Troubleshooting Table and Circuit Diagram Related collectively carry the following information. Carry out
troubleshooting work after fully grasping their contents.
Trouble Phenomenon occurring on machine
Related
Information on the failure occurred as well as the troubleshooting
information
<Contents>
• The standard values in normalcy by which to judge "Good"
or "No Good" about presumed causes.
1
• References for making judgement of "Good" or "No Good".
<Phenomena of wiring harness fault>

• Failure due to disconnection
Defective contact with connector or disconnection of wir-
ing harness has occurred.
• Grounding fault
2 A wiring harness that is not originally connected with a
grounding circuit is in contact with it.
• Failure due to short-circuiting
A wiring harness that is not originally connected with a
power source circuit (24 V) is in contact with it.
Possible causes Cause for presumed
and standard failure (The attached No. is <Points to remember in troubleshooting>
value in normal 3 for filing and reference 1) Connector denotation method and handling of T-adapters
state purpose only. It does not Insert or connect T-adapters in the following manner,
stand for any priority.) unless specifically owhterwise instructed.
• If there is no indication of "male" or "female" in the con-
nector No., pull off a connector and insert a T-adapter
into both sides of male and female
• If there is an indication of "male" and "female" in the
4 connector No., pull off a connector and insert a T-adapter
into only one side of "male" or "female".
2) Description sequence of pin No. and handling of circuit
tester leads
Connect the positive lead (+) and negative lead (-) for trou-
bleshooting in the following manner unless specifically
otherwise instructed.
• Connect the positive lead (+) to a pin No. marked at the
5
front or wiring harness.
• Connect the negative lead (-) to a pin No. marked at the
rear of wiring harness.
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
• Connector No.: Indicates (Type - numbers of a pin) (color)
• Arrow ( ) : Roughly indicates the location in the machine where it is installed.
6 HD325-7, HD405-7
E-1 Engine does not start 1

Trouble Engine does not start.
Related • When failure code related to engine controller or transmission is present, troubleshooting the corre-
information sponding failure code first.

Gravity Min. 1.26
1 Defective battery
Voltage Min. 25 V
Defective circuit breaker
When circuit breaker (FUA2), (FUB2) is shut off, or fuse BT2 (19 –
(FUA2) and (FUB2) or defec-
2 20), BT3 (13 – 14) is blown, it is highly possible that a defective
tive fuse BT2 (19 – 20) and
grounding has occurred in the circuit.
BT3 (13 – 14)
2) Start engine and carry out troubleshooting.
Defective engine starter The problem is
3 Replace relay (R01) Defective relay
relay (R01) resolved.
with other relay
(5 terminals) The problem is not
Relay is normal
resolved.
2) Connect T-adapter to connectors D01 (male) and D08 (male).
4 Defective diode (D01), (D08) Between (1) – (2) Continuity None
D01, D08 (male)
Between (2) – (1) Continuity Yes
• Troubleshooting in a diode range.
Defective alternator 2) Insert T-adapter in connector E02A.
Possible causes 5
(regulator)
and standard Between E02A (2) – ground Voltage Max. 12V
value in normal
state
2) Disconnect connectors SF1, battery relay, and starting switch
terminals.
3) Connect T-adapter to connector SF1 (male).
Wiring harness between BT2 (19) – battery Resis-
Max. 1 z
relay (76) terminal B tance
Wiring harness between BT3 (13) – battery Resis-
Max. 1 z
relay (77) terminal M tance
Harness between battery (+) terminal – bat- Resis-
tery relay (76) terminal B tance
harness
Harness between BT2 (20) – starting switch Resis-
6 (Disconnection or defective Max. 1 z
(terminal B) tance
contact)
(Power supply circuits) Resis-
Harness between BT3 (14) – SF1 (male) (1) Max. 1 z
tance
Harness between starting switch (terminal
BR) – battery relay (61) terminal BR
Continuity Continue
(Troubleshooting in the diode range from
starting switch (terminal BR) side)
Harness between battery relay (60) terminal Resis-
Max. 1 z
(-) – frame ground (ER2) tance
Harness between battery relay (77) terminal Resis-
Max. 1 z
M – starting motor (terminal B) tance
HD325-7, HD405-7 7

2) Disconnect connectors R01, R38, E02A, and starting switch ter-
minals.
Harness between starting switch (terminal Resis-
C) – R38 (female) (3) tance
harness
(Disconnection or defective Harness between R38 (female) (6) – R01 Resis-
7 Max. 1 z
contact) (female) (5) tance
(Related circuit after starting Harness between R01 (female) (3) – E02A Resis-
switch terminal C) Max. 1 z
(female) (1) tance
Harness between R01 (female) (1) – SF1 Resis-
Max. 1 z
(male) (4) tance
Harness between R01 (female) (2) – ground Resis-
Max. 1 z
(ER1) tance
Possible causes 2) Disconnect connectors E02A, CJE3, ATC1, BRC1, and D01.
and standard 3) Connect T-adapter to connector of circuit to be measured.
state Hot short of wiring harness between alternator (terminal R) – E02A Voltage Max. 1V
8
(a contact with 24 V circuit) (male) (2)
between CJE3 (female) (1) – ATC1 (female)
Voltage Max. 1V
(15), BRC1 (female) (15), and D01 (female)
(2)
Defective starting switch 2) Disconnect starting switch terminals.
9
(Between terminals B – C) Resis-
Starting switch unit (between B – C) Max. 1 z
tance
1) Turn starting switch ON and carry out troubleshooting.
Between starting motor (B terminal) –
Voltage 20 – 30 V
ground
10 Defective starting motor 1) Turn starting switch OFF.
2) Insert T-adapter in connector E02A.
Between E02A (1) – ground Voltage 20 – 30 V
8 HD325-7, HD405-7
HD325-7, HD405-7 9
E-2 Automatic preheating does not operate 1

Automatic preheating does not operate when coolant temperature is below 0°C and starting switch is
Trouble
ON.
Related • When failure code CA2555 or CA2556 is not displayed
information (if failure code is displayed, troubleshooting the code first.)

Defective circuit breaker When the circuit breaker is shut off or the fuse is blown, it is highly
1 FUA2, FUB2 or defective possible that a defective grounding has occurred in the circuit
fuse BT2 (20), BT4 (4) (troubleshooting cause 8).
Defective high current fuse Fuse is normal if continuity exists between inlet and outlet of high
2
(fuse is blown) current fuse (disconnect the inlet and outlet terminals).
1) Prepare with starting switch OFF and troubleshooting with start-
ing switch ON.
Between heater inlet terminal – ground Voltage 15 – 28 V
1) Prepare with starting switch OFF and troubleshooting with start-
Defect intake air heater
3 ing switch still OFF.
(inside disconnection)
Wiring harness between heater (-) terminal Resis-
Max. 1 z
– ground tance
• If no problem is found by above diagnoses, intake air heater is
defective.
Between heater relay terminal (E12B) –
Voltage 15 – 28 V
ground
Between heater relay terminal (PLY) –
Voltage 15 – 28 V
ground
Defective heater relay Between heater relay terminal (E11B) –
Voltage 15 – 28 V
4 (Internal disconnection or ground
defective contact) 1) Turn the starting switch OFF.
Possible causes 2) Disconnect heater relay terminal.
and standard
Between heater relay coil side (-) terminal – Resis-
ground tance
state
• If no problem is found by above diagnoses, heater relay is
defective.
2) Insert T-adapter in connector R37.
Defective auto preheater Between R37 (5) – ground Voltage 15 – 28 V
5
relay (R07) Between R37 (3) – ground Voltage 15 – 28 V
When a failure code is not displayed and no problem is found in
above diagnoses, auto-pre heater relay is defective.
* It can be also diagnosed by replacing relay with another one.
Between starting switch terminal B – ground Voltage 15 – 28 V
Defective starting switch
Between starting switch terminal ACC –
6 (Defective contact between Voltage 15 – 28 V
ground
contact points B and ACC)
• If no problem is found by above diagnoses, starting switch is
defective.
2) Disconnect terminals of circuit breaker, starting switch, slow-
Disconnection in wiring blow fuse, and heater relay.
harness
7 Wiring harness between heater relay termi- Resis-
nal (PLY) – air heater inlet terminal tance
contact)
Wiring harness between heater relay termi- Resis-
Max. 1 z
nal (E12B) – high current fuse outlet terminal tance
10 HD325-7, HD405-7

Wiring harness between high current fuse Resis-
Max. 1 z
inlet – battery relay terminal M (77) tance
Wiring harness between battery relay termi- Resis-
Max. 1 z
nal M (77) – circuit breaker FUB2 terminal tance
Wiring harness between circuit breaker
Resis-
FUB2 terminal – fuse BT4 (3), (4) – R37 Max. 1 z
Disconnection in wiring tance
(female) (5)
harness
7
(Disconnection or defective Wiring harness between battery relay termi- Resis- Max. 1 z
contact) nal B (76) – circuit breaker FUA2 terminal tance
Wiring harness between circuit breaker
Resis-
FUA2 terminal – fuse BT2 (19), (20) – start- Max. 1 z
tance
ing switch terminal B
Wiring harness between starting switch ter-
Resis-
minal ACC-fuse BT32 (19), (20) – J2P Max. 1 z
tance
(female) (39)
2) Disconnect terminals of circuit breaker, slow-blow fuse, heater
relay, and starting switch.
between heater relay terminal (PLY) – air Min. 1 Mz
and standard tance
heater inlet terminal
state Resis-
between heater relay terminal (E12B) – high Min. 1 Mz
tance
current fuse outlet terminal
Resis-
between high current fuse inlet – battery Min. 1 Mz
tance
relay terminal M (77)
Resis-
Short circuit of harness between battery relay terminal M (77) – cir- Min. 1 Mz
8 tance
(Contact with ground circuit) cuit breaker FUB2 terminal (62)
Resis-
between circuit breaker FUB2 terminal (63) Min. 1 Mz
tance
– fuse BT4 (3), (4) – R37 (female) (5)
Resis-
between battery relay terminal B (76) – cir- Min. 1 Mz
tance
cuit breaker FUA2 terminal
between circuit breaker FUA2 terminal – Resis-
Min. 1 Mz
fuse BT2 (19), (20) – starting switch terminal tance
B
Resis-
between starting switch terminal ACC-fuse Min. 1 Mz
tance
BT3 (19), (20) – J2P (female) (39)
HD325-7, HD405-7 11
12 HD325-7, HD405-7
HD325-7, HD405-7 13
E-3 Machine monitor does not display all, when starting switch is turned
ON 1
Trouble Lamps and gauges of machine monitor do not display all, when starting switch is turned ON.
Related
• When the machine related failure code is not displayed (if displayed, troubleshooting the code first.)
information

Defective fuse BT2 (20) or When the fuse BT2 (20) or (30), BT3 (20) is blown or the circuit
1 (30), BT3 (20) or defective breaker (FUA2) is shut off, it is highly possible that a defective
circuit breaker (FUA2) grounding has occurred in the circuit (troubleshooting cause 3).
2) Connect T-adapter to connector DPC1 (female) and disconnect
fuse and starting switch terminals.
Max. 1 z
(7) – fuse BT2 (20) tance
Disconnection in wiring Wiring harness between BT2 (19) – starting Resis-
harness Max. 1 z
2 switch terminal ACC tance
contact) Wiring harness between BT2 (20) – starting Resis-
Max. 1 z
switch terminal B tance
Wiring harness between circuit breaker Resis-
Max. 1 z
(FUA2) – fuse BT2 (19) tance
Max. 1 z
Possible causes (10) – ground ER2 tance
value in normal 2) Disconnect connector DPC1 and terminals of fuse and starting
state switch.
Resis-
between DPC1 (female) (6), (7) – fuse BT2 Min. 1 Mz
tance
(20)
3 between BT2 (19) – starting switch terminal Min. 1 Mz
ACC
Resis-
between fuse BT2 (20) – starting switch ter- Min. 1 Mz
tance
minal B
Resis-
between circuit breaker (FUA2) – fuse BT2 Min. 1 Mz
tance
(19)
Defective machine 2) Insert T-adapter in connector DPC1.
monitor
Between DPC1 (6), (7) – (9), (10) Voltage 20 – 30 V
14 HD325-7, HD405-7
HD325-7, HD405-7 15
E-4 Machine monitor does not operate when starting switch is OFF 1
Service meter and travel distance integrating meter, turn signal pilot lamp, and high beam pilot lamp
Trouble
do not flash, if the switches are operated with starting switch OFF.
Related
information

Defective fuse BT2 (30) or When the fuse BT2 (30) is blown or the circuit breaker (FUA2) is
1 defective circuit breaker shut off, it is highly possible that a defective grounding has
(FUA2) occurred in the circuit (troubleshooting cause 3).
2) Connect T-adapter to connector DPC1 (female) and disconnect
terminals of BT2 (30) and FUA2.
Disconnection in wiring Wiring harness between DPC1 (female) (4), Resis-
harness Max. 1 z
2 (5) – fuse BT2 (30) tance
contact) Wiring harness between circuit breaker Resis-
Max. 1 z
(FUA2) – fuse BT2 (29) tance
Possible causes Wiring harness between DPC1 (female) (9), Resis-
Max. 1 z
and standard (10) – ground ER2 tance
state 2) Connect T-adapter to connector DPC1 (female) and disconnect
terminals of BT2 (30) and FUA2.
3 between DPC1 (female) (4), (5) – fuse BT2 Min. 1 Mz
(30)
Resis-
between circuit breaker (FUA2) – fuse BT2 Min. 1 Mz
tance
(29)
2) Insert T-adapter in connector DPC1.
4 Defective machine monitor 3) Turn starting switch ON.
Between DPC1 (4), (5) – (9), (10) Voltage 20 – 30 V
16 HD325-7, HD405-7
HD325-7, HD405-7 17
E-5 Alarm buzzer does not sound 1

The alarm buzzer does not sound when the starting switch is ON, emergency stop item lamps are ON,
Trouble
and centralized warning lamp is ON.
Related
information

When the fuse BT2 (16) is blown, it is highly possible that a defective
1 Defective fuse BT2 (16)
grounding has occurred in the circuit (troubleshooting cause 3).
2) Connect T-adapter to connector DPC1 (female) and BZ2
(female).
Disconnection in wiring Wiring harness between DPC1 (female) Resis-
harness Max. 1 z
2 (13) – BZ2 (female) (2) tance
contact) Wiring harness between BZ2 (female) (1) – Resis-
Max. 1 z
fuse BT3 (10) tance
Max. 1 z
(10) – ground ER2 tance
Possible causes 2) Disconnect connector DPC1 and BZ2.
and standard 3) Connect T-adapter to DPC1 (female).
state 3 Between ground and wiring harness between Resis-
(Contact with ground circuit) Min. 1 Mz
DPC1 (female) (13) – BZ2 (female) (2) tance
Min. 1 Mz
between BZ2 (female) (1) – fuse BT2 (16) tance
2) Insert T-adapter in connector DPC1.
Measurement
DPC1 Voltage
conditions
When the buzzer
20 – 30 V
does not sound
Between (13) – (9), (10)
When the buzzer
Max. 1V
sounds
* Set up the conditions to actuate the buzzer for the measurement.
18 HD325-7, HD405-7
HD325-7, HD405-7 19
E-6 Gauges of machine monitor, caution lamps or character display

section do not display properly 1
Trouble Gauges, lamps or character display section are malfunctioning
Related
information

Defective sensors or Troubleshooting corresponding sensors or switches by the failure
Possible causes 1
switches code.
and standard
value in normal Defective CAN communica-
2 Troubleshooting by the communication related failure code
state tion circuit
If no problem is found in above 1 and 2, machine monitor is defec-
tive (since this is an internal defect, it cannot be diagnosed).
20 HD325-7, HD405-7
E-7 A selection of the display in character display section cannot be

changed 1
Trouble (1) When the mode selector switch 1 circuit for machine monitor is defective
Related
information

2) Connect T-adapter to connector CH1 (male).
Resis-
CH1 (male) Operation of switch (switch unit)
tance
Defective monitor mode
2 Press the switch [U]. Max. 1 z
selector switch 1 (CH1)
Between (3) – (2)
Switch is in the neutral. Min. 1 Mz
Press the switch [t]. Max. 1 z
Between (3) – (1)
2) Connect T-adapter to connectors DPC2A (female) and CH1
(female).
Disconnection in wiring Wiring harness between CH1 (female) (1) – Resis-
harness Max. 1 z
3 DPC2A (female) (14) tance
contact) Wiring harness between CH1 (female) (2) – Resis-
Max. 1 z
DPC2A (female) (8) tance
Possible causes
and standard Wiring harness between CH1 (female) (3) – Resis-
Max. 1 z
value in normal fuse BT2 (30) tance
2) Disconnect connectors DPC2A and CH1.
3) Connect T-adapter to DPC2A.
Resis-
between CH1 (female) (1) – DPC2A Min. 1 Mz
4 (female) (14)
Resis-
tance
(female) (8)
Min. 1 Mz
between CH1 (female) (3) – fuse BT2 (30) tance
2) Insert T-adapter in connector DPC2A.
DPC2A Operation of switch Voltage
5 Defective machine monitor Press the switch [U]. 20 – 30 V
Between (8) –
ground Switch is in the neutral. Max. 1V
Between (14) – Press the switch [t]. 20 – 30 V
HD325-7, HD405-7 21
Trouble (2) When the mode selector switch 2 circuit for machine monitor is defective
Related
information

2) Connect T-adapter to connector CH2 (male).
Resis-
CH2 (male) Operation of switch (switch unit)
tance
Defective monitor mode
2 Press the switch [>]. Max. 1 z
selector switch 2 (CH2)
Between (3) – (2)
Press the switch [<]. Max. 1 z
Between (3) – (1)
2) Connect T-adapter to connectors DPC2A (female) and CH2
(female).
Disconnection in wiring Wiring harness between CH2 (female) (1) – Resis-
harness Max. 1 z
3 DPC2A (female) (15) tance
contact) Harness between CH2 (female) (2) – Resis-
Max. 1 z
DPC2A (female) (6) tance
Possible causes
and standard Wiring harness between CH2 (female) (3) – Resis-
Max. 1 z
value in normal fuse BT2 (16) tance
2) Disconnect connectors DPC2A and CH2.
3) Connect T-adapter to DPC2A.
Resis-
4 (female) (15)
Resis-
tance
(female) (6)
Min. 1 Mz
between CH2 (female) (3) – fuse BT2 (16) tance
DPC2A Operation of switch Voltage
5 Defective machine monitor Press the switch [>]. 20 – 30 V
Between (6) –
Between (15) – Press the switch [<]. 20 – 30 V
22 HD325-7, HD405-7
HD325-7, HD405-7 23
E-8 Power mode selecting function does not operate properly 1

When power mode selector function does not operate properly, even if the power mode selector
Trouble
switch is operated.
Related
information

2) Connect T-adapter to connector PWM (male).
Defective power mode Resis-
2 PWM (male) Operation of switch (switch unit)
selector switch tance
Switch: down Max. 1 z
Between (1) – (3)
Switch: up Min. 1 Mz
2) Connect T-adapter to connectors DPC2A (female) and PWM
harness
3 Wiring harness between DPC2A (female) Resis-
Possible causes (13) – PWM (female) (3) tance
contact)
and standard Wiring harness between PWM (female) (1) Resis-
– fuse BT3 (10) tance
state
2) Disconnect connectors DPC2A and PWM.
3) Connect T-adapter to DPC2A (female).
Short circuit of harness Between ground and wiring harness
4 Resis-
(Contact with ground circuit) between DPC2A (female) (13) – PWM Min. 1 Mz
tance
(female) (3)
Min. 1 Mz
between PWM (female) (1) – fuse BT2 (16) tance
5 Defective machine monitor DPC2A Operation of switch Voltage
Between (13) – Switch: down 20 – 30 V
ground Switch: up Max. 1V
24 HD325-7, HD405-7
E-9 AISS function does not operate properly 1

Trouble When AISS function does not operate properly, even if the AISS LOW switch is operated.
Related
information

2) Connect T-adapter to connector AISS (male).
Resis-
2 Defective AISS switch AISS (male) Operation of switch (switch unit)
tance
Switch: up Min. 1 Mz
Between (1) – (3)
Switch: down Max. 1 z
2) Connect T-adapter to connectors DPC2A (female) and AISS
harness
3 Wiring harness between DPC2A (female) Resis-
Possible causes (2) – AISS (female) (3) tance
contact)
and standard Wiring harness between AISS (female) (1) – Resis-
fuse BT2 (16) tance
state
2) Disconnect connectors DPC2A and AISS.
3) Connect T-adapter to DPC2A (female).
4 Resis-
(Contact with ground circuit) between DPC2A (female) (2) – AISS Min. 1 Mz
tance
(female) (3)
Min. 1 Mz
between AISS (female) (1) – fuse BT2 (16) tance
5 Defective machine monitor DPC2A Operation of switch Voltage
Between (2) – Switch: down 20 – 30 V
ground Switch: up Max. 1V
HD325-7, HD405-7 25
E-10 Seat belt caution lamp does not display properly 1

The lamp lights up even if the seat belt is fastened, or the lamp does not light up even if the seat belt is
Trouble
not fastened.
Related
information

2) Connect T-adapter to connector SBS (male).
3) Check switch unit.
2 Defective seat belt switch Resis-
SBS Seat belt
tance
Fastened Max. 1 z
Between (1) – (2)
Unfastened Min. 1 Mz
2) Connect T-adapter to connectors DPC2B (female) and SBS
harness
3 Wiring harness between DPC2B (female) Resis-
Possible causes (Disconnection or defective Max. 1 z
(11) – SBS (female) (1) tance
and standard contact)
value in normal Wiring harness between SBS (female) (2) – Resis-
Max. 1 z
state fuse BT2 (16) tance
2) Disconnect connectors DPC2B and SBS.
3) Connect T-adapter to DPC2B (female).
4 Resis-
(Contact with ground circuit) between DPC2B (female) (11) – SBS Min. 1 Mz
tance
(female) (1)
Min. 1 Mz
between SBS (female) (2) – fuse BT2 (16) tance
2) Insert T-adapter in connector DPC2B.
5 Defective machine monitor DPC2B Seat belt Voltage
Between (11) – Fastened 20 – 30 V
ground Unfastened Max. 1V
26 HD325-7, HD405-7
E-11 Turn signal lamp or turning lamp (hazard lamp) do not work properly1
Trouble Turn signal lamp or turning lamp (hazard lamp) do not flash.
Related
information

When the fuse BT1 (4) or BT2 (24) is blown, it is highly possible
Defective fuse BT1 (4) or
1 that a defective grounding has occurred in the circuit (troubleshoot-
BT2 (24)
ing cause 7).
Since the lamp can be suspected to be defective, visually check it
2 Defective lamp
or replace it with known good lamp to make a judgement.
2) Insert T-adapter in connector FLS.
3 Defective turn signal lamp FLS Turn switch Voltage
Between (3) – GND At any positions 20 – 30 V
Turned to the left or 20 – 30 V – 0 V
Between (4) – GND
right repeatedly
2) Connect T-adapter to connector (male).
3) Check switch unit.
Resis-
CM (male) Turn switch (lever)
4 Defective turn switch tance
Turned to the left Max. 1 z
Between (6) – (7)
Turned to the right Min. 1 Mz
Turned to the right Max. 1 z
Between (6) – (8)
Turned to the left Min. 1 Mz
When the relay can be suspected to be defective, replace it with
another relay to make a judgement.
• As for the relay R16 (6 terminals): Replace with the relay R21,
Possible causes 5 Defective relay
R40 or R05, etc.
and standard • As for the relay R17 (5 terminals): Replace with the relay R11,
value in normal R32 or R27, etc.
state
2) Disconnect connectors HAZ, R17, R16, FLS, CM, DPC2A,
PR03, PL03, CJR, B02, and B03.
3) Connect T-adapter to connector of circuit to be checked.
Wiring harness between BT1 (4) – R17 Resis-
Max. 1 z
(female) (6) tance
Wiring harness between BT2 (24) – R17 Resis-
Max. 1 z
(female) (5) – HAZ (female) (1) tance
Wiring harness between HAZ (female) (3) – Resis-
Max. 1 z
R17 (female) (1) – R16 (female) (5) tance
Max. 1 z
Disconnection in wiring FLS (female) (3) tance
harness Wiring harness between R16 (female) (4) – Resis-
6 Max. 1 z
(Disconnection or defective CM (female) (7) – DPC2A (female) (7) tance
contact) Wiring harness between R16 (female) (2) – Resis-
Max. 1 z
CM (female) (8) – DPC2A (female) (16) tance
Wiring harness between R16 (female) (1), Resis-
Max. 1 z
(3) – FLS (female) (4) – CM (female) (6) tance
Wiring harness between CM (female) (7) – Resis-
Max. 1 z
PR03 (female) (3) (right front) tance
Max. 1 z
B03 (female) (1) (left front) tance
Max. 1 z
PL03 (female) (3) tance
Max. 1 z
B02 (female) (1) (left rear) tance
HD325-7, HD405-7 27

Wiring harness between PR03 (female) (2) Resis-
Max. 1 z
– ground (right front) tance
Wiring harness between PL03 (female) (2) Resis-
Max. 1 z
– ground (left front) tance
Wiring harness between B03 (female) (6) – Resis-
Max. 1 z
CJR (3), (6) – ground (B10) (right rear) tance
Disconnection in wiring Wiring harness between B02 (female) (6) – Resis-
Max. 1 z
harness CJR (2), (6) – ground (B10) (left rear) tance
6
(Disconnection or defective Wiring harness between HAZ (female) (4) – Resis-
Max. 1 z
contact) ground (ER1) tance
Max. 1 z
ground (ER1) tance
Max. 1 z
ground (ER1) tance
Wiring harness between FLS (female) (1) – Resis-
Max. 1 z
ground (ER1) tance
2) Disconnect connectors HAZ, R17, R16, FLS, CM, DPC2A,
PR03, PL03, CJR, B02, and B03.
3) Connect T-adapter to connector of circuit to be checked.
Min. 1 Mz
between BT1 (4) – R17 (female) (6) tance
Resis-
Possible causes between BT2 (24) – R17 (female) (3) – HAZ Min. 1 Mz
tance
and standard (female) (1)
Resis-
state between HAZ (female) (3) – R17 (female) Min. 1 Mz
tance
(1) – R16 (female) (5)
Resis-
between R17 (female) (3) – FLS (female) Min. 1 Mz
tance
(3)
Resis-
between R16 (female) (4) – CM (female) (7) Min. 1 Mz
tance
Short circuit of harness – DPC2A (female) (7)
7
Resis-
between R16 (female) (2) – CM (female) (8) Min. 1 Mz
tance
– DPC2A (female) (16)
Resis-
between R16 (female) (1), (3) – FLS Min. 1 Mz
tance
(female) (4) – CM (female) (6)
Resis-
between CM (female) (7) – PR03 (female) Min. 1 Mz
tance
(3) (right front)
Resis-
between CM (female) (7) – B03 (female) (1) Min. 1 Mz
tance
(left front)
Resis-
between CM (female) (8) – PL03 (female) Min. 1 Mz
tance
(5) (right front)
Resis-
between CJR (female) (8) – B02 (female) Min. 1 Mz
tance
(1) (left rear)
28 HD325-7, HD405-7
HD325-7, HD405-7 29
E-12 Night illumination (lighting) does not work properly 1

Trouble (1) Small lamps (clearance lamp, tail lamp), night illumination and head lamp do not light up at all.
Related
information

1 Defective fuse BT1(2)
2) Connect T-adapter to connector CM (male).
CM (male) Lamp switch Resistance
2 Defective lamp switch Between (1) – (2) Max. 1 z
1st detent
Between (1) – (3) Min. 1 Mz
Between (1) – (2) Max. 1 z
2nd detent
Between (1) – (3) Max. 1 z
Disconnection in wiring 2) Connect T-adapter to connector CM (female) and disconnect
harness BT1 (2).
3
contact) Wiring harness between fuse BT1 (2) – CM Resis-
(female) (1), (4) tance
and standard
state 2) Disconnect connectors R29, R30, R31, DPC2A, and DPC2B
and terminals of fuse.
Resis-
between fuse BT1 (8) – R29 (female) (3) – Min. 1 Mz
tance
R30 (female) (3), (1)
4 between fuse BT1 (11) – R30 (female) (5) – Min. 1 Mz
(Contact with ground circuit) R29 (female) (3) – DPC2A (female) (1) tance

Min. 1 Mz
between fuse BT1 (6) – R31 (female) (5) tance
Resis-
between fuse BT1 (17) – R46 (female) (3) – Min. 1 Mz
tance
LS (female) (1) – DPC2B (female) (5)
Wiring harness between fuse BT1 (9) – R31 Resis-
Min. 1 Mz
(female) (3) tance
30 HD325-7, HD405-7
Small lamps (clearance lamp and tail lamp) or night illumination do not light up at the first detent
Trouble (2)
position of the lamp switch.
Related
• When the head lamps light up.
information

2) Connect T-adapter to connector CM (female).
1 Defective lamp switch
Between (1) – (2) 1st detent Max. 1 z
Possible causes 2) Disconnect connectors CM, R46, and J02 and terminals of fuse.
and standard 3) Connect T-adapter to connector of circuit to be measured.
value in normal Wiring harness between CM (female) (2) – Resis-
state Disconnection in wiring har- Max. 1 z
R46 (female) (1) (branched point) tance
ness
2 Wiring harness between CM (female) (1), Resis-
contact)
Max. 1 z
BT1 (17) – (18) – J02 (female) (3) tance
Max. 1 z
ground (ER1) tance
Trouble (3) Left small lamp (clearance lamp) does not light up.
Related
• When right side and head lamps light up.
information

When the lamp (bulb) can be suspected to be defective, judge by
1 Defective lamp (bulb)
visual check or replacing the lamp bulb.
2) Disconnect connectors J02, CJB, and PL03.
3) Connect T-adapter to J02, CJB, and PL03.
Disconnection in wiring Wiring harness between J02 (female) (3) – Resis-
harness Max. 1 z
2 CJB (female) (1) tance
Possible causes contact) Wiring harness between CJB (female) (6) – Resis-
Max. 1 z
and standard PL03 (female) (1) tance
value in normal Wiring harness between PL03 (female) (2) – Resis-
state Max. 1 z
ground (PL07) tance
2) Disconnect connectors J02, CJB, and PL03.
3) Connect T-adapter to J02 (male).
Short circuit of harness Between ground and wiring harness Resis-
3 Min. 1 Mz
(Contact with ground circuit) between J02 (male) (3) – CJB (female) (1) tance
Resis-
between CJB (female) (6) – PL03 (female) Min. 1 Mz
tance
(1)
HD325-7, HD405-7 31
Trouble (4) Right small lamp (clearance lamp) does not light up.
Related
• When left side and head lamps light up.
information

2) Disconnect connectors J02, CJB, and PR03.
Disconnection in wiring Wiring harness between J02 (male) (3) – Resis-
Max. 1 z
harness CJB (female) (1) tance
2
(Disconnection or defective Wiring harness between CJB (female) (2) – Resis-
Possible causes contact) Max. 1 z
PR03 (female) (1) tance
and standard
value in normal Wiring harness between PR03(female) (2) – Resis-
Max. 1 z
state ground (PR07) tance
2) Disconnect connectors J02, CJB, and PR03.
3) Connect T-adapter to J02 (male).
3 Min. 1 Mz
(Contact with ground circuit) between J02 (male) (3) – CJB (female) (1) tance
Resis-
between CJB (female) (2) – PR03 (female) Min. 1 Mz
tance
(1)
Trouble (5) Left small lamp (tail lamp) does not light up.
Related
• When right side and head lamps light up.
information

2) Disconnect connectors J02, CJV, and B02.
3) Connect T-adapter to J02, CJV, and B02.
Disconnection in wiring Wiring harness between J02 (female) (3) – Resis-
harness Max. 1 z
2 B02 (female) (4) tance
Possible causes contact) Wiring harness between CJV (female) (5) – Resis-
Max. 1 z
and standard B02 (female) (5) tance
value in normal Wiring harness between B02 (female) (6) – Resis-
state Max. 1 z
ground (B10) tance
3) Connect T-adapter to J02 (female).
3 Min. 1 Mz
(Contact with ground circuit) between J02 (male) (3) – CJV (female) (4) tance
Resis-
between CJV (female) (5) – B02 (female) Min. 1 Mz
tance
(5)
32 HD325-7, HD405-7
Trouble (6) Right small lamp (tail lamp) does not light up.
Related
• When left side and head lamps light up.
information

3) Connect T-adapter to J02, CJV, and B03.
Disconnection in wiring Wiring harness between J02 (male) (3) – Resis-
harness Max. 1 z
2 CJV (female) (4) tance
Possible causes contact) Wiring harness between CJV (female) (3) – Resis-
Max. 1 z
and standard B03 (female) (1) tance
value in normal Wiring harness between B03(female) (2) – Resis-
state Max. 1 z
ground (B10) tance
3) Connect T-adapter to J02 (female).
3 Min. 1 Mz
(Contact with ground circuit) between J02 (male) (3) – CJV (female) (4) tance
Resis-
between CJV (female) (3) – B03 (female) Min. 1 Mz
tance
(1)
HD325-7, HD405-7 33
34 HD325-7, HD405-7
Trouble (7) Head lamps ”Lo beam” do not light up.

Related
• When the lamps light up in the Hi beam side.
information

When the fuse BT1 (6), (9) – (10) is blown, it is highly possible that
Defective fuse BT1(6), (9) –
1 a defective grounding has occurred in the circuit (troubleshooting
(10)
cause 5).
3 Defective lamp switch
Between (1) – (3) Turn to 2nd detent. Max. 1 z
2) Disconnect connectors PR01, PL01, CJA, R31, and CM and ter-
minals of fuse.
Max. 1 z
– CJA (female) (5) (right side) tance
Wiring harness between PL01 (female) (1) – Resis-
Max. 1 z
CJA (female) (3) (left side) tance
harness Wiring harness between CJA (female) (4) – Resis-
4 Max. 1 z
(Disconnection or defective fuse BT1 (10) tance
contact) Wiring harness between fuse BT1 (9) – R31 Resis-
Max. 1 z
Possible causes (female) (3) tance
and standard Wiring harness between CM (female) (3) – Resis-
R31 (female) (1) tance
state
Max. 1 z
BT1(6) tance
Max. 1 z
CJY(5), (16) – ground (ER1) tance
2) Disconnect connectors PR01, PL01, CJA, R31, and CM and ter-
minals of fuse.
Resis-
between PR01 (female) (1) – CJA (female) Min. 1 Mz
tance
(5) (right side)
Resis-
Short circuit of harness between PL01 (female) (1) – CJA (female) Min. 1 Mz
5 tance
(Contact with ground circuit) (3) (left side)
Min. 1 Mz
between CJA (female) (4) – fuse BT1 (10) tance
Min. 1 Mz
Min. 1 Mz
between CM (female) (3) – R31 (female) (1) tance
Min. 1 Mz
between R31 (female) (5) – BT1 (6) tance
HD325-7, HD405-7 35
Trouble (8) Head lamps ”Hi beam” do not light up.

Related
• When the lamps light up in the Lo beam side.
information

When the fuse BT1 (8), (11) – (12) is blown, it is highly possible
Defective fuse BT1 (8), (11) –
1 that a defective grounding has occurred in the circuit (troubleshoot-
(12)
ing cause 4).
2) Disconnect connectors PR02, PL02, CJA, DPC1, and CM and
terminals of fuse.
Max. 1 z
– CJA (female) (2) (right side) tance
Wiring harness between PL02 (female) (1) – Resis-
Max. 1 z
CJA (female) (6) (left side) tance
harness Wiring harness between CJA (female) (1) – Resis-
3 Max. 1 z
(Disconnection or defective fuse BT1 (12) tance
contact) Wiring harness between fuse BT1 (11) – Resis-
Max. 1 z
Max. 1 z
between R30 (female) (1) – CM (female) (3) tance
Wiring harness between DPC1 (female) Resis-
Max. 1 z
Possible causes (14) – R30 (female) (2) tance
and standard Wiring harness between BT1 (8) (female) Resis-
state
2) Disconnect connectors PR02, PL02, CJA, DPC1, and CM and
terminals of fuse.
Resis-
between PR02 (female) (1) – CJA (female) Min. 1 Mz
tance
(2) (right side)
Resis-
between PL02 (female) (1) – CJA (female) Min. 1 Mz
tance
(6) (left side)
4 Min. 1 Mz
(Contact with ground circuit) between CJA (female) (1) – fuse BT1 (12) tance
Min. 1 Mz
Min. 1 Mz
CM (female) (3) tance
Resis-
between DPC1 (female) (14) – R30 (female) Min. 1 Mz
tance
(2)
Resis-
between BT1 (8) (female) (1) – R30 Min. 1 Mz
tance
(female) (5)
36 HD325-7, HD405-7
Trouble (9) At passing position, “Hi“ beam lamps do not light up.
Related
• When head lamps light up properly.
information

1 Defective passing switch CM (male) Passing switch Resistance
Operated Max. 1 z
Between (4) – (5)
Not operated Min. 1 Mz

and standard 2) Disconnect connectors CM, R29, and DPC2A.
value in normal 3) Connect T-adapter to CM, R29, and DPC2A (female).
state Wiring harness between CM (female) (5) – Resis-
harness
2 Wiring harness between R29 (female) (5) – Resis-
R30 (female) (5) (to branched point) tance
contact)
Wiring harness between DPC2A (female) – Resis-
Max. 1 z
CM (female) (5) (to branched point) tance
Max. 1 z
ground (ER1) tance
Trouble (10) The brightness of the night illumination does not change, even if the rheostat is operated.
Related
information

2) Connect T-adapter to connector LS (male).
LS Rheostat Voltage
1 Defective rheostat Between (1) –
Neutral 20 – 30 V
ground
Between (2) – Left end 6 – 12 V
ground Right end 18 – 27 V
and standard 2) Connect T-adapter to connectors LS (female) and DPC2B
state harness
2 Wiring harness between LS (female) (2) – Resis-
DPC2B (female) (12) tance
contact)
Wiring harness between LS (female) (3) – Resis-
Max. 1 z
ground (ER1) tance
2) Disconnect connectors LS and DPC2B.
Short circuit of harness 3) Connect T-adapter to LS (female).
3
Resis-
between LS (female) (2) – DPC2B (female) Min. 1 Mz
tance
(12)
HD325-7, HD405-7 37
38 HD325-7, HD405-7
E-13 Emergency steering does not operate 1

Trouble (1) When the steering pomp stops operating, it does not operate with auto.
Related
• Check that the parking brake is released.
information

2) Connect T-adapter to B17 (male)
Defective parking brake
2 switch Resis-
PSWR (male) Parking brake operations
(internal defective contact) tance
Released (CLOSE) Max. 1 z
Between (1) – (2)
Operated (OPEN) Min. 1 Mz
2) Connect T-adapter to H01 (male)
Defective emergency oil
3 pressure switch Resis-
H01 (male) Steering pump
(internal defective contact) tance
Operated (OPEN) Min. 1 Mz
Between (A) – (B)
Stopped (CLOSE) Max. 1 z
2) Insert T-adapter in connector EM.
3) Turn parking brake ON.
1) Between EM (female) (3) – ground Voltage 20 – 30 V
Defective emergency 2) Between EM (female) (5) – ground Voltage 20 – 30 V
4
steering timer Turn starting switch OFF.
Possible causes
and standard Resis-
value in normal 3) Between EM (female) (1) – ground Max. 1 z
tance
state
• When the voltage of the above 1) is within the range and 2) is
out of range, the timer is defective.
• If the voltage of the above 1) is defective, troubleshooting cause 7.
2) Turn parking brake ON.
1) Between relay terminal (70) – ground Voltage 20 – 30 V
Defective emergency 1) Turn starting switch OFF.
5 2) Disconnect relay terminal (55).
steering relay
Resis-
4) Between relay terminal (55) – ground Max. 1 z
tance
• When the voltage of the above 1), 3) and 4) are within the
ranges, and 2) is out of range, the relay is defective.
• If the voltage of the above 1) is defective, troubleshooting cause
7.
Between motor terminal M and ground Voltage 20 – 30 V
Defective emergency 2) Disconnect motor terminals.
6
steering motor Resis-
Between motor terminal E and ground Max. 1 z
tance
• If no problem is found in above diagnoses, the steering motor is
defective.
HD325-7, HD405-7 39

2) Disconnect connectors PSWR, CJN, H01, EM, and BT3 (16)
and motor terminals.
Wiring harness between fuse BT-3 (16) – Resis-
Max. 1 z
Wiring harness between PSWR (female) (2) Resis-
Max. 1 z
– CJN (female) (4) tance
Wiring harness between CJA (female) (3) – Resis-
Max. 1 z
H01 (female) (C) tance
Disconnection in wiring Wiring harness between H01 (female) (A) – Resis-
Max. 1 z
harness EM (female) (3) tance
7
(Disconnection or defective Wiring harness between EM (female) (5) – Resis-
Max. 1 z
contact) relay terminal (56) tance
Wiring harness between relay terminal (73) Resis-
Max. 1 z
– motor terminal M tance
Wiring harness between EM (female) (1) – Resis-
Max. 1 z
ground tance
Wiring harness between motor terminal E – Resis-
Max. 1 z
ground tance
Possible causes Wiring harness between relay terminal (53) Resis-
– ground tance
value in normal
state Wiring harness between relay terminal (70) Resis-
Max. 1 z
– battery (+) tance
2) Disconnect connectors PSWR, CJN, H01, EM, and BT3 (16)
and motor terminals.
Resis-
between fuse BT-3 (16) – PSWR (female) Min. 1 Mz
tance
(1)
Resis-
between PSWR (female) (2) – CJN (female) Min. 1 Mz
tance
Short circuit (ground fault) of (4)
8 harness Between ground and wiring harness
Resis-
(Contact with ground circuit) between CJA (female) (3) – H01 (female) Min. 1 Mz
tance
(C)
Min. 1 Mz
between H01 (female) (A) – EM (female) (3) tance
Resis-
between EM (female) (5) – relay terminal Min. 1 Mz
tance
(56)
Resis-
between relay terminal (73) – motor terminal Min. 1 Mz
tance
M
40 HD325-7, HD405-7
Trouble (2) When the steering pump stops operating, it does not operate with manual.
Related • When it operates with auto (troubleshooting the symptom of failure (1) first, if it does not operate
information with auto), check that the parking brake is released.

If fuse BT2 (26) is blown, it is highly possible that a defective har-
ness grounding has occurred in the circuit.
2) Disconnect switch terminal and check switch unit.
Defective manual switch Manual switch Manual switch
2 Resistance
(internal defective contact) terminal operation
Between ST1 – ST2 Switch (pressed) Max. 1 z
(Switch unit) Switch (not pressed) Min. 1 Mz
2) Disconnect BT2 (26) and J02.
Possible causes 3) Connect T-adapter to J02 (female)
and standard
harness Wiring harness between BT2 (26) – manual Resis-
value in normal 3 Max. 1 z
(Disconnection or defective switch terminal ST1 tance
state
contact) Wiring harness between manual switch ter-
Resis-
minal ST2 – J02 (female) (13) (to branched Max. 1 z
tance
point)
2) Disconnect BT2 (26) and J02.
3) Connect T-adapter to J02 (female)
Short circuit (ground fault) of
harness Resis-
4 between BT2 (26) – manual switch terminal Min. 1 Mz
(Contact with ground tance
ST1
circuit)
Resis-
between manual switch terminal ST2 – J02 Min. 1 Mz
tance
(female) (13) (to branched point)
HD325-7, HD405-7 41
42 HD325-7, HD405-7
HD325-7, HD405-7 43

© 2007 KOMATSU
All Rights Reserved
44 HD325-7, HD405-7
SEN01193-01
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up
Troubleshooting of hydraulic and
mechanical system (H-mode)
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
HD325-7, HD405-7 1
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
2 HD325-7, HD405-7

a Troubleshooting Table and Related Circuit Diagram collectively carry the following information. Carry out
troubleshooting work after fully grasping their contents.
Trouble Phenomenon occurring on machine
Related
Information on the failure occurred as well as the troubleshooting
information
2
Possible causes Cause for presumed failure <Contents>
and standard (The attached No. is for fil-
value in normal • The standard values in normalcy by which to judge “Good“
3 ing and reference purpose
state or “No Good“ about presumed causes.
only. It does not stand for
any priority.) • References for making judgement of “good“ or “No Good“
4
HD325-7, HD405-7 3
H-1 Machine does not start 1

Trouble Machine does not start at any gear speed.
• Check that the transmission oil level is correct.
• If a failure code related to the input shaft speed sensor circuit or related to the machine is displayed,
Related
firstly troubleshooting the displayed code.
information
• Check that there is no defect in the drive shaft, etc.
• Check that the parking brake is completely released.

Defective power train pump The power train pump strainer is suspected to be clogged, check it
1
strainer directly.
Air sucked in at the suction Since the air can be suspected to be sucked in from the suction
2
side of the power train pump piping of the power train pump, check it directly.
a Prepare with the engine stopped and troubleshooting with
Defective power train pump engine running at low idle and high idle.
3
main relief valve Relief oil 3.43 ± 0.2 MPa
High idle
pressure {35.0 ± 2.0 kg/cm²}
a Prepare with the engine stopped and troubleshooting with the
Defective torque converter engine running at high idle.
4 oil pressure Torque converter inlet pressure 0.78 ± 0.1 MPa {8.0 ± 1.0 kg/cm²}
(relief valve) Torque converter outlet
0.59 ± 0.1 MPa {6.0 ± 1.0 kg/cm²}
pressure
5 Defective torque converter engine running at high idle.
Stall speed (power mode) 1,930 ± 100 rpm
Possible causes a Prepare with the engine stopped and troubleshooting with the
engine running at high idle.
and standard
value in normal Lo, Hi clutch ECMV output 1.62 ± 0.15 MPa
state pressure {16.5 ± 1.5 kg/cm²}
3rd, 4th clutch ECMV output 1.62 ± 0.15 MPa
Defective gear speed clutch pressure {16.5 ± 1.5 kg/cm²}
6
ECMV 1st, 2nd clutch ECMV output 2.98 ± 0.15 MPa
2.98 ± 0.15 MPa
R clutch ECMV output pressure
{30.0 ± 1.5 kg/cm²}
* A gear speed clutch operates using a combined operations of
two clutches; check the combination referring to Table 1.
• If the oil pressure is low in the item 6, leaks from the clutch seal
ring can be suspected.
7 Defective gear speed clutch
• If the oil pressures are within the ranges in the item 6, a slip of
the clutch can be suspected.
• If a defect is found in the item 3, disconnect the power train
pump outlet hose, crank the engine, and check if the oil comes
8 Defective power train pump
out.
• Judge by checking for presence of foreign materials.
Internally defective Since the transmission can be suspected to be internally defective,
9
transmission inspect the transmission directly.
4 HD325-7, HD405-7
Table 1
Operated clutches
Hi Lo 1st 2nd 3rd 4th R
R2 q q
R1 q q
N
F1 q q
Gear speed
F2 q q
F3 q q
F4 q q
F5 q q
F6 q q
F7 q q
HD325-7, HD405-7 5
H-2 Machine does not travel smoothly (hunting) 1

Trouble Machine does not travel smoothly (hunting).
Related • Check that the transmission oil level is correct.
information • If a failure code related to the machine is displayed, firstly troubleshooting the displayed code.

Defective power train pump Since the power train pump strainer can be suspected to be
1
strainer clogged, check it directly.
Air sucked in at the suction Since the air is potentially sucked in from the suction piping of the
2
side of the power train pump power train pump; visually check it.
Possible causes a Prepare with the engine stopped and troubleshooting with
and standard Defective power train pump engine running at low idle and high idle.
value in normal 3
state High idle
• If the oil pressure is low in the item 3, wear of the gear speed
clutch piston seal ring or wear of the ring groove can be sus-
4 Defective gear speed clutch pected.
the clutch can be suspected.
H-3 Lockup cannot be cancelled 1

Trouble Torque converter lockup cannot be cancelled.

Possible causes engine running at high idle.
Defective lockup solenoid
and standard 1
valve Lockup solenoid valve output 1.91 ± 0.15 MPa
value in normal
state pressure {19.5 ± 1.5 kg/cm²}
If the oil pressure is within the range in the item 1, a seizure of the
2 Defective lockup clutch
lockup clutch can be suspected.
6 HD325-7, HD405-7
H-4 Excessive shock when starting or shifting 1

Trouble Shock when starting or shifting is excessive.
Related
• If a failure code related to the machine is displayed, firstly troubleshooting the displayed code.
information

* There is some shock, but it is difficult to judge if the shock is
excessive or not, so judge that it is excessive in the following
Possible causes cases.
and standard • When it is apparent that the shock suddenly became severer
value in normal Defective gear speed clutch than before.
1
state ECMV
• The shock is severer compared with other machines of the same
class.
Since the operation of the gear speed clutch ECMV can be
suspected to be defective, check it directly.
HD325-7, HD405-7 7
H-5 Transmission does not shift up 1

Trouble Transmission does not shift up.
Related

1
High idle
Defective lockup solenoid engine running at high idle.
2
If the shit up operations take place when traveling down a slope,
3 Defective lockup clutch
a slip of the lockup clutch can be suspected.
Hi clutch ECMV output 1.62 ± 0.15 MPa
Possible causes Lo clutch ECMV output 1.62 ± 0.15 MPa
and standard pressure {16.5 ± 1.5 kg/cm²}
value in normal
state 1st clutch ECMV output 2.94 ± 0.15 MPa
Defective gear speed clutch 2nd clutch ECMV output 2.94 ± 0.15 MPa
4 pressure {30.0 ± 1.5 kg/cm²}
ECMV
3rd clutch ECMV output 1.62 ± 0.15 MPa
4th clutch ECMV output 1.62 ± 0.15 MPa
2.94 ± 0.15 MPa
{30.0 ± 1.5 kg/cm²}
Defective gear speed clutch
5 pected.
piston
• If the oil pressure is within the range in the item 4, a slip of the
gear speed clutch piston can be suspected.
Table 1
Operated clutches
R2 q q
R1 q q
N
F1 q q
Gear speed
F2 q q
F3 q q
F4 q q
F5 q q
F6 q q
F7 q q
8 HD325-7, HD405-7
H-6 Machine lacks power or speed when traveling 1

Trouble (1) When abnormality is present at all gear speeds (when traveling in lockup range).
Related • If a failure code related to the machine is displayed, firstly troubleshooting the displayed code.
information • Check that the parking brake is completely released and also check for dragging of the retarder brake.
• Check that the tire inflation pressure is proper.

1
strainer directly.
2
3
High idle
Possible causes Defective lockup solenoid engine running at high idle.
and standard 4
value in normal
state
• If the oil pressure is low in the item 4, wear of the lockup clutch
piston seal ring or wear of the ring groove can be suspected.
5 Slip of lockup clutch
the lockup clutch piston can be suspected.
If a defect is found in the item 3, the power train pump can be
6 Defective power train pump suspected to be defective.
Check for aluminum worn powder etc. residing on the line filter.
If no problem is found in item 1 through 6, measure the torque
converter stall speed (in the power mode: 1,930 ± 100 rpm). If it is
7 Decrease of engine output
below the standard value, the deterioration of the engine unit per-
formance can be suspected.
Trouble (2) When machine lacks power or speed while traveling in torque converter range.
information • Check for oil leaking from the piping to the outside.
• Check that the parking brake is completely released and also check for dragging of the retarder brake.

1
High idle
Possible causes a Prepare with the engine stopped and troubleshooting with the
and standard engine running at high idle.
value in normal Defective torque converter
state 2 Torque converter inlet pressure 0.78 ± 0.1 MPa {8.0 ± 1.0 kg/cm²}
oil pressure
Torque converter outlet pres-
0.59 ± 0.1 MPa {6.0 ± 1.0 kg/cm²}
sure
3 Defective torque converter engine running at high idle.
Stall speed (power mode) 1,930 ± 100 rpm
HD325-7, HD405-7 9
Trouble (3) Machine lacks speed or power when traveling in certain gear speeds.

Lo clutch ECMV output 1.62 ± 0.15 MPa
1st clutch ECMV output 2.94 ± 0.15 MPa
2nd clutch ECMV output 2.94 ± 0.15 MPa
Defective gear speed clutch pressure {30.0 ± 1.5 kg/cm²}
1
Possible causes ECMV
and standard
value in normal
state 4th clutch ECMV output 1.62 ± 0.15 MPa
2.94 ± 0.15 MPa
{30.0 ± 1.5 kg/cm²}
• It can be also diagnosed by replacing the ECMV.
gear speed clutch can be suspected.
Table 1
Operated clutches
R2 q q
R1 q q
N
F1 q q
Gear speed
F2 q q
F3 q q
F4 q q
F5 q q
F6 q q
F7 q q
10 HD325-7, HD405-7
H-7 Time lag is excessive when starting or shifting gear 1

Trouble Time lag is excessive when starting or shifting gear.
Related
• Check for oil leaking from the piping to the outside.

Defective power train pump Since the power train pump strainer can be suspected to be
1
strainer clogged, check it directly.
Air sucked in at the suction Since the air is potentially sucked in from the suction piping of the
2
side of the power train pump power train pump; visually check it.
3
High idle
Lo clutch ECMV output 1.62 ± 0.15 MPa
1st clutch ECMV output 2.94 ± 0.15 MPa
Possible causes pressure {30.0 ± 1.5 kg/cm²}
and standard 2nd clutch ECMV output 2.94 ± 0.15 MPa
value in normal Defective gear speed clutch pressure {30.0 ± 1.5 kg/cm²}
4
state ECMV
4th clutch ECMV output 1.62 ± 0.15 MPa
2.94 ± 0.15 MPa
{30.0 ± 1.5 kg/cm²}
• It can be also diagnosed by replacing the ECMV.
gear speed clutch can be suspected.
• If a defect is found in the item 3, the power train pump can be
6 Defective power train pump suspected to be defective.
Table 1
Operated clutches
R2 q q
R1 q q
N
F1 q q
Gear speed
F2 q q
F3 q q
F4 q q
F5 q q
F6 q q
F7 q q
HD325-7, HD405-7 11
H-8 Torque converter oil temperature is high 1

Trouble Torque converter oil temperature is high.
Related
information • If the oil temperature goes up when the torque converter is stalled and goes down when the trans-
mission is returned to the neutral position, the machine is normal and overload operation is a cause
of the problem.

1
strainer directly.
2
Defective power train pump
3 The filter can be suspected to be clogged; visually check it.
line filter
4
Possible causes High idle
and standard pressure {35.0 ± 2.0 kg/cm²}
value in normal • If a defect is found in the item 4, the power train pump can be
state 5 Defective power train pump suspected to be defective.
6
relief valve
Torque converter inlet pressure 0.78 ± 0.1 MPa {8.0 ± 1.0 kg/cm²}
7 Defective torque converter Torque converter inlet pressure 0.78 ± 0.1 MPa {8.0 ± 1.0 kg/cm²}
Torque converter outlet
0.59 ± 0.1 MPa {6.0 ± 1.0 kg/cm²}
pressure
12 HD325-7, HD405-7
H-9 Torque converter oil pressure is low 1

Trouble Torque converter oil pressure is low.
Related
information
• Check for oil leaking from the piping to the outside.

1
strainer directly.
2
3
High idle
Possible causes
and standard • If a defect is found in the item 3, the power train pump can be
value in normal 4 Defective power train pump suspected to be defective.
state Check for aluminum worn powder etc. residing on the line filter.
5
relief valve
Torque converter inlet pressure 0.78 ± 0.1 MPa {8.0 ± 1.0 kg/cm²}
6 Defective torque converter Torque converter inlet pressure 0.78 ± 0.1 MPa {8.0 ± 1.0 kg/cm²}
Torque converter outlet
0.59 ± 0.1 MPa {6.0 ± 1.0 kg/cm²}
pressure
HD325-7, HD405-7 13
H-10 Front brake is ineffective 1

Trouble Front brake is ineffective.
Related
information

Air sucked in at the suction
Since the air can be suspected to be sucked in from the suction
1 side of the brake control
piping of the brake control pump, check it directly.
pump
a Prepare with the engine stopped and measure with the engine
running at high idle.
Defective accumulator 14.2 (+0.49/0) MPa
2 Charge valve cut-in pressure
charge valve {145 (+5.0/0) kg/cm²}
20.6 (+0.98/0) MPa
Charge valve cut-out pressure
{210 (+10/0) kg/cm²}
• If the brake becomes ineffective as soon as the engine is
Possible causes
Defective accumulator for stopped, the gas charged in the accumulator is insufficient.
and standard 3
front brake * [Reference] Charged gas pressure: 4.4 ± 0.15 MPa {45 ± 1.5 kg/
value in normal
state cm²}
4 Defective front brake valve
Brake actuat- Brake pedal 18.4 (+0.76/–1.52) MPa
ing pressure operated {187.5 (+7.5/–16.5) kg/cm²}
When the initial response time of brake system is excessively long
Defective front brake slack
5 or excess pedal effort is required to obtain the specific braking
adjuster
force, the slack adjuster can be suspected to be defective.
• If the oil pressure is low in the item 4, a seal ring or ring groove
can be suspected to be defective.
6 Defective front wheel brake
• If the oil pressures are within the range in the item 4, a slip of the
brake disc is suspected.
14 HD325-7, HD405-7
H-11 Rear brake is ineffective 1

Trouble Rear brake is ineffective.
Related
information

1 side of the brake control
piping of the brake control pump, check it directly.
pump
Defective accumulator 14.2 (+0.49/0) MPa
2 Charge valve cut-in pressure
charge valve {145 (+5.0/0) kg/cm²}
20.6 (+0.98/0) MPa
Charge valve cut-out pressure
{210 (+10/0) kg/cm²}
• If the brake becomes ineffective as soon as the engine is
Defective accumulator for stopped, the gas charged in the accumulator is insufficient.
3
rear brake * [Reference] Charged gas pressure: 4.4 ± 0.15 MPa {45 ± 1.5 kg/
Possible causes cm²}
and standard
value in normal a Prepare with the engine stopped and measure with the engine
state running at high idle.
4 Defective rear brake valve
Brake actuat- Brake pedal
4.9 ± 0.49 MPa {50 ± 5 .0 kg/cm²}
ing pressure operated
Defective rear brake retarder running at high idle.
5
pressure reducing valve Brake actuat- Retarder lever 4.21 ± 0.29 MPa
ing pressure operated {43 ± 3.0 kg/cm²}
When the initial response time of brake system is excessively long
Defective rear brake slack
6 or excess pedal effort is required to obtain the specific braking
adjuster
force, the slack adjuster can be suspected to be defective.
• If the oil pressure is low in the item 4 or 5, a seal ring or ring
groove can be suspected to be defective.
7 Defective rear wheel brake
• If the oil pressures are within the range in the item 4 and 5, a slip
of the brake disc is suspected.
HD325-7, HD405-7 15
H-12 Steering wheel is heavy 1

Trouble Steering wheel is heavy.
• Check that the oil level in the hydraulic tank is correct.
• Check that the steering wheel play is correct (less than 150 mm).
Related
information • Check tha the hinge pin, etc. are greased sufficiently.
• Adjust the tire inflation pressure to the proper value before troubleshooting.
[Standard tire] 18.00-33-32PR × 2
(0.56 ± 0.01 MPa {5.57 ± 0.1 kg/cm²})

1 side of the steering and work
side of the steering and work equipment pump, check it directly.
equipment pump
Defective steering and work Since the steering and work equipment pump strainer is potentially
2
equipment pump strainer clogged, visually check it.
Defective relief valve of engine running at high idle.
3
demand valve Relief oil pressure (cylinder 20.6 (+0.98/0) MPa
stroke end) {210 (+10/0) kg/cm²}
Possible causes 4 Defective steering valve
and standard Relief oil pressure (cylinder 20.6 (+0.98/0) MPa
value in normal stroke end) {210 (+10/0) kg/cm²}
state Defective operation of If the oil pressure is within the range, the operation of the demand
5
demand valve spool valve spool can be suspected to be defective: check it directly.
Relief oil pressure (cylinder 20.6 (+0.98/0) MPa
6 Defective steering cylinder
When the oil pressure is low, disconnect the hydraulic hose in the
steering cylinder head side and relieve the pressure at the stroke
end. If the oil comes out from the cylinder side, the cylinder piston
ring is defective.
If the oil pressure is low in the item 3 or 4, the steering and work
Defective steering and work
7 equipment pump can be suspected to be defective.
equipment pump
16 HD325-7, HD405-7
H-13 Steering wheel does not work 1

Trouble Steering wheel does not work.
information • Check that the steering wheel play is correct (less than 150 mm).
• Check that the hinge pin, etc. are greased fufficiently.

If the dump body also does not work, the PTO can be suspected to
1 Defective PTO
be defective.
2 side of the steering and work
equipment pump
Defective steering and work Since the steering and work equipment pump strainer is potentially
3
equipment pump strainer clogged, visually check it.
4
demand valve Relief oil pressure (cylinder 20.6 (+0.98/0) MPa
Possible causes
and standard 5 Defective steering valve
value in normal Relief oil pressure (cylinder 20.6 (+0.98/0) MPa
state stroke end) {210 (+10/0) kg/cm²}
Defective operation of If the oil pressure is within the range, the operation of the demand
6
demand valve spool valve spool can be suspected to be defective: check it directly.
7 Defective steering cylinder
ring is defective.
If the oil pressure is low in the item 4 or 5, the steering and work
Defective steering and work
8 equipment pump can be suspected to be defective.
equipment pump
HD325-7, HD405-7 17
H-14 Steering wheel vibrates 1

Trouble Steering wheel vibrates.
Related • Check that the oil level in the hydraulic tank is correct.

1 Defective oil Check for deterioration of oil.
Possible causes stroke end) {210 (+10/0) kg/cm²}
and standard 2 Defective steering cylinder
value in normal
state
ring is defective.
If relief pressure (demand valve relief pressure) of steering circuit
Defective crossover relief is normal and piston rings of hydraulic cylinder checked in Cause 2
3
valve is also normal, "crossover relief valve" may be defective. (Replace
valve.)
18 HD325-7, HD405-7
H-15 Dump body lifting speed is slow 1

Trouble When lifting dump body, the speed is slow and the power is insufficient.
Related
information
• Check that the dump lever moves smoothly.

1 side of the work equipment
and steering pump
Defective work equipment The work equipment and steering pump strainer is potentially
2
and steering pump strainer clogged, visually check it.
3
demand valve Relief oil pressure (steering 20.6 (+0.98/0) MPa
cylinder stroke end) {210 (+10/0) kg/cm²}
Defective dump EPC valve engine running at high idle.
4 relief valve (dump pilot pres- 3.4 ± 0.49 MPa {35 ± 5 kg/cm²}
sure) Operate dump lever to
“raise“ or “lower“ position. (Reference: low idle)
2.6 ± 0.49 MPa {27 ± 5 kg/cm²}
If the oil pressure is low in the item 4, the operation of the dump
Possible causes Defective operation of dump
5 EPC valve can be suspected to be defective; visually check the
and standard EPC valve
valve.
value in normal
If the oil pressure is low in the item 4, the pilot pump for the dump
state Defective pilot pump for
6 EPC valve circuit can be suspected to be defective; check it
dump EPC valve
directly.
Defective hoist valve relief engine running at high idle.
7
valve Relief oil pressure (dump 20.6 (+0.98/0) MPa
cylinder raise stroke end) {210 (+10/0) kg/cm²}
If the oil pressure does not reach the standard value in the item 7,
Defective operation of the
8 the operation of the hoist valve main spool can be suspected to be
hoist valve main spool
defective. (Visually check the spool.)
9 Defective dump cylinder
dump cylinder head side and relieve the pressure at the raise
stroke end. If the oil comes out from the cylinder side, the cylinder
piston ring is defective.
HD325-7, HD405-7 19
H-16 Dump body does not work 1

Trouble Dump body does not work.
Related
information
• Check that the dump lever moves smoothly.

If the steering also does not work, the PTO can be suspected to be
1 Defective PTO
defective.
2 side of the work equipment
and steering pump
Defective work equipment The work equipment and steering pump strainer is potentially
3
and steering pump strainer clogged, visually check it.
4
demand valve Relief oil pressure (steering 20.6 (+0.98/0) MPa
cylinder stroke end) {210 (+10/0) kg/cm²}
Defective dump EPC valve engine running at high idle.
5 relief valve (dump pilot pres- 3.4 ± 0.49 MPa {35 ± 5 kg/cm²}
sure) Operate dump lever to
“raise“ or “lower“ position. (Reference: low idle)
2.6 ± 0.49 MPa {27 ± 5 kg/cm²}
Possible causes If the oil pressure is low in the item 5, the operation of the dump
and standard Defective operation of dump
6 EPC valve can be suspected to be defective; visually check the
value in normal EPC valve
valve.
state
If the oil pressure is low in the item 5, the pilot pump for the dump
Defective pilot pump for
7 EPC valve circuit can be suspected to be defective; check it
dump EPC valve
directly.
Defective hoist valve relief engine running at high idle.
8
valve Relief oil pressure (dump 20.6 (+0.98/0) MPa
cylinder raise stroke end) {210 (+10/0) kg/cm²}
If the oil pressure does not reach the standard value in the item 8,
Defective operation of the
9 the operation of the hoist valve main spool can be suspected to be
hoist valve main spool
defective. (Visually check the spool.)
dump cylinder head side.
If the oil comes out from the cylinder side at the raise stroke end,
the cylinder piston ring is defective.
20 HD325-7, HD405-7
H-17 Excessive hydraulic drift of dump body 1

Trouble Hydraulic drift of dump body is excessive.
Related
information

a Raise the dump body and troubleshooting with the engine
stopped.
Defective oil tightness of Raise the dump body and disconnect the hydraulic hose in the
Possible causes 1
hoist valve main spool dump cylinder head side.
and standard
value in normal If the oil flows out from the cylinder side, the oil tightness of the
state spool is defective.
Raise the dump body and disconnect the hydraulic hose in the
dump cylinder head side.
If the oil does not flow out from the cylinder side, the cylinder piston
ring is defective.
HD325-7, HD405-7 21

© 2007 KOMATSU
All Rights Reserved
22 HD325-7, HD405-7
SEN01194-01
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up
Troubleshooting of mechanical system
(S-mode)
Method of using troubleshooting charts .......................................................................................................... 4
S-1 Starting performance is poor .................................................................................................................... 8
S-2 Engine does not start ............................................................................................................................. 10
S-3 Engine does not pick up smoothly.......................................................................................................... 14
S-4 Engine stops during operations .............................................................................................................. 15
S-5 Engine does not rotate smoothly ............................................................................................................ 16
S-6 Engine lacks output (or lacks power) ..................................................................................................... 17
S-7 Exhaust gas color is black (incomplete combustion).............................................................................. 18
S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 20
S-9 Oil becomes contaminated quickly ......................................................................................................... 21
S-10 Fuel consumption is excessive............................................................................................................. 22
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 23
S-12 Oil pressure drops ................................................................................................................................ 24
S-13 Oil level rises (Entry of coolant/fuel)..................................................................................................... 26
HD325-7, HD405-7 1
S-14 Coolant temperature becomes too high (overheating) ......................................................................... 28

S-15 Abnormal noise is made ....................................................................................................................... 29
S-16 Vibration is excessive ........................................................................................................................... 30
2 HD325-7, HD405-7
HD325-7, HD405-7 3
Method of using troubleshooting charts 1

The troubleshooting chart consists of the "questions", "check items", "causes", and "troubleshooting" blocks.
The questions and check items are used to pinpoint high probability causes by simple inspection or from
phenomena without using troubleshooting tools.
Next, troubleshooting tools or direct inspection are applied to check the narrowed causes in order from the
most probable one to make final confirmation according to the troubleshooting procedure.
Questions:
Items to be drawn from the user or operator. They correspond to A and B in the chart on the right.
The items in A are basic ones. The items in B can be drawn from the user or operator, depending on their
level.
Check items:
Simple check items used by the serviceman to narrow the causes. They correspond to C in the chart on the
right.
Causes:
Items to be narrowed from the questions and check items.
The serviceman narrows down the probable causes from A, B, and C.
Troubleshooting:
Items used to find out the true cause by verifying the narrowed causes finally in order from the most probable
one by applying troubleshooting tools or direct inspection.
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, and w.
E: Causes to be referred to for questions and check items
Q: Causes related to questions and check items
w: Causes highly probable among ones marked with Q
a When narrowing the "causes", apply the items marked with w before those marked with Q.
When narrowing the "causes", do not apply the items marked with E (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
4 HD325-7, HD405-7
HD325-7, HD405-7 5
<Example of troubleshooting> Exhaust gas color is black (incomplete combustion)

Let us assume that a trouble of "Exhaust gas color is black" occurred and we checked the [Questions] and
[Check items] and found the following 3 items to be the causal symptoms; [Color of exhaust gas gradually
became black], [Power was lost gradually], and [Dust indicator is red].
6 HD325-7, HD405-7
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 6 items in
the [Causes] sections.
The method of pinpointing the [cause] from the causal relationship and approaching the [troubleshooting] is
explained according to Step 1 — Step 3 shown below.
HD325-7, HD405-7 7
S-1 Starting performance is poor 1

General causes why starting performance is poor Causes
• Defective electrical system
Cracked EGR cooler (Coolant in exhaust pipe)

• Insufficient supply of fuel
Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap
Defective alternator (generator section)

Defective alternator (regulator section)
• Insufficient intake of air
Defective contact of valve, vale seat
Stuck, seized supply pump plunger
Defective intake air heater system

Clogged feed pump gauze filter
• Improper selection of fuel
Defective, deteriorated battery

Clogged air cleaner element
Clogged fuel filter, element

Worn piston ring, cylinder
• Coolant in exhaust pipe
a The common rail fuel injection system (CRI) recognizes the fuel
Defective injector
injection timing electrically. Accordingly, even if the starting opera-
tion is carried out, the engine may not start until the crankshaft
revolves 2 turns at maximum. This phenomenon does not indicate
a trouble, however.
Confirm recent repair history

Degree of use of
machine
Operated for long period EE EE E
Became worse gradually QQww QQ
Starting performance
w w
Questions
Engine starts easily when warm

Non-specified fuel is being used QQQQ
Replacement of filters has not been carried out according to Operation and Mainte-
nance Manual w wwQQ
Engine oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does not
indicate normally (if monitor is installed) w
During operation, charge level monitor indicates abnormal charge ww
Dust indicator is red w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w Q
When priming pump is operated, it makes no reaction or it is heavy wQQ
Starting motor cranks engine slowly Q w
If air bleeding plug of fuel filter is removed, fuel does not
While engine is
flow out ww
cranked with starting
w
Check items
motor If spill hose from injector is disconnected, little fuel spills

When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low w
Engine does not pick up smoothly and combustion is irregular QQ w
There is hunting from engine (rotation is irregular) QwQQ
Blow-by gas is excessive w
Inspect air cleaner directly q
When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows
out (*1) q
When compression pressure is measured, it is found to be low qq
When air is bled from fuel system, air comes out q
Troubleshooting
Inspect fuel filter, strainer directly q

Inspect feed pump gauze filter directly q
Carry out troubleshooting according to "No-pressure feed by supply pump (*2)" q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change q
When starting switch is turned to HEAT, intake air heater mount does not become
warm q
Is voltage (27.5 – 29.5V) between alternator terminal R and terminal E Yes q
with engine at low idle? No q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
8 HD325-7, HD405-7
*1: EGR cooler outlet gas piping

Loosen 4 mounting bolts (1) of the EGR cooler outlet gas piping and check that the coolant flows out. A
little condensate produced from cooled exhaust gas may flow out. If it is colorless and transparent, how-
ever, it is not a problem.
*2: Code [CA559] and code [CA2249]
HD325-7, HD405-7 9
S-2 Engine does not start 1

a) Engine does not turn Causes
Cracked EGR cooler (Coolant in exhaust pipe)

General causes why engine does not turn
Defective starting motor (safety relay section)

• Internal parts of engine seized
Defective connection of battery terminal
Defective starting motor (motor section)

o See "S-4 Engine stops during operations."
Defective or deteriorated battery

• Water hammer caused by coolant which entered cylinder
Defective starting circuit wiring

Broken flywheel ring gear
• Defective electrical system
Defective starting switch

Defective battery relay
Defective power train

• Defective power train

Degree of use of
Questions
machine
Operated for long period EEE
Condition of horn when Horn does not sound Q Q w
starting switch is turned
ON Horn volume is low w
Battery electrolyte is low w
Battery terminal is loose w
When starting switch is turned ON, there is no operating sound from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q w
Check items
Speed of rotation is low Q w

When starting switch is
turned to START, start- Makes grating noise w w
ing pinion moves out, Soon disengages again w
but
Makes rattling noise and does not turn w Q Qw
When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out (*1). q
Inspect flywheel ring gear directly q Carry out troubleshooting on H mode

Carry out troubleshooting on E mode
Troubleshooting
There is not voltage (20 – 30 V) between battery relay terminal B and

terminal E
q
When terminal B and terminal C of starting switch are connected,

Turn starting switch
engine starts
q
OFF, connect cord, and
carry out troubleshoot- When terminal B and terminal C at safety relay outlet are connected,
ing at ON engine starts
q
Even if terminal B and terminal C at safety relay outlet are connected,

engine does not start
q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy — —
10 HD325-7, HD405-7

HD325-7, HD405-7 11
b) Engine turns but no exhaust smoke comes out Causes
Defective operation of overflow valve (Does not close)

General causes why engine turns but no exhaust smoke comes out
• Fuel is not being supplied

Wrong connection of supply pump PCV

• Supply of fuel is extremely small
Seized, abnormally worn feed pump
Defective operation of flow damper

Broken supply pump shaft, key

• Improper selection of fuel (particularly in winter)
Defective supply pump PCV

Clogged fuel filter element
Insufficient fuel in tank
Defective fuel injector

Use of improper fuel
Degree of use of
Questions
machine
Operated for long period EEE
Exhaust smoke suddenly stopped coming out (when starting again) wQwww EE
Replacement of filters has not been carried out according to Operation and Main-
tenance Manual
ww E Q
When fuel tank is inspected, it is found to be empty w
Air breather hole of fuel tank cap is clogged Qw
Rust and water are found when fuel tank is drained QQQ QQ
When fuel filter is removed, there is not fuel in it w w
Fuel is leaking from fuel piping w
Check items

While engine is If air bleeding plug of fuel filter is removed, fuel does not flow
Q Q wQ
cranked with start- out
ing motor If spill hose from injector is disconnected, little fuel spills Q wwww Q
Inspect fuel filter directly q
q
Troubleshooting
Inspect feed pump gauze filter directly

Inspect feed pump directly q
Carry out troubleshooting according to "No-pressure feed by supply pump (*1)" qq q q
Carry out troubleshooting according to "Abnormality in PCV1 (*2) or Abnormality in
PCV2 (*3)"
q
Inspect overflow valve directly q
Engine can be started in reduced cylinder mode qq
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Clean
Add

12 HD325-7, HD405-7
c) Exhaust smoke comes out but engine does not start (fuel is being injected) Causes
Worn dynamic valve system (Valve, rocker lever, etc.)
Defective coolant temperature sensor, wiring harness

General causes why exhaust smoke comes out but engine does not start
Leaking or clogged fuel system, entry of air

• Lack of rotating force due to defective electrical system

Defective intake air heater system

Clogged injector, defective spray
Worn piston ring, cylinder liner
Defective, deteriorated battery

Clogged fuel filter, strainer

Use of improper fuel

Degree of use of machine Operated for long period E EE E
Suddenly failed to start w w Q
Questions
Non-specified fuel is being used QQ

Replacement of filters has not been carried out according to Operation and Maintenance
Manual
w ww
Engine oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does not indicate
normally
w
Air breather hole of fuel tank cap is clogged Q
Rust and water are found when fuel tank is drained ww
When fuel filter is removed, there is not fuel in it w
Starting motor cranks engine slowly w
When engine is cranked, abnormal sound is generated around cylinder head w
Check items
While engine is cranked If air bleeding plug of fuel filter is removed, fuel does not flow out Q ww
with starting motor, If spill hose from injector is disconnected, little fuel spills w
When exhaust manifold is touched immediately after starting engine, temperature of some
cylinders is low
w

Inspect dynamic valve system directly q
When compression pressure is measured, it is found to be low q
Troubleshooting

When injector unit is tested, spray condition is bad q
Coolant temperature gauge does not indicate normally (if coolant temperature gauge is
installed)
q
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
Clean
Clean
Clean
Clean
Clean
HD325-7, HD405-7 13
S-3 Engine does not pick up smoothly 1

General causes why engine does not pick up smoothly Causes
Defective operation of flow damper (Large leakage from injector)

Seized turbocharger, interference of turbocharger

• Defective condition of fuel spray


Defective contact of valve and valve seat
• Controller is controlling in derate mode (limiting injection rate (output)
Clogged injector, defective spray

because of an error in electrical system)


Improper valve clearance
• EGR valve is stuck open
(There is much EGR gas and intake of air is insufficient)
Stuck EGR valve

Degree of use of
Operated for long period EEE E EE
machine
Questions
Engine pick-up suddenly became worse Q w Q Q Q

Non-specified fuel is being used w w w w
w w w
nance Manual
Oil must be added more frequently w
Rust and water are found when fuel tank is drained w w
When priming pump is operated, it makes no reaction or it is heavy w Q Q
Q w
some cylinders is low
Color of exhaust Blue under light load w
Check items
gas Black w Q w w
When engine is cranked, interference sound is generated around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w w
There is hunting from engine (rotation is irregular) Q Q w Q

Carry out troubleshooting according to "Abnormality in EGR valve servo (*1)" q
When compression pressure is measured, it is found to be low q q
Troubleshooting
Inspect valve clearance directly q

When turbocharger is rotated by hand, it is found to be heavy q
q q
not change
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
Clean
Clean
Clean
Clean

14 HD325-7, HD405-7
S-4 Engine stops during operations 1

General causes why engine stops during operations Causes
Broken dynamic valve system (valve, rocker arm, etc.)
Broken auxiliary equipment (pump, compressor, etc.)

• Seized parts inside engine

• There is overheating
Broken, seized piston, connecting rod

Broken, seized crankshaft bearing
• Defective power train
Broken supply pump shaft, key

Leaking, clogged fuel piping
Broken, seized feed pump

Broken, seized gear train
Defectiv power train

Degree of use of machine Operated for long period EE
Abnormal noise was heard and engine stopped suddenly w w w w Q w Q w w
Condition when engine Engine overheated and stopped w Q Q
Questions
stopped Engine stopped slowly w Q Q

There was hunting and engine stopped w Q Q Q Q
Non-specified fuel is being used Q Q Q Q
w w
nance Manual
Fuel level monitor indicates low level (if monitor is installed) w
Rust and water are found when fuel tank is drained w w
Metal particles are found when oil is drained w w Q Q
Check items
Does not turn at all w w

When engine is cranked Turns in opposite direction w
by hand Moves by amount of gear backlash w w
Supply pump shaft does not turn w
Engine turns, but stops when load is applied to machine w
Inspect piston, connecting rod directly q
Inspect crankshaft bearing directly q

Carry out troubleshooting on H mode
Troubleshooting
Inspect gear train directly q
Inspect feed pump directly q
Carry out troubleshooting according to "No-pressure feed by supply pump (*1)" q q
Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is removed
q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy —
Add
HD325-7, HD405-7 15
S-5 Engine does not rotate smoothly 1

General causes why engine does not rotate smoothly Causes
Defective operation of flow damper (Large leakage from injector)

• Air in fuel system
• Defective speed sensor (Error at degree that it is not indicated)
• Defective EGR valve
Clogged injector, defective spray (dirt in injector)
Defective Bkup speed sensor, wiring harness

Defective Ne speed sensor, wiring harness
• Defective bypass valve

Defective operation of bypass valve
Defective operation of EGR valve

Low setting of low idle speed

Degree of use of machine Operated for long period EE EE
Occurs at a certain speed range Q Q Q Q Q
Questions
Occurs at low idle w Q Q Q Q Q Q Q

Condition of hunting
Occurs even when speed is raised Q Q Q Q Q
Occurs on slopes w Q Q
w w
nance Manual
Check items
Rust and water are found when fuel tank is drained Q Q

Carry out troubleshooting according to "Abnormality in bypass valve servo (*2)" q
Troubleshooting

q q
not change
Carry out troubleshooting according to "Abnormality in engine Ne speed sensor
q
(*3)"
Carry out troubleshooting according to "Abnormality in engine Bkup speed sensor
q
(*4)"
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Remedy
Clean
Add

*3: Code [CA689]
*4: Code [CA778]
16 HD325-7, HD405-7
S-6 Engine lacks output (or lacks power) 1

General causes why engine lacks output Causes
Air leakage from air intake piping, air linkage from aftercooler
Defective installation of charge pressure sensor (air leakage)

Defective fuel temperature sensor, wiring harness

Defective charge pressure sensor, wiring harness
Clogged injector, defective spray (dirt in injector)

Defective drive of injector (signal, solenoid)


Leaking, clogged fuel piping

o See "S-14 Coolant temperature becomes too high (Overheating)"

• Controller is controlling in derate mode (limiting injection rate (out-
put) because of a trouble in electrical system)

Degree of use of
machine
Operated for long period E E E E E
Q Q Q Q
Questions
Suddenly
Power was lost
Gradually Q Q Q Q Q Q Q
Non-specified fuel is being used Q Q
nance Manual
w
Engine oil must be added more frequently Q Q Q
Dust indicator is red (if indicator is installed) w
Output becomes insufficient after short stop of operation w
Black w w
Color of exhaust gas
Blue under light load w
w
Check items

High idle speed is too low Q
High idle speed under no load is normal, but speed suddenly drops when load is
applied
w w Q
Engine does not pick up smoothly and combustion is irregular w Q Q w
There is hunting from engine (rotation is irregular) Q Q Q Q
Inspect air intake piping directly q
When boost pressure is measured, it is found to be low q q q
Troubleshooting

not change
q q
Inspect boost pressure sensor mount directly q
Carry out troubleshooting according to "Abnormality in charge pressure sensor (*2)" q
Carry out troubleshooting according to "Abnormality in fuel temperature sensor (*3)" q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Clean
Remedy

HD325-7, HD405-7 17
S-7 Exhaust gas color is black (incomplete combustion) 1

General causes why exhaust gas color is black Causes
Leakage of air between turbocharger and cylinder head


• Excessive injection of fuel
Clogged fuel spill piping (on cylinder head side)



Clogged EGR gas pressure piping
Improper fuel injection pressure

o See "S-14 Coolant temperature becomes too high (Overheating)"
Improper fuel injection timing

Crushed, clogged muffler
Abnormally worn injector

Clogged, seized injector
• Controller is controlling in derate mode (limiting injection rate
(output) because of an error in electrical system)
Stuck EGR valve

• EGR valve is stuck open (There is much EGR gas and intake of air
is insufficient)
• EGR gas pressure piping is clogged (Exhaust gas is mixed in intake
air during acceleration and deceleration)
Degree of use of
machine
Suddenly became black w Q Q Q Q
Questions
Color of exhaust gas Gradually became black w w Q Q Q

Blue under light load w
Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Air leaks between turbocharger and cylinder head, clamp is loosened w
Engine is operated in low-temperature mode at normal temperature Q Q Q
Q w
Check items

Torque converter stall speed or pump relief speed is high (Fuel is injected excessively) Q Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q Q w
If spill hose from injector is disconnected, abnormally much fuel spills w
When turbocharger is rotated by hand, it is found to be heavy q
Check EGR gas pressure piping directly (*2) q
Troubleshooting

When muffler is removed, exhaust color improves q
Carry out troubleshooting according to "No-pressure feed by supply pump (*3)" q q
not change
q
Inspect fuel spill piping (on cylinder head side) directly q
Carry out troubleshooting according to "Abnormality in coolant temperature sensor
(*4)"
q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Remedy
Clean
18 HD325-7, HD405-7

*2: EGR gas pressure pipings
Remove 2 EGR gas pressure pipings (2) and check their inside for clogging.

HD325-7, HD405-7 19
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1

General causes why oil consumption is excessive Causes
Turbocharger
• Abnormal consumption of oil
Oil leakage from oil pan, cylinder head, etc.

Worn, damaged valve (stem, guide, seal)
• Long-time operation of engine at low idle or high idle (Do not run
engine at idle for more than 20 minutes continuously)
Dust sucked in from intake system
Oil leakage from EGR valve stem

Clogged breather, breather hose
Worn seal at turbocharger end
Oil leakage from oil drain plug

• External leakage of oil
Worn, damaged rear oil seal
Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at blower end
Oil leakage from oil filter

• Wear of pats in lubrication system
Broken piston ring
Broken oil cooler

Degree of use of
EEEE E
Questions
Operated for long period

machine
Oil consumption suddenly increased w Q
Oil must be added more frequently Q w Q
Oil becomes contaminated quickly Q Q w
Outside of engine is dirty with oil w w w w w
There are loose piping clamps in intake system w
Inside of turbocharger intake outlet pipe is dirty with oil w
Inside of turbocharger exhaust outlet pipe is dirty with oil Q w
Check items
There is oil in coolant w

Oil level in damper chamber is high w
Exhaust smoke is blue under light load Q w w
Amount of blow-by Excessive Q Q w w
gas None w
When intake manifold is removed, dust is found inside q
When intake manifold is removed, inside is found to be dirty abnor-
q
mally
q q
Troubleshooting
Excessive play of turbocharger shaft

When EGR valve is removed, exhaust port is found to be dirty with
q
oil
Check breather and breather hose directly q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
20 HD325-7, HD405-7
S-9 Oil becomes contaminated quickly 1

General causes why oil becomes contaminated quickly Causes
Clogged turbocharger lubrication drain tube

• Entry of exhaust gas into oil due to internal wear
Defective turbocharger turbine side seal

• Clogging of lubrication passage
Clogged breather, breather hose

• Use of improper fuel
Defective oil filter safety valve

• Use of improper oil
Worn valve, valve guide

Worn EGR valve guide
Exhaust smoke is bad

• Operation under excessive load
Clogged oil cooler

Clogged oil filter
Degree of use of
Operated for long period EEEE
Questions
machine
Non-specified fuel is being used Q
Engine oil must be added more frequently Q w
Even when engine oil temperature rises, oil filter clogging monitor indi-
w Q
cates clogging (if monitor is installed)
Metal particles are found when oil is drained Q Q w
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
Color of exhaust gas Blue under light load w
Check items
color Black w
Excessive Q Q w Q
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q
When EGR valve is removed, exhaust port is found to be dirty with oil q
Troubleshooting

See S-7
Inspect breather and breather hose directly q

Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy —
HD325-7, HD405-7 21
S-10 Fuel consumption is excessive 1

General causes why fuel consumption is excessive Causes

• Leakage of fuel
• Defective condition of fuel spray (fuel pressure, injection timing)
• Excessive injection of fuel
Fuel leakage from fuel filter, piping, etc.
Defective common rail pressure

Fuel leakage inside head cover
Defective supply pump plunger
Defective operation of injector

Defective feed pump oil seal
Defective spray by injector

Degree of use of
EE E
Questions
Operated for long period

machine
More than for other machines of same model Q Q Q Q
Condition of fuel
Gradually increased Q Q
consumption
Suddenly increased Q Q
There is external leakage of fuel from engine w
Combustion is irregular w
Engine oil level rises and oil smells of diesel fuel w w
When exhaust manifold is touched immediately after starting engine, tempera-
w
ture of some cylinders is low
Check items
Low idle speed is high Q

Torque converter stall speed or pump relief speed is high Q
Exhaust smoke Black Q Q Q Q
color White Q
Remove and inspect head cover directly q
Inspect feed pump oil seal directly q
Carry out troubleshooting according to "No-pressure feed by supply pump
Troubleshooting
q
(*1)"
When a cylinder is cut out for reduced cylinder mode operation, engine speed
q
does not change
If spill hose from injector is disconnected, much fuel spills q
Carry out troubleshooting according to "Abnormality in coolant temperature
q
sensor (*2)"
Confirm with monitoring function q q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Remedy

22 HD325-7, HD405-7
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
General causes why oil is in coolant Causes
Damaged cylinder liner O-ring, holes caused by pitting

• Internal leakage in lubrication system
• Internal leakage in cooling system
Insufficient protrusion of cylinder liner

Broken cylinder head, head gasket
Internal cracks in cylinder block
Broken oil cooler core, O-ring
Broken power train oil cooler

E E
Questions
Degree of use of machine Operated for long period

Suddenly increased Q Q Q
Oil level
Gradually increased Q Q
Hard water is being used as coolant Q Q
Oil level has risen and oil is milky Q Q w
There are excessive air bubbles in radiator, coolant spurts back w w
Check items
Power train oil is milky w
When power train oil is drained, water is found w
Carry out troubleshooting on

Pressure-tightness test of cylinder head shows there is leakage q
Troubleshooting
Inspect cylinder block, liner directly q q
Inspect cylinder liner directly q

H mode
Pressure-tightness test of oil cooler shows there is leakage q

Replace
Replace
Replace
Replace
Replace
Remedy —
HD325-7, HD405-7 23
S-12 Oil pressure drops 1

General causes why oil pressure drops Causes
Defective oil pressure sensor, wiring harness

• Leakage, clogging, wear in lubrication system
Leaking, crushed, clogged hydraulic piping
Defective oil level sensor, wiring harness

• Defective oil pressure control
• Improper selection of fuel (improper viscosity)
Clogged, broken pipe in oil pan
Defective oil pump relief valve
Leaking EGR hydraulic piping

• Deterioration of oil due to overheating
Clogged strainer in oil pan
Defective EGR oil pump

Worn journal of bearing
Lack of oil in oil pan
Defective oil pump

Coolant, fuel in oil
Clogged oil filter

Degree of use of
Operated for long period E E E
Questions
machine
Oil pressure monitor indicates low oil pressure (if monitor is installed) Q w
Non-specified oil is being used Q Q
Replacement of filters has not been carried out according to Operation and
w
Maintenance Manual
Indicates pressure drop at low idle w Q Q
Oil pressure Indicates pressure drop at low, high idle Q w w w Q Q Q
monitor
(if installed) Indicates pressure drop on slopes w
Sometimes indicates pressure drop w Q Q
Oil level monitor indicates oil level drop (if monitor is installed) w w
Oil level in oil pan is low w
External hydraulic piping is leaking, crushed w w
Check items
Oil is milky or smells of diesel oil w

Metal particles are found when oil pan is drained w
Metal particles are found when oil filter is drained w Q Q
Metal particles are found in oil filter q

Inspect oil pan strainer, pipe directly q q
Oil pump rotation is heavy, there is play in oil pump q
Troubleshooting
Valve and spring of oil pump relief valve are fatigued, damaged q
See S-13
Inspect oil filter directly q

Relief valve of EGR oil pump is damaged, oil leaks from it q
Inspect EGR hydraulic piping directly q
Carry out troubleshooting according to "Abnormality in oil pressure sensor
q
(*1)"
If oil level sensor is replaced, oil pressure monitor indicates normally q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Remedy —
Add
24 HD325-7, HD405-7
HD325-7, HD405-7 25
S-13 Oil level rises (Entry of coolant/fuel) 1

General causes why oil level rises Causes
Clogged water pump drain hole (breather hole), defective seal

• Coolant in oil (milky)
Defective seal of auxiliary equipment (pump, compressor)

• Fuel in oil (smells diluted diesel fuel)
Damaged cylinder liner O-ring, holes caused by pitting

a If oil is in coolant, carry out troubleshooting for "S-11 Oil is in coolant"
Cracked EGR cooler (Entry of coolant)

Fuel leakage inside head cover
Broken oil cooler core, O-ring

Worn, damaged rear oil seal
Cracks inside cylinder block
Defective thermostat seat

Defects in supply pump
Questions
Degree of use of
Operated for long period EE E E
machine
Fuel must be added more frequently w w
Coolant must be added more frequently Q Q w
There is oil in coolant Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q Q w
When engine is started, drops of water come from muffler Q Q
When radiator cap is removed and engine is run at low idle, an abnormal num-
w Q
ber of bubbles appear, or coolant spurts back
Check items
Exhaust smoke is white Q Q

Water pump drain hole (breather hole) is clogged w
When water pump drain hole (breather hole) is cleaned, coolant comes out w
Oil level in damper chamber is low w
Oil level in hydraulic tank is low w
When EGR cooler outlet gas piping is removed, coolant containing antifreeze
q
flows out (*1)
Troubleshooting
Remove and inspect head cover directly q

Inspect cylinder block, liner directly q q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q
Remove and inspect water pump directly q
Remove and inspect thermostat cover directly q
Remove and inspect supply pump directly q
Inspect seal of auxiliary equipment directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
26 HD325-7, HD405-7

HD325-7, HD405-7 27
S-14 Coolant temperature becomes too high (overheating) 1

General causes why coolant temperature becomes too high Causes
Damaged cylinder liner O-ring, hole caused by pitting

• Lack of cooling air (deformation, damage of fan)
• Drop in heat dissipation efficiency
External leakage of coolant from EGR cooler
Defective radiator cap (pressure valve)

• Problem in coolant circulation system
Defective coolant temperature gauge

Rise in power train oil temperature

Defective operation of thermostat
Slipping fan belt, worn fan pulley

• Rise in oil temperature in power train
Clogged, crushed radiator fins

Clogged, broken oil cooler
Clogged radiator core

Broken water pump
Lack of coolant
Degree of use of
Questions
machine
Condition of Sudden overheated Q Q w Q
overheating Always tends to overheat Q w w Q
Coolant temperature Rises quickly Q w
gauge (if installed) Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level Q w
Engine oil level has risen, oil is milky w Q
Fan belt tension is low w
When fan pulley is turned, it has play w
Milky oil is floating on coolant w
There are excessive air bubbles in radiator, coolant spurts back w
Check items
When light bulb is held behind radiator core, no light passes through w
Radiator shroud, inside of underguard are clogged with dirt or mud w w
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Power train oil temperature enters red range faster than engine coolant temperature w
Inspect EGR cooler for coolant leakage q

Inspect cylinder liner directly q
Carry out troubleshooting on H mode
Inspect oil cooler directly q

Troubleshooting
Temperature difference between upper and lower tanks of radiator is large q

When operation of thermostat is carried out, it does not open at cracking tempera-
q
ture
Temperature difference between upper and lower tanks of radiator is slight q
Inspect radiator core directly q
When operation of radiator cap is carried out, its cracking pressure is low q
Inspect fan belt, pulley directly q
When coolant temperature is measured, it is fount to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy —
Add
28 HD325-7, HD405-7
S-15 Abnormal noise is made 1

General causes why abnormal noise is made Causes
Deformed cooling fan, loose fan belt, interference of fan belt

• Abnormality due to defective parts
Defective inside of muffler (dividing board out of position)

Leakage of air between turbocharger and cylinder head
• Abnormal combustion
Broken dynamic valve system (valve, rocker lever)

Interference of turbocharger, seized turbocharger
• Air sucked in from intake system
(abnormality in coolant temperature sensor)

Excessive wear of piston ring, cylinder liner
a Judge if the noise is an internal noise or an external noise before
Removed, seized gear train bushing

starting troubleshooting.
Cracked, leaking EGR gas piping

a The engine is operated in the low-temperature mode while it is

Improper gear train backlash
not warmed up sufficiently. Accordingly, the engine sound
Clogged, seized injector

becomes a little larger. This does not indicate abnormality, how-
Dirt caught in injector

ever.
a When the engine is accelerated, it is operated in the acceleration

mode and its sound becomes a little larger for up to about 5 sec-
onds. This does not indicate abnormality, however.

Degree of use of
Operated for long period E
machine
Questions
Condition of Gradually occurred Q Q

abnormal noise Sudden occurred Q Q Q Q
Non-specified fuel is being used Q
Metal particles are found when oil filter is drained w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, abnormal sound is generated around EGR gas piping w
When engine is cranked, abnormal sound is generated around cylinder head w w
When engine is cranked, beat noise is generated around muffler w
Check items
When exhaust manifold is touched immediately after starting engine, temperature

w Q
of some cylinders is low
Color of exhaust Blue under light load w
gas Black Q w Q
Engine does not pick up smoothly and combustion is irregular w
Abnormal noise is loud when engine is accelerated Q Q Q Q
When turbocharger is rotated by hand, it is fount to be heavy q
Inspect EGR gas piping directly q
When muffler is removed, abnormal noise disappears q
Troubleshooting

Inspect gear train directly q q
Inspect fan and fan belt directly q
When a cylinder is cut out for reduced cylinder mode operation, engine speed
q q
does not change
Abnormal noise is heard only when engine is started q
Confirm with monitoring function q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Adjust
Remedy
HD325-7, HD405-7 29
S-16 Vibration is excessive 1

General causes why vibration is excessive Causes
Stuck dynamic valve system (valve, rocker lever)

• Defective parts (abnormal wear, breakage)
Loose engine mounting bolts, broken cushions

Misalignment between engine and power train
Worn main bearing, connecting rod bearing
• Misalignment between engine and chassis
Worn front support spigot joint portion

Broken output shaft, parts in damper
• Abnormal combustion
a If abnormal noise is made and vibration is excessive, carry out trou-
Improper gear train backlash

bleshooting for "S-15 Abnormal noise is made", too.
Improper injection timing

Worn camshaft bushing
Degree of use of
Questions
Operated for long period E E E

machine
Condition of Suddenly increased Q Q
vibration Gradually increased Q Q Q Q
Metal particles are found when oil filter is drained w w
Metal particles are found when oil pan is drained w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at mid-range speed Q Q

Vibration follows engine speed Q Q Q Q Q
Exhaust smoke is black w

Inspect main bearing and connecting rod bearing directly q
Troubleshooting
Inspect gear train directly q

Inspect camshaft bushing directly q
Confirm with monitoring function q
Inspect engine mounting bolts and cushions directly q
When alignment is checked, radial runout or facial runout is detected q
Inspect front support spigot joint portion directly q
Inspect output shaft or inside of damper directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Remedy
30 HD325-7, HD405-7
HD325-7, HD405-7 31
SEN01194-01

© 2007 KOMATSU
All Rights Reserved
32 HD325-7, HD405-7
SEN01954-01
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up
50 Disassembly and assembly1

General information on disassembly and
assembly
How to read this manual ................................................................................................................................. 2
List of adhesives ............................................................................................................................................. 4
Special tool list ................................................................................................................................................ 7
Sketches of special tools .............................................................................................................................. 10
HD325-7, HD405-7 1
SEN01954-01 50 Disassembly and assembly
How to read this manual 1

1. Removal and installation of assemblies
Special tools Removal

q Special tools which are deemed neces- q The "Removal" section contains procedures
sary for removal or installation of parts are and precautions for implementing the work,
described as A1,•••X1 etc. and their part know how and the amount of oil or coolant to
names, part numbers and quantities are be drained.
described in the special tool list. q Various symbols used in the "Removal" section
q Also the following information is described are explained and listed below.
in the special tool list. k : Precautions related to safety in execution
1) Necessity of work.
t : Special tools that cannot be substi- a: This mark gives guidance or precautions when
tuted and should always be used doing the procedure.
(installed). [*1] : This mark shows that there are instructions or
q : Special tools that will be useful if avail- precautions for installing parts.
able and are substitutable with com- 6 : This mark shows the amount of oil or coolant
mercially available tools. to be drained.
2) Distinction of new and existing special 4 : Weight of part or component
tools
N: Tools newly developed for this
model. They respectively have a Installation
new part number. q Except where otherwise instructed, installation
R: Tools with upgraded part numbers. of parts is done in the reverse order of removal.
They are remodeled from already q Instructions and precautions for installing parts
available tools for other models. are shown with [*1] mark in the "Removal" sec-
Blank: Tools already available for other tion, identifying which step the instructions are
models. They can be used without intended for.
any modification. q Marks shown in the "Installation" section stand
3) Circle mark Q in sketch column: for the following.
q The sketch of the special tool is pre- k : Precautions related to safety in execution
sented in the section of "Sketches of of work.
special tools". a: This mark gives guidance or precautions when
q Part No. of special tools starting with doing the procedure.
2 : Type of coating material
* *** ****
79 T- - :
means that they can not be supplied 3 : Tightening torque
5
from Komatsu in Japan (i.e. locally : Quantity of oil or coolant to be added
made parts ).
Sketches of special tools
a General tools that are necessary for
q Various special tools are illustrated for the con-
removal or installation are described as
venience of local manufacture.
[1], [2]•••etc. and their part names, part
numbers and quantities are not described.
2 HD325-7, HD405-7
2. Disassembly and assembly of assem-

blies
Special tools Disassembly

q Special tools which are deemed neces- q In "Disassembly" section, the work procedures,
sary for disassembly and assembly of precautions and know-how for carrying out
parts are described as A1,•••X1 etc. and those procedures, and quantity of the oil and
their part names, part numbers and quan- coolant drained are described.
tities are described in the special tool list. q The meanings of the symbols used in "Disas-
q Also the following information is described sembly" section are as follows.
in the special tool list. k : Precautions related to safety in execution
1) Necessity of work.
t : Special tools that cannot be substituted a: This mark gives guidance or precautions when
and should always be used (installed). doing the procedure.
q : Special tools that will be useful if avail- 6: Quantity of oil or coolant drained
able and are substitutable with com-
mercially available tools.
2) Distinction of new and existing special
tools Assembly
N : Tools newly developed for this q In "Assembly" section, the work procedures,
model. They respectively have a precautions and know-how for carrying out
new part number. those procedures, and quantity of the oil and
R : Tools with upgraded part numbers. coolant added are described.
They are remodeled from already q The meanings of the symbols used in "Assem-
available tools for other models. bly" section are as follows.
Blank : Tools already available for other k : Precautions related to safety in execution
models. They can be used without of work
any modification. a: This mark gives guidance or precautions when
3) Circle mark Q in sketch column: doing the procedure.
q The sketch of the special tool is pre- 2 : Type of coating material
sented in the section of "Sketches of 3 : Tightening torque
special tools". 5 : Quantity of oil or coolant to be added
q Part No. of special tools starting with
* *** ****
79 T- - :
means that they can not be supplied
Sketches of special tools
q Various special tools are illustrated for the con-
from Komatsu in Japan (i.e. locally venience of local manufacture.
made parts ).
a General tools that are necessary for dis-

assembly and assembly are described
as [1], [2]•••etc. and their part names,
part numbers and quantities are not
described.
HD325-7, HD405-7 3
List of adhesives
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this list.
Cate- Komatsu
Part No. Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cushions, and
LT-1A 790-129-9030 150 g Tube
cork plugs from coming out.
• Used for plastic (except polyethylene, polypropylene,
20 g Polyethylene tetrafluoroethylene and vinyl chloride), rubber, metal,
LT-1B 790-129-9050
(2 pcs.) container and non-metal parts which require immediate and
strong adhesion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060 Adhesive:
(Set of 1 kg
LT-3 Can • Used to stick and seal metal, glass, and plastics.
adhesive and Hardener:
hardener) 500 g
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH
790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
705
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics, and
woods.
• Quick-setting adhesive.
Aron-alpha Polyethylene • Quick-setting type.
790-129-9130 2g
201 container (max. strength is obtained after 30 minutes)
• Used mainly to stick rubbers, plastics, and metals.
Loctite Polyethylene • Features: Resistance to heat and chemicals.
79A-129-9110 50 cc
648-50 container • Used for fitted portions used at high temperatures.
• Used to stick or seal gaskets and packings of power
LG-1 790-129-9010 200 g Tube
train case, etc.
• Used to seal various threaded portions, pipe joints,
Polyethylene and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nipples of
hydraulic piping.
• Features: Silicon-based heat and cold-resistant seal-
Gasket sealant
ant.
LG-6 790-129-9020 200 g Tube
• Used to seal flange surfaces and threaded portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9070 1 kg Tube • Used to seal flywheel housing, intake manifold, oil
pan, thermostat housing, etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Features: Silicon-based, heat and cold-resistant,
ThreeBond
419-15-18131 100 g Tube vibration-resistant, impact-resistant sealant.
1207B
• Used to seal transfer case, etc.
4 HD325-7, HD405-7
Cate- Komatsu
gory code
molybdenum disulfide
• To be sed as lubricant (anti squeaking) for slid-

LM-G 09940-00051 60 g Can
Lubricant with
ing part.
• To be used for press fit, shrink fit and prevent-

ing scratching or seizure of thread.
LM-P 09940-00040 200 g Tube
• To be used as lubricant for linkage and bearing
etc..
SYG2-400LI
SYG2-350LI
Various
G2-LI SYG2-400LI-A Various kinds • Versatile type
kinds
SYG2-160LI
SYGA-160CNLI
SYG2-400CA
• To be used for the place where the bearing
SYG2-350CA
Various designed for normal temperature and low load
G2-CA SYG2-400CA-A Various kinds
kinds condition is used and contacts water and
SYG2-160CA
steam.
SYGA-160CNCA
Grease with
SYG2-400M 400 g x 10 Bellows type
molybdenum
SYG2-400M-A 400 g x 20 • To be used for heavy load places.
disulphide
Grease
SYGA-16CNM 16 kg Can
LM-G(G2-M)
SYG2-400T-A
Hyper white
SYG2-16CNT
grease • Higher anti seizure and heat resistance than
SYG0-400T-A 400 g Bellows type
G2-T GO-T(*) grease with molybdenum disulphide
(*) 16 kg Can
*: For cold • Body dirt is not distinctive due to white color.
SYG0-16CNT
region
(*)
Biological
SYG2-400B
grease G2-B
SYGA-16CNB
G2-BT(*) • To be shortly dissolved by a bacteria in nature
SYG2-400BT 400 g Bellows type
*: For heat so that the influence to microorganism and ani-
(*) 16 kg Can
resistance mals and plants is suppressed to the minimum.
SYGA-16CNBT
and heavy
(*)
load
Sunstar
• To be used as primer for cab side.
primer for Glass
20 ml (Term of validity: 4 months after manufac-
painting plane container
turing)
580 super
417-926-3910
Sunstar
• To be used as primer for glass side.
primer for Glass
20 ml (Term of validity: 4 months after manufac-
glass 580 container
For adhesion of cab glass
turing)
super
Sunstar • To be used as primer for painting plane of
primer for Glass cab side.
Primer
22M-54-27230 20 ml
painting plane container (Term of validity: 4 months after manufac-
435-95 turing)
• To be used as primer for black ceramic
Sunstar
coated plane of glass side and polycarbon-
primer for
22M-54-27240 150 ml Steel can ate hard coat plane.
glass
(Term of validity: 4 months after manufac-
435-41
turing)
Sunstar • To be used as primer for sash (Alumite
primer for Glass surface treatment)
22M-54-27250 20 ml
sash container (Term of validity: 4 months after manufac-
GP-402 turing)
HD325-7, HD405-7 5
Cate- Komatsu
gory code
• "S" and "W" are used as glass adhesive
Sunstar pen- compound in high temperature (April -
guin seal 580 Polyethylene October) and in low temperature (October
417-926-3910 320 ml
Adhesive compound
super "S" or container -April ) respectively.

"W" (Term of validity: 4 months after manufac-
turing)
Sika Ltd, • To be used as glass adhesive compound.
Polyethylene
For adhesion of cab glass

Japan Sika 20Y-54-39850 310 ml (Term of validity: 6 months after manufac-
container
Flex 256HV turing)
Sunstar ECOCART • To be used as glass adhesive compound.
pengiun 22M-54-27210 320 ml (special con- (Term of validity: 6 months after manufac-
super 560 tainer) turing)
Sunstar • To be used as seal for joints of glass.
Polyethylene
pengiun seal 417-926-3920 320 ml (Term of validity: 4 months after manufac-
container
Coaking compound
No. 2505 turing)

• To be used for seal of front window.
Sekisui sili- Polyethylene
20Y-54-55130 333 ml (Term of validity: 6 months after manufac-
cone sealant container
turing)
• To be used as seal for joints of glass.
GE Toshiba
semi-transparent white seal
Silicones 22M-54-27220 333 ml Cartridge
(Term of validity: 12 months after manu-
Tosseal 381
facturing)
6 HD325-7, HD405-7
Special tool list 1

a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they must be locally manufactured).
a Necessity : t . . . . . . Cannot be substituted, should always be installed (used)
: q . . . . . . Extremely useful if available, can be substituted with commercially available part
a New/Remodel: N. . . . . . Tools newly developed for this model and given new part Nos.
: R. . . . . . Tools remodeled from tools already available for other models and given
upgraded part Nos.
: Blank . . Tools already available for other models, usable without any modification
a Tools marked with Q in the sketch column are tools introduced in the sketches of the special tools (See
Sketches of special tools).
New/remodel
Necessity
Sym-
Component Part No. Part Name Nature of work, remarks
Sketch
bol
Q’ty
1 795-630-5500 Standard puller t 1
Removal and installa- Removal of fuel supply
A 2 01010-81090 Bolt t 2
tion of engine assembly pump
3 01643-31032 Washer t 2
790-201-2840 Spacer t 1 Q
791-600-1120 Bolt t 1
Disassembly, assem- 01580-01613 Nut t 1
B 1
bly of output shaft 01643-31645 Washer t 1
790-101-2102 Puller t 1
790-101-1102 Pump (30 ton) t 1
Centering of engine and
1 790-413-1110 Centering tool t 1
torque converter
Unit repair stand (100 V) t 1
790-501-5000
or Unit repair stand
790-501-5200 (110 – 120V or t 1 Torque converter, P.T.O.
Disassembly, assem- 2
220 – 240V) repair stand
bly of torque converter C
P.T.O. assembly 790-901-2110 Bracket t 1
793-310-2141 Plate t 1 Q
Removal installation P.T.O.
3 790-102-1871 Nut wrench t 1
gear bearing ringnut
Removal, installation of
4 792-103-5110 Wrench t 1
pump bearing locknut
Disassembly, assem-
Check operation of clutch,
bly of transmission D 1 799-301-1600 Oil leak tester kit (A) t 1
piston
assembly
HD325-7, HD405-7 7
New/remodel
Necessity
Sym-
Sketch
bol
Q’ty
790-501-5000 Unit repair stand (100V) t 1
790-501-5200 t 1
1 (110–120V or 220–240V) Differential repair stand
790-901-4110 Bracket t 1
790-901-3430 Plate t 1 Q
2 792-525-2100 Nut runner Removal, installation of dif-
ferential bevel pinion nut
3 790-102-1100 Power wrench (No. 16) and locknut
Side bearing adjustment
4 792-103-0901 Wrench t 1 Q
nut
Disassembly, assem-
bly of differential H 5 Tightening of pinion gear
797-101-1171 Wrench t 1
assembly round nut
6 792-525-1220 Adapter t 1
7 792-525-1000 Depth micrometer t 1 Adjusting bearing preload
8 792-103-0901 Wrench t 1
790-102-1100 Power wrench t 1 Removal, installation of
790-102-1110 Lever t 1 bearing cap bolt
a Use comercially avail-
9 790-102-1120 Bolt t 1 able socket (width
01580-02419 Nut t 1 across flats: 46 mm,
insertion angle 38.1 mm)
01644-12408 Washer t 1 Kit Part No. 790-103-1130
1 792-103-1201 Fixture t 3 Q
792-520-2121 Installer t 1 Installation of floating seal
Disassembly, assem-
bly of final drive wheel J 791-580-1600 Push tool t 1 (small seal)
brake assembly 4
792-520-2110 Installer t 1 Installation of floating seal
791-580-1600 Push tool t 1 (large seal)
792-103-4102 Push tool t 1 Q
Press fitting of suspension
1 792-101-5421 Grip t 1
Disassembly, assem- cylinder coil bushing
bly of front, rear sus- 01010-51240 Bolt t 1
Q
pension cylinder 792-610-1000 Suspension tool t 1
assembly Charging suspension cylin-
2 792-610-1100 • Pump assembly t 1
der with oil, gas
792-610-1200 • Charging tool t 1
8 HD325-7, HD405-7
New/remodel
Necessity
Sym-
Sketch
bol
Q’ty
1 790-502-1003 Cylinder repair stand t 1
790-101-1102 Pump t 1 Removal, installation of cyl-
2 inder round head
790-102-3802 Wrench assembly t 1
(Hoist cylinder)
790-102-2303
3 or Wrench assembly t 1 (Steering cylinder)
790-330-1100
Removal, installation of
4 790-302-1270 Socket t 1
nylon nut (steering)
790-201-1881 Push tool t 1 Press fitting of No. 1 coil
5
790-101-5021 Grip t 1 bushing (hoist cylinder)
01010-50816 Bolt t 1 Kit Part No. 790-201-1700
797-201-1841 Push tool t 1

Press fitting of No. 2 coil
6 790-101-5021 Grip t 1 bushing (hoist cylinder)
Kit Part No. 790-201-1700
01010-50816 Bolt t 1
Disassembly, assem- 790-201-1690 Plate t 1 Press fitting of No. 1 gland
bly of hoist cylinder,
U 7 790-101-5021 Grip t 1 dust seal (hoist cylinder)
steering cylinder
01010-50816 Bolt t 1 Kit Part No. 790-201-1500
assembly
790-201-1650 Plate t 1 Press fitting of No. 2 gland
8 790-101-5021 Grip t 1 dust seal (hoist cylinder)
01010-50816 Bolt t 1 Kit Part No. 790-201-1500
790-201-1570 Plate t 1 Press fitting of dust seal

9 790-101-5021 Grip t 1 (steering cylinder)
01010-50816 Bolt t 1 Kit Part No. 790-201-1500
790-720-1000 Expander t 1 Installation of piston, wear

10 796-720-1680 Ring t 1 ring
07281-01589 Clamp t 1 (No. 1 hoist cylinder)
796-720-1670 Ring t 1 Installation of piston, wear

11 ring
07281-01279 Clamp t 1 (No. 2 hoist cylinder)
796-720-1640 Ring t 1 Installation of piston, wear
12 ring
07281-00909 Clamp t 1 (steering cylinder)
Removal of dump body V 1 790-441-1320 Hook t 4 Q
799-703-1200 Service tool kit t 1
799-703-1100 Vacuum pump (100V) t 1
Air conditioner Filling with air conditioner
X 1 799-703-1111 Vacuum pump (220V) t 1
assembly refrigerant (gas)
799-703-1121 Vacuum pump (240V) t 1
799-703-1401 Gas leak tester t 1
HD325-7, HD405-7 9
Sketches of special tools 1

Note: Komatsu cannot accept any responsibility for special
tools manufactured according to these sketches.
B1 Spacer
C2 Plate
10 HD325-7, HD405-7

H1 Plate
H4 Wrench
HD325-7, HD405-7 11

J1 Fixture
Q1 Push tool
12 HD325-7, HD405-7

V1 Fook
HD325-7, HD405-7 13

© 2007 KOMATSU
All Rights Reserved
14 HD325-7, HD405-7
SEN01955-01
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up

Engine and cooling system
Removal and installation of engine assembly ................................................................................................. 2
Removal and installation of radiator assembly ............................................................................................... 8
Removal and installation of output shaft assembly ....................................................................................... 16
Disassembly and assembly of output shaft assembly .................................................................................. 18
Removal and installation of fuel supply pump assembly .............................................................................. 21
Removal and installation of fuel injector assembly ....................................................................................... 25
HD325-7, HD405-7 1
Removal and installation of 4. Remove right side cover (2).

engine assembly 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
Vacuum pump
799-703-1100 t 1
(100 V)
Vacuum pump
X 1 799-703-1111 t 1
(220 V)
5. Remove washer tank (3).
Vacuum pump a Remove the window washer tank and
799-703-1121 t 1
(240 V) mounting bracket together.
799-703-1401 Gas leak detector t 1
6. Remove cover (4).
Removal
k Stop the machine on a level ground and
lock the tires with chocks.
k Raise the body and lock it with the safety
pin.
k Disconnect the cable from the negative (–)
terminal of the battery.
k If the air conditioner refrigerant (R134a)
gets in your eyes, you may lose your sight.
Accordingly, when collecting or adding it,
you must be qualified for handling it and
put on protective goggles.
k Collect the air conditioner refrigerant (R134a). 7. Remove plate (5).
1. Close the fuel supply valve. 8. Remove bracket (6).
2. Remove the radiator assembly. For details, 9. Disconnect wiring harness (7).
see "Removal and installation of radiator
assembly".
q Chassis side
3. Remove left side cover (1).
2 HD325-7, HD405-7
q Upper side of engine 14. Remove muffler band (14).

10. Disconnect heater hose (8). a Sling the muffler temporarily.
a There are 2 mounting bands.
15. Remove bracket (15).
11. Disconnect heater terminal HTR (9).
16. Lift off muffler assembly (16).

4 Muffler assembly: 60 kg
q Parts related to muffler

12. Remove covers (10) – (12).
13. Remove muffler band (13).

18. Remove rubber part (18). [*1]
HD325-7, HD405-7 3
19. Remove seat (19). q Left side of engine

22. Disconnect air conditioner compressor IN hose
(22) and air conditioner compressor OUT hose
(23). [*3]
a Disconnect compressor connector E07.
a Disconnect the compressor wiring clips
which may be obstacles to slinging of the
engine assembly.
23. Remove rubber part (24).
21. Remove air cleaner tube (21). [*2]
24. Remove cushion (25).
4 HD325-7, HD405-7
25. Disconnect overflow hose (26). 30. Disconnect engine oil level connector E04
(31).
26. Disconnect fuel hose inlet hose (27).
31. Disconnect ground wire GS (32).
27. Disconnect clamp (28).
32. Disconnect engine controller connectors J3P
(33) and J2P (34).
28. Disconnect oil filter connector E05 (29).
q Rear side of engine

33. Disconnect front drive shaft (35). [*4]
29. Remove engine controller cover (30).
34. Disconnect fuel hose clip (36).
35. Disconnect heater hose clip (37).
HD325-7, HD405-7 5
q Right side of engine 40. Remove fan (45).

37. Disconnect alternator terminal E connector
E06 (39), terminal R connector E01 (40) and
terminal B connector E09 (41).
41. Sling engine assembly temporarily.
42. Remove 4 mounting bolts (46). [*5]

38. Disconnect starting motor terminal B E14 (42) a The part No. of the cushion fitted to the
and starting motor wiring E02A (43). front mounting bolt is different from that fit-
ted to the rear mounting bolt. Take care
when removing them.
39. Disconnect engine ground wire (44).
43. Lift off engine assembly (47).

a Check that all the wires and pipes are dis-
connected.
a When removing the engine assembly, take
care that it will not interfere with the chas-
sis.
4 Engine assembly: 1,300 kg
6 HD325-7, HD405-7
Installation q Refilling with coolant

Add coolant through the coolant filler to the
q Carry out installation in the reverse order to specified level. Run the engine to increase the
removal. coolant temperature. Then, check the coolant
q After installing the engine assembly, install the level again.
radiator assembly. For details, see "Removal
5 Coolant: 134 l
and installation of radiator assembly".
q When installing each hose, take care that it will
not twist or interfere with another part.
[*1]
3 Rubber part:
24.5 – 41.2 Nm {2.5 – 4.2 kgm}
[*2]
a Install the hose clamp as shown in the figure.
a Set hose insertion length (a) as shown below.
1) Engine side: 40 mm
2) Air cleaner side: 50 mm
3 Hose clamp: 8.8 ± 0.5 Nm {90 ± 5 kgm}
[*3]
3 Air compressor hose:
20 – 25 Nm {2.0 – 2.5 kgm}
[*4]
3 Drive shaft: 98 – 123 Nm {10 – 12.5 kgm}
2 Drive shaft: Adhesive (LT-2)
[*5]
3 Engine mounting bolt:
662 – 829 Nm {67.5 – 84.5 kgm}
a For alignment of the engine assembly and
torque converter and transmission assembly,
see "Procedure for aligning engine assembly
and torque converter and transmission assem-
bly".
q Charging air conditioner with refrigerant gas

Using tool X1, charge the air conditioner circuit
with refrigerant gas (R134a).
HD325-7, HD405-7 7
Removal and installation of 5. Remove left engine side covers (5) – (7).
radiator assembly 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
Vacuum pump
799-703-1100 t 1
(100 V)
Vacuum pump
X 1 799-703-1111 t 1
(220 V)
6. Disconnect gas spring (8).
Vacuum pump q Perform this step only when the gas
799-703-1121 t 1
(240 V) spring is installed.
799-703-1401 Gas leak detector t 1 a Sling the engine hood assembly tempo-
rarily and then remove the gas spring.
Removal
7. Disconnect stay (9).
k Collect the air conditioner refrigerant (R134a).
k Disconnect the cable from the negative (–) 8. Lift off engine hood assembly (10).
4 Engine hood: 40 kg
1. Remove radiator cover (1).
2. Drain the coolant.

5 Coolant: 134 l
9. Remove radiator grille (11).

4 Radiator grille: 27.3 kg
3. Remove left engine side covers (2) and (3).
4. Remove air conditioner compressor cover (4).
8 HD325-7, HD405-7
10. Remove right and left mirror stays (12) and 15. Remove shims (20). (EU specification) [*1]
(13). (EU specification) a Check the thickness and quantity of the
shims. (Right and left sides)
11. Remove brackets (14) and (15). (EU specifica- q Kinds of shim thickness: 1.0 mm, 2.3 mm
tion)
12. Remove blades (16). (EU specification)

a There are 2 types in the blades. Take
care when installing them.
13. Disconnect horn connector HRN (17) and

remove clamp (18).
17. Remove rubber caps (22) and upper and lower

radiator guard mounting bolts.
a Sling the radiator guard temporarily and
then remove the mounting bolts.
14. Lift off guard (19). (EU specification)

a Sling the guard temporarily and then
remove the mounting bolts.
4 Guard: 115 kg
HD325-7, HD405-7 9
18. Lift off radiator guard (23). 24. Remove plate (30).
4 Radiator guard: 97.5 kg
4 Radiator guard:
103.1 kg (EU specification)
25. Remove hose (31). [*6]

19. Remove radiator inlet hose (24). [*2]
a Disconnect radiator coolant level sensor 27. Remove aftercooler hose (33). [*7]
connector FR02.
28. Disconnect heater hose (34).
20. Disconnect air hoses (25) and (26). [*3]
29. Remove radiator nets (35).
21. Reservoir tank hose (27). [*4] a Remove the 2 nets, upper and lower ones.
22. Remove aftercooler hose (28). [*5] 30. Remove coolant hose (36). [*8]
10 HD325-7, HD405-7
31. Disconnect receiver tank (37). [*9] 37. Loosen cushion bolt (45).
a Disconnect receiver tank connector HRN.
a Move the receiver tank to a place where it 38. Remove radiator upper mounting nut (46).
will not be an obstacle. a Before removing, check dimension (a) on
the right and left sides.
39. Remove radiator lower mounting bolt (47).
33. Remove rod tightening nut (39). a Sling the radiator assembly temporarily
and then remove the mounting bolt.
34. Remove radiator nets (40) and (41).
35. Lift off stay (42).

4 Stay: 31.6 kg
40. Lift off radiator assembly (48).

4 Radiator assembly: 450 kg
36. Remove oil cooler tubes (43) and (44).
HD325-7, HD405-7 11
Installation [*3]
a Install the hose so that it will not twist.
q Carry out installation in the reverse order to a When using 2 clamps continuously, set their
removal. clamp bolts 180° apart from each other.
[*1]
a When installing the shims, check its quantity.
[*2]
a When using 2 clamps, set them 180° apart
from each other as shown in the figure.
aInstall the hose clamp as shown in the figure.

aSet hose insertion length (b) as shown below.
3) Radiator side (25): 34 mm
3 Hose clamp: 3.3 ± 0.49 Nm {34 ± 5 kgm}

a Set hose insertion length (b) as shown below.
1) Radiator side: 85 mm
2) Engine side: 90 mm
3 Hose clamp: 10.5 ± 0.5 Nm {107 ± 5 kgm}
a When removing air hose (26) from the clamp,

clamp it so that it will not interfere with the
shroud.
12 HD325-7, HD405-7
[*4] a Install the hose so that pieces (c) at the hose

a Install the hose so that it will not twist. ends will be directed as shown in the figure.

aInstall the hose clamp as shown in the figure. Hose insertion length (b): 50 mm
aSet hose insertion length (b) as shown below. a When installing the rubber hoses between the
4) Radiator side: 27 mm turbocharger, aftercooler and engine, secure
3 Hose clamp: 3.3 ± 0.49 Nm {34 ± 5 kgm} the clearance of at least 5 mm between those
hoses and radiator, each guard, coolant piping,
etc.
3 Hose clamp: 10.5 ± 0.5 Nm {107 ± 5 kgm}
[*5]
HD325-7, HD405-7 13
[*6] a Install the hose so that pieces (c) at the hose

a Install the hose clamp as shown in the figure. ends will be directed as shown in the figure.

aInstall the hose clamp as shown in the figure. Hose insertion length (b): 50 mm
aSet hose insertion length (b) as shown below. a When installing the rubber hoses between the
Hose insertion length (b): 65 mm turbocharger, aftercooler and engine, secure
3 Hose clamp: 10.5 ± 0.5 Nm {107 ± 5 kgm} the clearance of at least 5 mm between those
hoses and radiator, each guard, coolant piping,
etc.
3 Hose clamp: 10.5 ± 0.5 Nm {107 ± 5 kgm}
[*7]
from each other as shown in the figure. [*8]
14 HD325-7, HD405-7

Hose insertion length (b): 65 mm
3 Hose clamp: 10.5 ± 0.5 Nm {107 ± 5 kgm}
[*9]
q Charging air conditioner with refrigerant gas
with refrigerant gas (R134a).
q Refilling with coolant

specified level. Run the engine to increase the
coolant temperature. Then, check the coolant
level again.
5 Coolant: 134 l
HD325-7, HD405-7 15
Removal and installation of 5. Remove guard (3).

output shaft assembly 1 6. Remove lock bracket (4).
Special tools
7. Lift off drive shaft assembly (5). [*1]
4 Drive shaft assembly: 25 kg
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
790-201-2840 Spacer t 1 Q
791-600-1120 Bolt t 1
01580-01613 Nut t 1
B 1
01643-31645 Washer t 1
790-101-2102 Puller t 1
790-101-1102 Pump (30 t) t 1
Removal
8. Remove coupling (6). [*2]
lock the tires with chocks. 9. Remove oil seal gauge (7). [*3]
pin. 10. Remove snap ring (8).
1. Remove the engine assembly. For details, see

"Removal and installation of engine assembly".
2. Remove the retarder pump assembly and work

equipment and steering pump assembly. For
details, see "Removal and installation of power
line assembly".
4. Disconnect hose clamps (2).
11. Lift off cover (9). [*4]

4 Cover: 35 kg
a Use forcing screw [1] and guide bolt [2] to
remove the cover.
16 HD325-7, HD405-7
12. Lift off output shaft assembly (10). [*5] Installation

4 Output shaft assembly: 60 kg
q Carry out installation in the reverse order to
removal.
q For the procedure for supplying ENS grease,
see "Disassembly and assembly of output
shaft assembly".
[*1]
2 Drive shaft mounting bolt: Adhesive (LT-2)
3 Drive shaft mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
[*2]
2 Spline: ENS grease
a Before supplying ENS grease, remove all of
13. Remove bearing (11). [*6] the other grease to prevent it from mixing in
ENS grease. (Use a special grease gun for
ENS grease.)
a ENG grease:
Use 427-12-11871 (GREASE) (2kg can).
[*3]
2 Mating face of flange:
Gasket sealant (LG-4)
2 Oil seal cage cover mounting bolt:
Adhesive (LT-2)
3 Oil seal cage cover mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
[*4]
Sling cover (9) and set it to the output shaft. Using
tool B1, press fit the inner part of the bearing and
install cover (9).
[*5]
2 Output shaft mounting bolt: Adhesive (LT-2)
3 Output shaft mounting bolt:
98.0 – 123.0 Nm {10 – 12.5 kgm}
[*6]
2 Bearing: Apply ENS grease all around
inside of bearing and outside of shaft.
HD325-7, HD405-7 17
Disassembly and assembly of output shaft assembly 1
Disassembly
1. Oil cage assembly
Remove oil seal (1) from cage (2).
2. Cover assembly
Remove bearing (3) from cover (4).
3. Damper assembly (5)

1) Before disassembling, make marks of
flange (6), body assembly (7), and outer
body (10) for balancing them after reas-
sembly.
2) Remove body assembly (7) and rubber
parts (8) and (9) from outer body (10).
3) Remove bearing (11) from the flywheel.
18 HD325-7, HD405-7
Assembly 3. Install damper assembly (5) to the flywheel.

2 Spline of body assembly shaft:
ENS grease
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
4. Press fit bearing (3) to cover (4).

2 Bearing: ENS grease
5. Install the cover assembly to the flywheel.

4 Cover assembly: 35 kg
6. Fit oil seal (1) to cage (2).

2 Oil seal: ENS grease
1. Using the push tool, press fit bearing (11) to
the flywheel. 7. Install the cage assembly to the cover assem-
2 Inside of flywheel and bearing:
bly.
2 Mating face: Gasket sealant (LG-4)
ENS grease
3 Mounting bolt:
2. Assembly of damper assembly
98 – 123 Nm {10.0 – 12.5 kgm}
1) Apply gasket sealant to outer body (10)

and the mating face of flange (6), then
install them.
3 Mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
2) Install body assembly (7).
3) Install rubber parts (8) and (9).
a Before installing these parts, apply
grease to them.
2 All outside surfaces of rubber part,
outside of inner body and inside of
outer body: ENG grease (G2-U-S)
4) Install flange (6).
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
a When installing, match the marks of
the outer body and body assembly
flange.
HD325-7, HD405-7 19
q Procedure for filling ENS grease

1) Part No. of ENS grease: 427-12-11871
2) Parts to be filled with ENS grease and
quantity of ENS grease to be supplied
(Total: Approx. 225 g)
20 HD325-7, HD405-7
Removal and installation of fuel 3. Disconnect connectors PCV1 (6) and PCV2
(7).
supply pump assembly 1 a Remove the 2 scatter prevention covers
from the connectors first.
Special tools
4. Remove the stay and clamps (8) – (13).
New/Remodel
Necessity
Sym-
Part No. Part name 5. Remove 2 high pressure pipes (14).
Sketch
bol
a Remove the 2 scatter prevention covers
Q'ty
from the common rail side of the high-
1 795-630-5500 Standard puller t 1 pressure pipes first.
A 2 01010-81090 Bolt t 2
3 01643-31032 Washer t 2
Removal
1. Remove engine side covers (1) – (3).
6. Disconnect connector G (15).
7. Disconnect fuel hose (16).
8. Disconnect tubes (17) – (24). [*1]
2. Remove corrosion resistor (4) and fuel filter

(5).
9. Remove tube (25). [*2]
HD325-7, HD405-7 21
10. Remove cover (26). 13. Remove bracket (30) and loosen 4 mounting
bolts (31).
11. Rotate the crankshaft forward and set interme-
diate point (a) between the stamps of "2/5TOP" 14. Set tools A1, A2 and A3 to drive shaft (32) and
and "3/4TOP" on damper (27) to pointer (28). tighten the center bolt of tool A1 to remove
a Rotate the crankshaft with hexagonal part drive gear (32) from the shaft.
(b) at the end of the water pump drive
shaft. 15. Remove mounting bolts (31) and fuel supply
a At this time, check that the forcing tap of pump assembly (33).
the drive gear is set to bolt hole (c) at the a If tools A1, A2 and A3 are removed, drive
top of cover (29). (If not, rotate the crank- gear (32) falls. Accordingly, keep those
shaft 1 more turn.) tools installed until the fuel supply pump
a At this position, the key of the pump shaft assembly is installed.
is rotated clockwise 15° from the top.
12. Remove mounting nut (29). [*3]

a Take care not to drop the nut in the gear
case.
22 HD325-7, HD405-7
Installation High-pressure pipe

k When handling the high-pressure pipe and
1. Set fuel supply pump assembly (33).
clamp, observe the following.
a Before setting, check that key (d) of the
q Do not bend the high-pressure pipe to col-
shaft is matched to key way (e) of the
lect before installing or use it for another
drive gear.
section.
q Install the specified clamp to the specified
2. Finger tighten 4 mounting bolts (31) and
position securely.
bracket (30).
q Do not apply lubricant to the high-pressure
pipe sleeve nut and the threads of the
mating part.
a If lubricant is applied, the axial tension
is increased too much and the high-
pressure pipe may be broken when the
sleeve nut is tightened.
k Before installing the high-pressure pipe,
check it. If it has any defect, replace it
since fuel may leak.
q Check the taper seal of the connecting
part (Part (a): Part of 2 mm from the end)
for visible lengthwise slit (b) and dent (c).
q Check part (d) (End of the taper seal: Part
at 2 mm from the end) for stepped-type
wear (fatigue) which your nail can feel.
HD325-7, HD405-7 23
3. Finger tighten high-pressure pipe (14) first and 9. Carry out the following installation in the
then tighten it to the following torque. reverse order to removal.
3 Sleeve nut (Common rail side): [*1]
39.2 – 58.8 Nm {4 – 6 kgm} 3 Joint bolt of fuel tubes (17) and (19):
3 Sleeve nut (Supply pump side): 14.8 – 19.6 Nm {1.5 – 2.0 kgm}
39.2 – 49 Nm {4 – 5 kgm} (Supply pump side)
3 Sleeve nut: 43 – 47 Nm {4.4 – 4.8 kgm}
4. Tighten 4 mounting bolts (31) permanently. 3 Joint bolt of tube (21) (Supply pump
side): 7.9 – 12.7 Nm {0.8 – 1.3 kgm}
5. Tighten bracket (30) permanently. 3 Sleeve nut of oil tube (23):
3 Mounting bolt: 43 – 47 Nm {4.4 – 4.8 kgm}
19.6 – 29.4 Nm {2.0 – 3.0 kgm} 3 Joint bolt fuel tube (24):
17.7 – 22.6 Nm {1.8 – 2.3 kgm}
6. Tighten clamps (10), (9) and (12) and stays (1), (Common rail side)
(8) and (13).
[*2]
7. Tighten clamps (10), (9) and (12) permanently. 3 Joint bolt of fuel tube (25):
a Tighten clamps (10), (9) and (12) in order. 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3 Clamp bolt: 9.8 ± 1.0 Nm {1 ± 0.1 kgm} (Filter side)
3 Joint bolt of fuel tube (25):
8. Tighten stays (11), (8) and (13) permanently. 14.8 – 19.6 Nm {1.5 – 2.0 kgm}
a Tighten stays (11), (8) and (13) in order. (Supply pump side)
a Set the notch of the scatter prevention
cover on the supply pump toward the [*3]
block and set that on the common rail side 3 Nut: 176 – 196 Nm {18 – 20 kgm}
down.
k Check that each high-pressure pipe is
at least 10 mm apart from the wiring
harness around it. If not, adjust the
wiring harness to secure a clearance of
10 mm.
q Bleeding air
Bleed air from the fuel circuit. For details,
see Testing and adjusting, "Bleeding air
from fuel circuit".
24 HD325-7, HD405-7
Removal and installation of fuel 5. Remove tube (6) and block (7).
injector assembly 1
Removal
a The procedure for removing the No. 1 fuel
injector assembly is explained in this section.
1. Remove engine side covers (1) and (2).
6. Remove cover (8). [*2]
7. Remove bracket (9) and clamps (10) and (11).
8. Remove stays (12) – (14) and clamp (15).
3. Remove washer tank (4).
4. Remove tube (5). [*1]
HD325-7, HD405-7 25
9. Remove high-pressure pipe (16). 13. Loosen sleeve nut (26) and remove high-pres-
sure pipe (27) from the injector.
14. Remove wiring harness clamp bolt (28) and

clip (29). [*6]
15. Remove 2 wiring harness capture nuts (30)

from the fuel injector assembly. [*7]
a Loosen the capture nuts alternately.
16. Remove holder mounting bolts (31).
10. Remove cylinder head cover (17). [*3]
17. Insert L-bar [1] under inlet connector (a) of the

fuel injector assembly and pry off fuel injector
assembly (32) slowly.
a Never hold and pull out the solenoid valve
on the top of the fuel injector with pliers,
11. Remove cover (18). [*4]
etc.
12. Remove mounting bolts (19) – (21) and rocker
arm and rocker shaft assembly (22). [*5]
a Loosen locknut (24) and loosen adjust-
ment screw (25) 2 – 3 turns so that an
excessive force will not be applied to push
rod (23) when the rocker arm is installed.
26 HD325-7, HD405-7
Installation 6) Tighten bolt (31) permanently.

3 Bolt (31):
1. Install the fuel injector assembly. 58.8 – 73.5 Nm {6 – 7.5 kgm}
1) Check that there is no foreign matter in the 7) Tighten sleeve nuts (26) and (16) perma-
injector sleeve. nently.
3 Sleeve nuts (26) and (16):
2) Install O-rings (34) and (35) and gasket
(36) to the injector. 39.2 – 49 Nm {4 – 5 kgm}
a Take care not to fit the O-ring to
groove (b).
3) Set holder (33) and fuel injector (32)

assembly together to the cylinder head.
4) Fit spherical washer (37) to bolt (31) and
tighten bolt (31) temporarily.
2 Spherical washer: Engine oil
5) Tighten high-pressure pipe sleeve nuts
(26) and (16).
k Before installing the high-pres-
sure pipe, check it. If it has any
defect, replace it since fuel may
leak.
q Check the taper seal of the connect-
ing part (Part (a): Part of 2 mm from
the end) for visible lengthwise slit (b)
and dent (c).
q Check part (d) (End of the taper seal:
Part at 2 mm from the end) for
stepped-type wear (fatigue) which
your nail can feel.
HD325-7, HD405-7 27
2. Install the high-pressure pipe clamp and stays. 3. Carry out the following installation in the
1) Finger tighten all of the clamping bolts and reverse order to removal.
stay mounting bolts of the high-pressure
pipe clamp and stays (13) and (38) - (42). [*1]
2) Tighten the high-pressure pipe clamping a Install the hose so that it will not twist.
bolt permanently. a When using 2 clamps, set them 180 degrees
3 Clamping bolt: apart from each other as shown in the figure.
9.8 ± 1 Nm {1 ± 0.1 kgm} a Set hose insertion length "a" as shown below.
3) Tighten the stay mounting bolts perma- Hose insertion length "a": 50 mm
nently. 3 Hose clamp: 10.5 ± 0.5 Nm {107 ± 5 kgm}
4) Finger tighten all of the clamping bolts and
stay mounting bolts of the high-pressure
pipe clamp and stays (12) and (44) - (48).
5) Install cover (8).
a Install the cover with the notch toward
the cylinder block.
6) Install high-pressure pipe clamps (10) and
(11) and gate-type bracket (9) temporarily.
7) Tighten the clamping bolts of high-pres-
sure pipe clamps (10) and (11) perma-
nently.
3 Clamping bolt:
9.8 ± 1 m {1 ± 0.1 kgm}
8) Tighten gate-type bracket (9) permanently.
9) Tighten the clamping bolts of the high-
pressure pipe clamp and stays (12) and
(44) - (48) permanently.
3 Clamping bolt:
9.8 ± 1 m {1 ± 0.1 kgm}
10) Tighten the stay mounting bolts perma-
nently.
[*2]
a Direct the notch down.
[*3]
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
[*4]
a Direct the notch down.
[*5]
a Before tightening the mounting bolts of rocker
arm and rocker shaft assembly (22), check that
the ball of adjustment screw (25) is fitted
securely to the socket of push rod (23).
28 HD325-7, HD405-7
a The 3 mounting bolts are different from each

other. When installing them, see the following.
q Mounting bolt (19):
Stem length is 120 mm.
q Mounting bolt (20): Stem length is 90 mm.
q Mounting bolt (21):
Stem length is 75.2 mm.
3 Mounting bolts (19), (20) and (21):

93 – 103 Nm {9.5 – 10.5 kgm}
a Adjust the valve clearance. For details, see

Testing and adjusting, "Adjusting valve clear-
ance".
[*6] [*7]
a Install the wiring harness according to the fol-
lowing procedure.
1) Install clip (29).
2) Tighten 2 capture nuts (30).
a Tighten the capture nuts alternately.
3 Capture nut:
2 ± 0.2 Nm {0.2 ± 0.02 kgm}
3) Tighten wiring harness clamping bolt (28).
HD325-7, HD405-7 29

© 2007 KOMATSU
All Rights Reserved
30 HD325-7, HD405-7
SEN01956-01
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up

Power train, Part 1
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
HD325-7, HD405-7 1
Removal and installation of 6. Remove bleeder (6).

torque converter and a Remove the bleeder and bracket together.
transmission assembly 1 7. Disconnect connectors PM (7), SL (8), CJB

(9), CJA (10), CJE3 (11) and CJL (12).
Removal
k Stop the machine on a level ground and 8. Remove bracket (13).
pin.
k Disconnect the cable from the negative (-)
1. Drain the transmission oil.

6 Transmission case:
165 l (including brake system tank)
2. Drain the hydraulic oil.

6 Hydraulic tank: 211 l
q Muffler related 9. Disconnect breather hose (14).

3. Remove covers (1) – (3)
10. Disconnect connector H01 (15).
4. Remove muffler band (4). a Connector CJN (16) is not used.
a Sling the muffler temporarily.
13. Remove plate (19).

a The plate is made of 3 pieces.
a Disconnect the wiring under the plate and
move it to a place where it will not be
obstacle.
5. Lift off muffler assembly (5).

4 Muffler assembly: 60 kg
2 HD325-7, HD405-7
14. Disconnect hoses (20) – (29). 18. Lift off work equipment and steering pump
assembly (35).
4 Work equipment steering pump assem-
bly: 35 kg
15. Disconnect tubes (30) and (31). [*1]
16. Disconnect hose (32) and tube (33).

19. Remove tube (36).
20. Remove the mounting bolts of tube (37).

a Remove only the bolts on the pump side.
17. Disconnect tube (34). [*2]
21. Lift off retarder cooling pump assembly (38).

4 Retarder cooling pump assembly: 35 kg
HD325-7, HD405-7 3
22. Disconnect front drive shaft assembly (39). 26. Remove cover (45).
[*3]

23. Remove guard (40).
28. Disconnect hoses (47) – (49).
24. Disconnect rear drive shaft assembly (41). [*4]
29. Remove 2 underguard mounting bolts (50).

25. Remove covers (42) – (44). a Sling the underguard temporarily with a
nylon sling etc. to prevent it from falling.
a After removing the mounting bolts, lower
the underguard slowly.
4 HD325-7, HD405-7
30. Disconnect tubes (51) – (53). [*5] 34. Disconnect connector BCVR (59).
31. Disconnect tubes (54) – (56). [*6] 35. Disconnect hose (60).
32. Disconnect hose clamp (57). 36. Disconnect tubes (61) and (62).
33. Remove brake system tank (58). 37. Remove front mounting bolts (63).
a Sling the brake system tank with nylon
sling etc. and lower it slowly. 38. Remove rear mounting bolts (64).
HD325-7, HD405-7 5
39. Lift off torque converter and transmission

assembly (65).
a Check that all the wires and pipes are dis-
connected.
a When removing the assembly, take care
that it will not interfere with the chassis.
4 Torque converter and transmission
assembly: 1,390 kg
6 HD325-7, HD405-7
Installation [*5]
a When the clamping bolts are loosened.
3 Clamping bolts (51) and (53):
removal. 13.7 ± 0.5 Nm {1.4 ± 0.05 kgm}
3 Clamping bolt (52):
10.1 ± 12.4 Nm {1.03 ± 1.26 kgm}
[*1] a When using 2 clamps, set them 180 degrees
a Install only 1 bolt (a). apart from each other as shown in the figure.
2 Tube mounting bolt (a):
49 ± 4.9 Nm {5 ± 0.5 kgm}
[*6]
a When the clamping bolts are loosened.
3 Clamping bolts (54):
[*2]
a When the clamping bolts are loosened. 13.7 ± 0.5 Nm {1.4 ± 0.05 kgm}
3 Clamping bolt (55):
from each other as shown in the figure. 10.1 ± 12.4 Nm {1.03 ± 1.26 kgm}
3 Clamping bolt:
a When using 2 clamps, set them 180 degrees
13.7 ± 0.5 Nm {1.4 ± 0.05 kgm} apart from each other as shown in the figure.
[*3] [*7]
2
3
Front drive shaft: Adhesive (LT-2) Mounting bolt (64):
3 Front drive shaft: 172 – 215 Nm {17.5 – 215 kgm}
98 – 123 Nm {10.0 – 12.5 kgm}
q Refilling with oil
[*4] Add oil through the oil filler to the specified
a See the procedure for aligning the engine level. Run the engine to circulate the oil
assembly and torque converter and transmis- through the system. Then, check the oil level
sion assembly. again.
2 Rear drive shaft: Adhesive (LT-2)
3 Rear drive shaft:
6 Transmission case: 165 l
157 – 196 Nm {16 – 20 kgm}
(including brake system tank)
6 Hydraulic tank: 211 l
HD325-7, HD405-7 7
a Align the engine assembly with the torque con- 3. After installing the drive shaft between the
verter and transmission assembly according to engine and torque converter, measure dimen-
the following procedure. sion (f).
a If the engine assembly or transmission and q (f): 210 (0/-3) mm
torque converter assembly or drive shaft was a If (f) is not in the tolerance, adjust it.
removed, align the engine and transmission in
the lateral direction, using tool C1.
1. Check that the rear drive shaft mounting yokes

are set in the same direction.
a Match marks (d) must be set in the same
direction as shown below.
2. Align the drive shaft between the engine and

torque converter according to the following
procedure.
1) Either of the misalignments of the shaft
((c) and (d) in the following illustration)
must not exceed 3 mm.
2) e = e
a If the shafts are not in parallel, the
widest clearance must not exceed 3
mm.
a Measure right or left misalignment of
the shaft (Top view).
8 HD325-7, HD405-7
Disassembly and assembly of Assembly

torque converter and control a Check all the parts for dirt and damage and
valve assembly 1 coat their sliding surfaces with engine oil
before installing.
Disconnect
1. Fit the O-ring and install plate (19).
1. Remove body (1).
2. Install spool (18) to body (1).
2. Remove cover (2) and spring (3).
3. Fit the O-ring and install cover (17).
3. Remove plate (4), valves (5) and (7), spring (6)
and torque converter relief valve (8).
4. Remove cover (9), shim (10) and spring (11).
5. Install valves (15) and (13) and spring (14) to
a Check the quantity and thickness of the
main relief valve (16) and then install them to
shims.
body (1).
5. Remove plate (12), valves (13) and (15),
6. Install shim (10) and spring (11) to cover (9)
spring (14) and main relief valve (16).
and then fit the O-ring and install them to body
(1).
6. Remove cover (17), spool (18) and plate (19).
8. Install valves (7) and (5) and spring (6) to

torque converter relief valve (8).
9. Install spring (3) to cover (2).
HD325-7, HD405-7 9
Disassembly and assembly of 3) Using eye bolts [1], remove PTO assem-
bly (4) with forcing screw.
torque converter assembly 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
Unit repair stand
1 790-413-1110 t 1
(100V)
790-501-5000 Unit repair stand
or (110 – 120V or t 1
790-501-5200 220 – 240V)
C 2
790-901-2110 Bracket t 1
3. Turbine • clutch assembly
793-310-2141 Plate t 1 Q 1) Remove 30 mounting bolts (5).
3 790-102-1871 Nut wrench t 1 2) Using eye bots [1], remove turbine • clutch
4 792-108-5110 Wrench t 1 assembly (6).
Disassembly
1. Control valve assembly
Remove control valve assembly (1).
4. Stator assembly
Remove assembly (7) with pulling up.
2. PTO assembly
1) Set torque converter assembly (2) on tool
C2.
2) Remove input coupling (3).
10 HD325-7, HD405-7
5. Pump assembly 4) Using push tool [3], remove bearing (13)

1) Using tool C4, remove nut (8). from guide.
2) Using puller [2], remove inner race (9) and 6. Stator shaft
pump assembly (10). 1) Remove mounting bolts, then remove sta-
tor shaft (14).
3) Remove mounting bolt, then remove

retainer (11) and guide (12). 2) Remove plug, then remove inner race (15)
with bar.
3) Remove seal ring (16).
HD325-7, HD405-7 11
q Disassembly of turbine • clutch assembly 9. Housing assembly

7. Input shaft 1) Remove mounting bolt, then lift off hous-
1) Using forcing screw [4], remove input ing assembly (22).
shaft (17). 2) Remove piston (23) from housing assem-
2) Using puller [5], remove bearing (18). bly, then remove seal ring (24).
8. Turbine 3) Using push tool [7], remove bearing (25)

1) Remove snap ring (19), then remove from housing.
plate (20). 4) Remove seal ring (26).
5) Remove pin (27).
2) Using forcing screw [6], remove turbine

(21). 10. Disc
Remove disc (29) from case (28).
12 HD325-7, HD405-7
q Disassembly of stator assembly Assembly

11. Stator
Remove mounting molt, then remove stator q Assembly of stator assembly
(30). 1. Race • free wheel
Install free wheel (35) and race (34) in race
(31).
a Assemble the free wheel so that the arrow
on the end face of the gauge is at the input
shaft end.
a Coat the race sliding surface with engine
oil (EO30-CD or EO10-CD)
12. Bushings
Remove bushings (32) and (33) from race
(31).
a Be careful not to lose balls.
13. Race • free wheel

Remove race (34) and free wheel (35) from
2. Bushings
race (31).
Install bushings (33) and (32) in race (31).
a Be careful not to forget assembling of
balls.
3. Stator
Installstator (30).
3 Mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
a Check the direction of rotation of the sta-
tor.
Dirredtion of rotation as seen from input
end:
Clockwise: Free
Counterclockwise: Locked
HD325-7, HD405-7 13
q Assembly of turbine • clutch assembly a Install sealring as shown figure.

4. Tubine • case 2 Rings: Grease (G-LI)
Set turbine (21) and case (28) on push tool [8].
a Use block to prevent from case (28) direct
contacting with turbine (21).
3) Install piston in housing assembly (22),

then install housing assembly on case
(28).
5. Disc 2 Mounting bolt: Adhesive (LT-2)
Install disc (29). 3 Mounting bolt:
a Coat the disc sliding surface with engine 98.1 – 122.6 Nm {10 – 12.5 kgm}
oil (EO30 - CD or EO10 - CD).
7. Bearing
6. Housing assembly 1) Using push tool [9], press fit bearing (25).
1) Install pin (27).
a Expand fit pin (27) to the housing.
2) Install seal rings (24) and (26) on piston
(23) and housing (22).
14 HD325-7, HD405-7
2) Fit plate (20), then install snap ring (19). 3) Set torque converter case on tool C2.
4) Install stator shaft (14) on case.
3 Mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}
8. Input shaft
1) Using push tool, press fit bearing (18) on
input shaft (17).
2) Install input shaft (17) on housing.
2 Mounting bolt: Adhesive (LT-2) 10. Pump assembly
3 Mounting bolt: 1) Using push tool [10], press fit bearing (13)
269.7 – 308.9 Nm {27.5 – 31.5 kmg} in guide (12).
q Assembly of torque converter assembly 2) Install guide (12) and retainer (11) with
9. Stator shaft mounting bolts.
1) Install seal ring (16). 2 Mounting bolt: Adhesive (LT-2)
2 Seal rings: Grease (G2-LI) 3 Mounting bolt:
2) Using push tool, press fit inner race (15). 58.8 – 73.5 Nm {6 – 7.5 kmg}
HD325-7, HD405-7 15
3) Set pump assembly (10) and inner race 12. Turbine • clutch assembly
(9) on mounting position. Using eye bolts [1], set turbine assembly (6) on
4) Using push tool [11], press fit inner race mounting position, then tighten 30 mounting
(9). bolts (5).
a Apply a drop of engine oil (EO30-CD 2 Mounting bolt: Adhesive (LT-2)
or EO10-CD), and rotate the bearing. 3 Mounting bolt:
49.0 – 58.8 Nm {5 – 6 kgm}
5) Tighten nut (8) with tool C4.

2 Nut: Adhesive (LT-2) 13. PTO assembly
3 Nut: 1) Fit O-ring, using eye bolt: [1], install PTO
441.3 – 490.3 Nm {45 – 50 kgm} assembly (4).
11. Stator assembly 2) Fit O-ring, install input coupling (3), then
Install stator assembly (7). install holder (36).
2 Mounting: Adhesive (LT-2)
3 Mounting bolt:
279.5 ± 29.4 Nm {28.5 ± 3.0 kgm}
16 HD325-7, HD405-7
14. Control valve assembly

Fit gasket, then install control valve assembly
(1).
3 Mounting bolt:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
HD325-7, HD405-7 17
Disassembly and assembly of

PTO assembly 1
Disassembly
1. Using tool C3, remove nut (1).
a Disassemble in same way for all three

pump drive gears.
5. Remove cover (11), then remove oil seal (12).
6. Remove other race (14) from case (13).

2. Using puller [1], remove gear (2) and bearing
(3).
3. Remove plate (4) and bearing (5) from gear

(2).
4. Remove snap ring (6), then remove plate (7),

outer race (8), plate (9) and outer race (10).
18 HD325-7, HD405-7
Assembly q Assemble all three pump drive gears as fol-

lows.
1. Using push tool [1], press fit outer race (14) in
case (13). 4. Install outer race (10), plate (9), outer (8) and
plate (9), then install snap ring (6).
2. Using push tool [2], install oil seal (12) in cover a The bearing form a set, so assembly the
(11). same production numbers, and match
marks [A] and [A], [B] and [B].
3. Fit O-ring, then install cover (11).
a Install the snap rings as shown in the fig-

ure (all of the 3 pieces).
5. Using push tool, press fit gear (2) and bearing

(5).
HD325-7, HD405-7 19
6. Set plate (4) in case (13). a Install the nut as shown in the figure.
7. Using block [2] and push tool [3], press fit bear-
ing (3).
8. Tighten nut (1) with tool C3.

2 Nut: Adhesive (LT-2)
3 Nut:
313.8 – 392.3 Nm {32 – 40 kgm}
a Bend lock washer securely.
20 HD325-7, HD405-7
Disassembly and assembly of 3. Remove intermediate shaft rotation sensor,

torque converter output shaft sensor cover,
transmission assembly 1 then remove intermediate shaft rotation sensor
(4) and torque converter out put shaft sensor
Special tools
(5).
a Remove the torque converter output shaft
New/Remodel
and intermediate shaft sensor cover first.
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
Oil leak tester kit
D1 799-301-1600 t 1
(A)
Disassembly
q Disconnect torque converter assembly
1. Lift off Transmission control valve assembly (2)

from transmission assembly (1).
4. Speedometer sensor
Remove cover (6), then disconnect sensor
connector (7).
2. Sleeve
Using eye bolt [1], remove 5 sleeves (3).
5. Oil pan assembly

1) Set transmission assembly on block
(Height = 150 mm) facing input shaft top.
2) Lift off oil pan (8).
HD325-7, HD405-7 21
q Disassembly of oil pan q Disassembly of No.1 clutch assembly

3) Remove baffle plate (9). 1) Input shaft assembly
4) Remove valve (10). 1] Remove input shaft assembly (18).
5) Remove block (11), then remove valves
(12) and (13).
6) Remove cover (14), spring (15) then
remove magnet assembly (16).
2] Disassemble input shaft assembly as

follows.
1> Remove snap ring (19), then
remove gear (20) from shaft (21).
6. Checking piston operation
Using tool D1, check piston operation of No. 1,
2, and 3 clutches.
2> Remove bearing (22) from gear

(20).
a Air pressure: 0.3 – 0.6 Mpa {3 – 6 kg/cm2}
7. No.1 clutch assembly

Sling shaft, then remove No. 1 clutch assembly
(17).
22 HD325-7, HD405-7
3> Remove snap ring (23), then 2] Remove snap ring (34).
remove bearing (24). 3] Remove inner race (35).
4> Remove snap ring (25).
5) Plate
2) No. 1 housing • piston Remove bearing (36) from plate (33).
Remove housing (26) together with piston.
8. Lift off No. 2 clutch assembly (37).

3) Discs • plates • spring
Remove discs (27), plates (28) and
springs (29) and (30).
4) Ring gear • guide pins
1] Removen ring gear (31) and guide
pins (32).
HD325-7, HD405-7 23
q Disassembly of No. 2 clutch assembly 2) Discs • plates

1) Housing assembly Remove discs (47), plates (48) and spring
1] Remove housing (38). (49).
2] Remove cylinder (39), then remove 3) Remove plates (50).

piston (40) from housing (38).
3] Remove seal (41) from piston (40).
4) Remove drum (51).
4] Remove seal rings (42) and (43), and

bearing (44) from housing (38).
5] Remove seal ring (45).
6] Remove bearing (46) from housing
(38).
24 HD325-7, HD405-7
5) Planetary gear 9. Transmission case assembly

1] Remove shafts (52) Lift off transmission case assembly (63).
a Be careful not to lose balls (53).
2] Remove gear (54), bearing (55), and
thrust washer (56) from carrier (57).
10. Trasmission case

1) Remove snap ring (64).
2) Remove collar (65).
3] Remove bearing (58), seal ring (62), 3) Remove inner race (66) from collar.
and inner race (59) from carrier (57),
then remove ring gear (60).

a When removing ringer (60) from car- 5, 6, and 7 cutch.
rier (57), use two of the four holes in
the ring gear on opposite sides, insert
round bar [1] (max. diameter: ø8
mm), compress snap ring (61), and
pull out the ring gear.
HD325-7, HD405-7 25
12. No. 3 clutch housing 4] Remove seal rings (72) and (73), and
Lift off No. 3 clutch housing (67). bearing (74) from housing (68).
6] Remove bearing (76) from housing
(68).
q Disassembly of No. 3 clutch assembly

1) Housing assembly
1] Remove housing assembly (68).
2) Drum, disc, plate, spring
Remove disc (78), plate (79), and spring
(80) from drum (77).
2] Remove cylinder (69), then remove

piston (70) from housing (68).
3] Remove seal ring (71) from piston
(70). 13. No. 3 clutch ring gear
1) Remove ring gear (81).
2) Remove seal ring (82) and inner race (83)
from ring gear (81).
26 HD325-7, HD405-7
14. Tie bolt 19. No. 5 clutch discs • plates • springs

Remove tie bolt (84). Remove discs (93), plates (94) and springs
(95) and (96).
15. No. 4 clutch plate
Remove plate (85).
20. Guide pins

Remove guide pins (97).
16. No. 4 clutch discs, plates, springs
Remove discs (86), plates (87), and springs
(88) and (89).
21. No. 5 clutch ring gear

Remove ring gear (98).
17. No. 4 ring gear

18. No. 4 piston, housing

Remove housing (91) together with piston (92),
then remove piston (92) from housing (91).
HD325-7, HD405-7 27
22. No. 5 housing, piston 25. No. 4, 5 carrier assembly

Using eyebolts, remove No. 5 housing (99) Lift off No. 4 and 5 carrier assembly (109).
together with piston (100).
q Disassembly of no. 4, 5 carrier assembly

23. No. 6 clutch discs • plates • springs 1) Planetary gear for reverse
Remove discs (101), plates (102) and springs 1] Knock shaft (110) for reverse gear out
(103) and (104). to ball end, and remove ball (111).
2] Knock shaft (110) out from ball end,
and remove reverse gear (112), bear-
ing (113), collar (114), and thrust
washer (115).
24. Sun gear

1) Remove snap ring (105).
2) Remove No. 4 sun gear (106) and No. 5
sun gear (107).
a Remove seal ring (108) from No. 4 a Knock shaft (110) out to the No. 4 car-
sun gear. rier end. Be careful not to lose ball
(111).
28 HD325-7, HD405-7
2) No. 4, 5 planetary gear 26. No. 6, 7 housing, No. 6, 7 piston

1] Knock shaft (116) out to ball end, and 1) Lift off No. 6 and 7 housing (129), No. 6
remove ball (117). piston (130), and No. 7 piston (131).
2] Knock out shaft (116), then remove 2) Remove No. 6 piston (130) and No. 7 pis-
No. 4 planetary gear (118), bearing ton (131) from housing (129).
(119), thrust washer (120), No. 5
planetary gear (121), bearing (122),
collar (123), and thrust washer (124).
3) Remove seal rings (132) from pistons

(130) and (131).
4) Remove seal ring (133) from housing
3) Bearing, ring gear (129).
1] Remove bearing (125) from carrier.
2] Remove ring gear (126).
27. Guide pin

Remove guide pin (134).
a When removing ring gear (126) from
carrier (127), use two of the four 28. No. 7 clutch discs, plates, springs
holes in the ring gear on opposite Remove discs (135), plates (136), and springs
sides, insert round bar [1] (max. diam- (137) and (138).
eter: ø8 mm), compress snap ring
(128), and pull out ring gear (126).
HD325-7, HD405-7 29
29. No. 6, 7 carrier assembly

Using eyebolts, remove No. 6 and 7 carrier
assembly (139).
2] Remove sun gear (145) and snap ring

(146) from intermediate shaft (143).
3] Remove inner race (147).
q Disassembly of no. 6, 7 carrier assembly
1) Collar
Remove collar (140).
2) Remove inner races (141) and (142) from
collar (140).
4) Bearing, seal ring

2] Remove bearing (149).
3) Intermediate shaft, sun gear, bearing

1] Knock out intermediate shaft (143),
and remove intermediate shaft and
bearing (144).
30 HD325-7, HD405-7
5) No. 6 planetary gear 31. Worm, collar

1] Remove snap ring (150). Remove worm (158) and collar (159) from
cage (157).
2] Pull out shaft (151), then remove No.

6 planetary gear (152), bearing (153), 32. Output shaft
thrust washer (154), and ball (155). 1) Remove output shaft assembly (160) from
cage (157).
6) No. 7 planetary gear

a Follow Steps 1] and 2] to disassem- 2) Set cage (161) on block, press output
ble. shaft (162) with press, and pull out from
bearing.
30. No. 7 ring gear
HD325-7, HD405-7 31
3) Disassembly of cage Assembly of transmission assembly

1] Remove oil seal (163) from cage
(161). Caution when assembling
2] Remove bearing (164) from cage a Clean all parts, and remove burr.
(161). a Coat seal ring with grease (G2-LI) before
installing.
a Coat rotating surfaces and sliding surfaces
with engine oil before installing.
1. Output shaft assembly

1) Install bearing (166) in cage (157).
3] Remove bearing (165) from output

shaft (160).
2) Assemble output shaft assembly as fol-

lows.
1] Install bearing (165) in output shaft
(160).
4) Remove bearing (166) from cage

(157).
2] Install bearing (164) in case (161).

3] Install oil seal (163) in cage (161).
2 Oil seal lip: Grease (G2-LI)
32 HD325-7, HD405-7
4] Set output shaft (162) on press, then 2. No. 7 ring gear

press inner race to install cage (161). Install ring gear (156).
a Install ring gear so that outer gear which is
cut faces top.
3) Fit O-ring, install output shaft assembly

(160) in cage (157).
2 Mounting bolt: Adhesive (LT-2) q Assembly of no. 6, 7 carrier assembly
1] Assemble bearings (153) in gear
(152), set gear and thrust washers
(154) on carrier.
2] Knock in shaft (151), then assemble
ball (155) to install completely.
4) Turn over cage (157), and assemble collar

(159) and worm (158).

a For details, refer to step 1) (No. 7
planetary gear).
3) Inner race . snap ring (No. 7 side)
1] Install snap ring (150).
HD325-7, HD405-7 33
2] Install bearings (149). 5) Collar

3] Install seal ring (148). 1] Install inner races (141) and (142) on
collar (140).
2] Install collar (140) on carrier (139).
4) Intermediate shaft . No. 6 sun gear

1] Install inner race (147) on intermedi-
ate shaft (143). 3. No. 6, 7 carrier assembly
2] Install snap ring (146). Using eyebolts, install No. 6, 7 carrier assem-
bly (139).
a Be careful not to fall piston.
3] Install intermediate shaft (143) on car-

rier (139).
4] Install sun gear (145). 4. Guide pins
5] Using push tool [1], install bearing Install guide pins (134).
(144).
5. No. 7 clutch discs • plates • springs
Install discs (135), plates (136) and springs
(137) and (138).
a There are four discs and three plates.
a Free length of spring (137): 58 mm
34 HD325-7, HD405-7
6. No. 6, 7 housing • No. 6, 7 pistons q Assembly of No. 4, 5, carrier assembly

1) Assemble seal ring (132) to piston (130), 4) No. 4, 5, planetary gear
then assemble seal ring (133) to housing 1] Assemble bearing (119) in No. 4 plan-
(129). etary gear (118), then fit thrust wash-
2) Assemble piston (130) in housing (129). ers (120) to both sides, and set in
carrier.
2] Insert collar (123) between 2 bearings
(122), assemble in No. 5 planetary
gear (121), then fit thrust washers
(124) to both sides, and set in carrier.
3] Cool shaft (116) with dry ice and
assemble to carrier.
a Check that the positions for the
holes of the bearing, thrust washer,
and carrier are aligned correctly,
then assemble the shaft, being
extremely careful not to damage
the bearing or thrust washer.
a When assembling, align the hole
a Install the seal ring so that the portion
in the carrier with the hole for
with the groove faces the side taking
mounting the ball.
the pressure.
4] Fit ball (117) and install shaft (116)

3) Using eyebolts, align with springs, then
completely.
install housing (129).
a Check that the gear rotates
a Knock in dowel pin with plastic ham-
smoothly.
mer.
a Check that the spring is fitted
securely into the seat of the piston
and housing.
HD325-7, HD405-7 35
5) Planetary gear for reverse 6) Bearing

1] Insert collar (114) between 2 bearings Install bearing (125) in carrier (109).
(113), assemble in gear (112), then fit
thrust washers (115) to both sides,
and set in carrier.
7) No. 6 ring gear

Install snap ring (127) to carrier case
(109), then assemble ring gear (126).
2] Align with bearing and thrust washer, a Keep the snap ring compressed and
and push in shaft (110). push the ring gear in.
3] Knock shaft (110) out until ball hole
can be seen completely, then assem-
ble ball (111) and knock into carrier to
install.
a When press fitting the shaft, align
the center of the bearing and
shaft to prevent the bearing cage
from becoming deformed. Do not
hit the shaft when assembling.
a Check that the gear rotates
smoothly.
7. No. 4, 5 carrier assembly

Using eyebolts, install No. 4, 5 carrier assem-
bly (109).
36 HD325-7, HD405-7
8. Sun gear a Knock in dowel pin with plastic ham-

1) Install No. 5 sun gear (107) and No. 4 sun mer.
gear (106). a Check that the spring is fitted
a Install seal ring (108) on No. 4 sun securely into the seat of the piston
gear. and housing.
2) Install snap ring (105).
11. No. 5 ring gear

9. No. 6 clutch discs • plates • springs Install ring gear (98).
Install discs (101), plates (102) and springs a Install ring gear so that inner gear which is
(103) and (104). cut faces lower.
a There are four discs and three plates.
a Free length of spring (103): 58 mm 12. Guide pins
Install guide pins (97).
10. No. 5 housing • No. 5 piston

1) Assemble seal ring, then install piston
(100) in housing.
a Install seal ring with groove side fac-
ing pressure receiving side.
2) Using eyebolts, align with springs, then
install housing (99).
HD325-7, HD405-7 37
13. No. 5 clutch discs • plate • springs 15. No. 4 ring gear
Install discs (93), plates (94) and springs (95) Install ring gear (90).
and (96). a Install ring gear so that outer gear which is
a There are five discs and four plates. cut faces lower.
a Free length of spring (95): 77 mm

14. No. 4 housing • No. 4 piston Install discs (86), plates (87) and springs (88)
1) Assemble seal ring, then install piston (92) and (89).
in housing. a No. 4 clutch discs and plates are different
a Install seal ring with groove side fac- from No. 5, 6 and 7 clutch.
ing pressure receiving side. a There are three discs and two plates.
2) Align spline, then install housing (91). a Free length of spring (88): 54 mm
a Knock in dowel pin with plastic ham- 17. No. 4 plate

mer. Aligning with spring, install plate (85).
a Check that the spring is fitted a Check that the spring is fitted securely into
securely into the seat of the piston the seat of the piston and plates.
and housing.
38 HD325-7, HD405-7
18. Tie bolts 21. No. 3 clutch drum

Install tie bolts (84). Install drum (77).
3 Tie bolt: 166.7 ± 9.8 Nm (17 ± 1 kgm)

19. Install inner race (83) and seal ring (82) to ring Install discs (78), plates (79) and springs (80).
gear (81). a There are three discs, two plates and
three springs.
20. No. 3 clutch ring gear

Install ring gear (81). 23. Housing assembly
1) Assemble housing assembly as follows.
1] Install bearing (76) in housing (68).
2] Install seal ring (75).
HD325-7, HD405-7 39
3] Install bearing (74) in housing (68). 2) Using eye bolts, align outer teeth of piston
4] Install seal ring (72) and (73). with inner teeth of drum, then install hous-
5] Install seal ring (71) on piston (70). ing assembly (67).
3 Mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}
a Install seal ring with groove side fac-


5, 6, and 7 clutch.
6] Assemble piston (70) in housing (68),

then install cylinder (69).
a Air pressure: 0.3 – 0.6 MPa (3 – 6 kg/

cm2)
a Standard piston stroke:
Piston No. Stroke mm
No. 4 4
No. 5 7
No. 6 5
No. 7 5
40 HD325-7, HD405-7
25. Transmission case 7) Planetary gear

1) Install inner race (66) in collar (65). 1] Assemble bearing (55) in gear (54),
2) Install collar (65) in transmission case. set gear and thrust washers (56) on
3) Install snap ring (64). carrier.
4) Install O-ring at cage end. 2] Align bearing with thrust washer, then
push in shaft (52).
3] Assemble ball (53) to install com-
pletely.
a If shaft comes off, punch from
carrier end.
a Check that gear rotates smoothly.
5) Secure eyebolts with nuts, then install

transmission case (63).
4] Install inner race (59), bearing (58)

and seal ring (62) in carrier (57).
q Assembly of no. 2 clutch assembly

6) Install snap ring (61) to carrier (57), then
assemble ring gear (60).
a When assembling the ring gear, keep
the snap ring compressed and push
the ring gear in.
8) Assemble drum (51) to carrier assembly
(57).
a Set block [1] under the carrier when
assembling the drum.
HD325-7, HD405-7 41
9) Install plate (50). a Install seal ring with groove side fac-
10) Discs • plates • springs

Install discs (47), plates (48) and springs 6] Assemble piston (40) in housing (38),
(49). then install cylinder (39).
a There are two discs, three plates and
four springs.
7] Align outer teeth of piston with inner

teeth of drum, then install housing
11) Housing assembly assembly (38).
• Assemble housing assembly as fol- 2 Mounting bolt:
lows. Thread tightener (LT-2)
1] Install bearing (45) in housing (38). 3 Mounting bolt:
2] Install seal ring (46). 98.1 – 122.6 Nm {10 – 12.5 kgm}
3] Install bearing (44) in housing (38).
4] Install seal ring (42) and (43).
5] Install seal ring (41) on piston (40).
42 HD325-7, HD405-7
12) Raise No. 2 clutch assembly (37) and 3] Install ring gear (31) in plate (33).
install.
15) Guide pins

q Assembly of no. 1 clutch assembly Install guide pins (32).
13) Plate
Install bearing (36) in plate (33). 16) Discs • plates • springs
Install discs (27), plates (28) and springs
(29) and (30).
a There are three discs and two plates.
a Free length of spring : 54 mm
14) Ring gear

1] Install inner race (35).
17) Housing assembly

1] Install piston assembled seal ring in
housing.
a Install seal ring with groove side
facing pressure receiving side.
2] Install housing assembly (26) in plate
(35).
3 Mounting bolt:
156.9 - 176.5 Nm {16 - 18 kgm}
HD325-7, HD405-7 43
18) Input shaft assembly 26. No. 1 clutch assembly

Assemble input shaft assembly as follows. Slinging shaft, install No. 1 clutch assembly (17).
1] Install snap ring (25), then install
bearing (24).

2, and 3 clutch. (However, about No. 2 and 3
3] Assemble bearing (22) on gear (20). clutch, it is impossible to measure piston
4] Install gear (20) on shaft (21). stroke, check movement of discs or plates.)
5] Install snap ring (19). a Standard piston stroke of No. 1 clutch:
5 mm
6] Install input shaft assembly (18) on

ring gear of No. 1 clutch. q Assembly of oil pan assembly
Assemble oil pan (8) as follows.
1) Assemble magnet assembly (16), then fit O-
ring and install spring (15) and cover (14).
2) Assemble valves (13) and (12), and fit O-rings,
then install block (11).
3) Install valve (10).
4) Install buffle plate (9).
44 HD325-7, HD405-7
28. Oil pan 31. Sleeves

Fit gasket, then install oil pan (8). Fit O-rings, then install 5 sleeves (3).
29. Speedometer sensor (If equipped) 32. Raise Transmission control valve assembly (2)
Fit O-ring, set sensor (7) in case, then install and install to transmission assembly (1).
cover (6).
a For installation procedure, see "Testing
and adjusting, adjusting engine transmis-
sion speed sensors"
30. Torque converter output shaft rotation sensor,

intermediate shaft rotation sensor
Fit O-ring, set torque converter output rotation
shaft sensor (5) and intermediate shaft rotation
sensor (4) in case, then install cover.
a For installation procedure, see "Testing
and adjusting, adjusting engine transmis-
sion speed sensors"
HD325-7, HD405-7 45
Removal and installation of Installation

transmission control valve q Carry out installation in the reverse order to
assembly (ECMV assembly) 1 removal.
Removal [*1]
k
Before removing the Transmission control valve
Stop the machine on a level ground and
assembly, clean the area around the valve thor-
k
oughly, and make sure that no dirt or dust gets in.
Raise the dump body and lock with the
safety pin.
k
[*2]
3
Disconnect the cable fro the negative (–)
ECMV assembly mounting bolt:
7.85 – 9.81 Nm {0.8 – 1.0 kgm}
1. Remove cover.
2. Disconnect wiring connectors (1) and (2).
3. Remove transmission control valve assembly

(3). [*1] [*2]
a Only 1 wiring connector is used for the
lockup clutch ECMV assembly.
46 HD325-7, HD405-7
Disassembly and assembly of transmission control valve assembly

(ECMV assembly) 1
Disassembly
q Before removing the ECMV assembly from the 3. Pressure control valve
transmission assembly, clean around it thor- 1) Remove solenoid valve (12).
oughly so that dirt will not enter it or transmis- 2) Remove valve (14) and ball (13).
sion. 3) Remove spool (15), shims (16) and (17)
q Keep the removed parts so that they will not be and spring (18).
damaged. a Check the quantity and thickness of
the shims.
1. Remove plug (2) and spool (3) from valve body
(1).
a When disassembling the valve, check that
the spool moves smoothly.
2. Flow sensor valve

1) Remove bracket (4) and fill switch assem-
bly (5).
2) Remove spring (6) and shims (7) and (8).
a Check the quantity and thickness of
the shims.
3) Remove seat (9), spring (11) and pin (10).
HD325-7, HD405-7 47
ECMV for lockup clutch
q Before removing the ECMV assembly from the

transmission assembly, clean around it thor-
oughly so that dirt will not enter it or transmis-
sion.
q Keep the removed parts so that they will not be
damaged.
1. Remove bracket (2) and plate (3) from valve

body (1).
a When disassembling the valve, check that
the spool moves smoothly.
2. Remove seat (4) and sleeve (5).

1) Remove solenoid valve (6).
2) Remove valve (8) and ball (7).
3) Remove spool (9), shims (10) and (11)
and spring (12).
a Check the quantity and thickness of
the shims.
48 HD325-7, HD405-7
Assembly 2. Flow sensor valve

1) Install pin (10) and spring (11) to seat (9).
a If the pressure control section was disassem- 2) Fit the O-ring to plug (2), install spool (3)
bled or any part in it was replaced, be sure to to valve body (1), and install plug (2).
2 O-ring: Grease (G2-L1)
check the oil pressure.
a Clean all the parts and check them for dirt or 3) Install seat (9), shims (8) and (7) and
damage. Coat their sliding surfaces with axle spring (6) to valve body (1).
oil before installing. q Standard number of shims: 2
q Standard thickness of shims: 1.0 mm
1. Pressure control valve (Thickness of 1 shim: 0.5 mm)
1) Install shims (10) and (11) and spring (12) q Kinds of shims: 0.2, 0.5 mm
to spool (9). 4) Install switch assembly (5) and bracket
q Standard number of shims: 3 (4).
3 Mounting bolt:
(Thickness of 1 shim: 0.5 mm) 4.9 ± (+2/0) Nm {0.5 ± (+0.2/0) kgm}
q Kinds of shims: 0.2, 0.5 mm
2) Install ball (13) and O-ring to valve (14). 3. Measuring of ECMV oil pressure
Measure the ECMV oil pressure. For details,
3) Install spool (15) and valve (14) to valve see Testing and adjusting, "Measuring ECMV
body (1). oil pressure".
3 Valve:
19.6 ± (+2.0/0) Nm {2.0 ± (0.2/0) kgm} 4. Adjusting ECMV oil pressure
4) Fit the O-ring to solenoid valve (12) and Adjust the ECMV oil pressure. For details, see
install them to valve body (1). Testing and adjusting, "Adjusting ECMV oil
pressure".
3 Solenoid valve:
49.0 ± 5.0 Nm {5.0 ± 0.5 kgm}
a When installing the solenoid valve,
check the solenoid ID No. 425 (part
a).
a When reusing all of solenoid valve

(12), valve (14), spool (15) and spring
(18), insert the shims of the number
checked when disassembled.
a When replacing solenoid valve (12),
check that spring (18) is installed
securely.
HD325-7, HD405-7 49
ECMV for lockup clutch 5) Install sleeve (5) and seat (4) to valve
a If the pressure control section was disassem- body (1).
bled or any part in it was replaced, be sure to
check the oil pressure. 6) Fit the O-ring to valve body (1) and then
a Clean all the parts and check them for dirt or install plate (3) and bracket (2).
damage. Coat their sliding surfaces with axle 3 Mounting bolt:
oil before installing. 4.9 – 6.9 Nm {0.5 – 0.7 kgm}

1) Install shims (10) and (11) and spring (12)
to spool (9).
q Standard number of shims: 3
(Thickness of 1 shim: 0.5 mm)
q Kinds of shims: 0.2, 0.5 mm
2) Install ball (7) and O-ring to valve (8).
3) Install spool (9) and valve (8) to valve
body (1).
3 Valve:
19.6 ± (+2.0/0) Nm {2.0 ± (0.2/0) kgm}
4) Fit the O-ring to solenoid valve (6) and
install them to valve body (1).
3 Solenoid valve:
49.0 ± 5.0 Nm {5.0 ± 0.5 kgm}
a When installing the solenoid valve,
check the solenoid ID No. 425 (part
a).
a When reusing all of solenoid valve

(12), valve (14), spool (15) and spring
(18), insert the shims of the number
checked when disassembled.
a When replacing solenoid valve (12),
check that spring (18) is installed
securely.
50 HD325-7, HD405-7
HD325-7, HD405-7 51

© 2007 KOMATSU
All Rights Reserved
52 HD325-7, HD405-7
SEN01957-01
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up

Power train, Part 2
Removal and installation of differential assembly ........................................................................................... 2
Disassembly and assembly of differential assembly....................................................................................... 3
Removal and installation of rear final drive carrier assembly........................................................................ 16
Disassembly and assembly of rear final drive carrier assembly ................................................................... 18
Disassembly and assembly of rear final drive assembly .............................................................................. 20
Disassembly and assembly of front wheel hub assembly............................................................................. 24
HD325-7, HD405-7 1
Removal and installation of 6. Remove guard (9).

differential assembly 1 7. Lift off rear drive shaft assembly (10). [*1]
4 Rear drive shaft assembly: 65 kg
Removal
1. Drain oil
6 Final drive case: 15 l (each side)
6 Differential case: 45 l
3. Remove shaft (2).

a Fit eyebolts, and pull out with bar.
8. Lift off differential and parking brake assembly

(11). [*2]
4 Differential and parking brake assem-
bly: 750 kg
4. Remove tube (3), (4), (6), (7).
5. Disconnect hose (5) and (8).
Installation
removal.
[*1]
2 Rear drive shaft mounting bolt:
Thread tightener (LT-2)
3 Rear drive shaft mounting bolt:
157 – 196 Nm {16 – 20 kgm}
[*2]
3 Differential mounting bolt:
490 – 610 Nm {50 – 62 kgm}

Add oil to the specified level, and run the
engine to circulate the oil through the system.
Then check the oil level again.
5 Differential case: 45 l
5 Final drive case: 15 l (each side)
2 HD325-7, HD405-7
Disassembly and assembly of dif- 3. Caliper assembly

1) Remove plate (4) on one side, then
ferential assembly 1 remove caliper (6) together with pad (5).
2) Remove plate on other side.
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
Unit repair stand
t 1
790-501-5000 (100V)
1 790-501-5200 (110–120V or t 1
220 – 240V)
790-901-4110 Bracket t 1
790-901-3430 Plate t 1 Q
2 792-525-2100 Nut runner 3) Remove disc plate (7).
Power wrench
3 790-102-1100 4. Coupling
(No. 16)
t 1 Q
Remove mounting bolts (8), then remove cou-
H 4 792-103-0901 Wrench
pling (10) together with retainer (9) and O-ring.
5 797-101-1171 Wrench t 1
6 792-525-1220 Adapter t 1 5. Case
7 792-525-1000 Diff micrometer t 1 Remove case (11).
8 792-103-0901 Wrench t 1
790-102-1100 Power wrench t 1
790-102-1110 Lever t 1
9 790-102-1120 Bolt t 1
01580-02419 Nut t 1
01644-12408 Washer t 1
Disassembly
1. Set differential assembly in tool H1.
2. Parking brake chamber assembly

Pump air into parking brake chamber to retract
rod, then pull out connecting pin (2) of slack
adjuster (1) lever, and remove parking brake
chamber (3).
HD325-7, HD405-7 3
6. Pinion, cage assembly 3) Bearing, outer race

Screw in forcing screws, then lift off pinion and Remove bearing (19), and using push
cage assembly (12). tool, remove outer races (20) and (21)
a Check the number and thickness of the from case (16).
shims, and keep in a safe place.
7. Differential gear assembly

q Disassembly of pinion assembly 1) Remove lock (22).
1) Pinion assembly 2) Using tool H8, loosen adjustment nut (23)
Remove color (15) from pinion (14). to a point where it can be turned by hand.
2) Pinion, bearing
1] Remove pinion assembly (14) from
case (16).
2] Using puller, remove bearing (18),
spacer (17) pull out.
4 HD325-7, HD405-7
3) Remove 4 nuts (25) of cap (24). 2] Using puller [1], remove bearing (27).
4) Using tool H9, raise differential gear
assembly (26), remove cap (24) and nut
(23) then remove gear assembly.
a Be careful not to drop the outer race.
6) Case
1] Remove mounting bolts, then remove
case (28).
2] Remove washer (29).
7) Bevel gear (small), pinion

q Disassembly of differential gear sub 1] Remove bevel gear (small) (30).
assembly 2] Remove pinion (31) together with
cross shaft (32).
5) Bearing
1] Set gear assembly (26) on block
(height: approx. 200 mm).
HD325-7, HD405-7 5
q Disassembly of pinion 10) Outer race

8) Nut Using push tool [3], remove outer races
Using tool H5, remove nut (33). (38) and (39), and outside circumference
seat (40).
9) Sleeve, bearing
1] Using push tool [1], pull out sleeve 11) Bevel gear (small), washer
(34), and remove bearing (35). 1] Remove bevel gear (small) (41).
2] Rmove washer (42).
2] Remove inside circumference seat

(36). 12) Bearing, bevel gear (large)
3] Using push tool [2], remve bearing 1] Using puller, remove bearing (43).
(37). 2] Remove mounting bolts, then remve
bevel gear (large) (44) from case
(45).
6 HD325-7, HD405-7
Assembly 2. Assembly of pinion

1) Outer races, bearing
1. Assembly of differential gear assembly 1] Install outside circumference seat
1) Bevel gear (large) (40) to pinion (31).
1] Set bevel gear (large) (44) on block a When installing the outside cir-
(height: approx. 200 mm). cumference seat (40), set it with
2] Set case (45) on gear, and tighten the side that has a step on the
bolts. inside diameter facing the bear-
2 Mounting bolt:
ing (large).
3 Mounting bolt:
490 – 610 Nm {50 – 62 kgm}
2) Bearing, washer
1] Shrink fit bearing (43) to case (45).
a Shrink-fitting temperature:
At 100°C for approx. 30 minutes
2] Expand fit outer races (39) and (38).

a Dry ice cooling time:
Approx. 5 minutes
2] Turn over case, and install washer

(42).
3) Bevel gear (small)

Install bevel gear (small ) (41).
HD325-7, HD405-7 7
2) Sleeve, bearing 3. Pinion, cross shaft, bevel gear (small)

1] Shrink fit bearing (37) to sleeve (34). 1) Assemble pinion (31) to cross shaft (32).
a Shrink-fitting temperature: 2) Align dowel pin of case with groove of
At 100°C for approx. 10 minutes sleeve (34) and install.
2] Install inside circumference seat (36). a If the dowel pin is not fitted com-
pletely into the groove in the sleeve,
3) Pinion, bearing, nut the cross shaft will come up and the
1] Install pinion (31) to sleeve (34), and pinion will not rotate smoothly, so
shrink fit bearing (35). check these two points.
a Shrink-fitting temperature: 3) Install bevel gear (small) (30).
At 100°C for approx. 10 minutes
4. Case
2] Using tool H5, tighten nut (33). 1) Install washer (29) to case (28).
2 Nut: Thread tightener (LT-2) 2) Align case (28) with position of number of
3 Nut: mating case (45) and install.
490 – 610 Nm {50 – 62 kgm} 2 Mounting bolt:
a After tightening the nut, rotate the Thread tightener (LT-2)
pinion at least five turns, and 3 Mounting bolt:
check that it rotates smoothly. 490 – 610 Nm {50 – 62 kgm}
3 Starting torque:
1.27 ± 1.27 Nm {0.13 ± 0.13 kgm}
8 HD325-7, HD405-7
5. Bearing 7. Cap
Shrink fit bearing (27). 1) Install cap (24) and temporarily tighten
a Shrink-fitting temperature: nuts (25).
100°C for 30 min. 2) Usinng tool H9, tighten nuts (25).
2 Bolt: Adhesive (LT-2)
3 Bolt:
1,620 – 1,720 Nm {165 – 175 kgm}
q Assembly of differential gear assembly

6. Differential gear assembly
1) Align with groove of differential case (46)
and install nut (23).
2) Raise gear case assembly (26), assemble
outer race on bearing, then install in case.
HD325-7, HD405-7 9
8. Adjusiting preload of bearing a Precautions when adjusting preload

1) Install tool H6 on both sides of cap (24). If the adjustment nut is tightened too far and
2) Measure distance between tools H6 with the increase in bend exceeds the standard
tool H7. value, loosen the adjustment nut and return to
a When measering, hold the microme- the position before adjustment.
ter securely with one hand and put When doing this, rotate the bevel gear, and tap
the probe in contact with and parallel the bearing cap and bevel gear with a plastic
to the measuring adapters. copper hammer. Check that there is no gap at
a When doing this, leave the adjust- (b), then adjust again.
ment nut loosened.
3) Add 0.45 ± 0.1mm to the measured value,
and set the scale of the micrometer.
(Take the dimension after setting as (A).)
a The amount added is equal to the
deformation of the case before apply-
ing preload and after applying prelad.
9. Assembly of pinion assembly

1) Outer reces
Install oute reces (21) and (20) in case
(16).
a When installing the outer race to the
case, eliminate clearance between
them.
4) Tighten adjustment nut (23) from both a Outer race O.D. (20): 180 mm
sides with tool H8 so that the distance Outer race O.D. (21): 215 mm
between the adapters is (A). Be careful of
the groove where the lock enters.
a When doing this. to make the bearing
sit properly, rotate the bevel gear and
tap the bearing cap and bevel gear
with a copper hammer.
10 HD325-7, HD405-7
2) Pinion 4) Bearing
a Always use the pinion and bevel gear Rotate case (16) and install bearing (19).
as a set. a Never push with a press.
If the combination is wrong, the cor- a Coat the bearing with engine oil.
rect tooth contact cannot be obtained.
Shrink-fit bearing (18) on pinion (14).
a Shrink-fitting temperature:
Approx. 100°C for 30 min.
3) Pinion case
Stand pinion (14) upright and apacer (17),
install case (16).
10. Adjustment
1) Install collar (15) to pinion assembly (14),
then install cage (13).
a When installing the cage, take care
not to break the O-ring and dust seal.
a Apply G2-LI to the seal lip.
a Apply LG-1 to the inside of the cage.
HD325-7, HD405-7 11
2) Install case (11), coupling (10), and 11. Pinion assembly

retainer (9) to pinion cage assembly (14), 1) Install the O-ring and the removed shim,
then tighten mounting bolt (8) until it then install pinion assembly (14) by using
reaches the retainer. the hanging bolts
2 Mounting bolt: Adhesive (LT-2) 2) Tighten three bolts.
3) Place the pinion cage assembly on its 3) Adjust the tooth contact, then tighten the
side, then rotate it by 20 – 30 turns and all bolts to the specified torque.
tighten mounting bolt (8) gradually. 3 Mounting bolt:
3 Mounting bolt: 245 – 310 Nm {25 – 31.5 kgm}
825 – 1,030 Nm {84 – 105 kgm}
12. Adjusting tooth contact, backlash

4) Adjust so that the tangential force at the Adjust backlash and tooth contact of bevel
bolt hole of the case will be 6.8kg when gear at the same time.
the bolt is tightened to the specified 1) Adjust backlash as follows.
torque. 1] Mobe bevel gear with adjustment nut
a After the adjustment, confirm that the (23). When adjusting the bevel gear,
all bearing rollers turn. do not change the preload of the
bearing. Always turn the adjustment
nuts at both ends the sane amount in
the same direction.
12 HD325-7, HD405-7
2] Put dial [3] at right angles in contact 3) Adjusting tooth contact of bevel gear and
with the reverse face of the tooth at bevel pinion
the outside of the bevel gear. turn the
adjustment nut and adjust until to Inspection
movement of the gauge indicator is 1] Coat the tooth face of the bevel pinion
0.3 or 0.4 mm. lightly with red lead (minimum).
a Adjust at 3 to 4 places. Keep the Rotate the bevel gear forward and
pinion gear locked when measur- backward and inspect the pattern left
ing. on the teeth.
2) Adjust tooth contact as follws. 2] The tooth contact pattern should

1] Adjust the position of the bevel pinion cover about 30 to 60% (a) of the
by changing the shims between the length of the tooth, and should be
differential case and bearing case. located about 33% (b) from the small
a Use the shims removed during end. It should be in the center of the
disassembly. tooth height.
2] Adjust tooth contact. There should be no strong contact at
For details, see 3) "Adjusting tooth the top or bottom of the tooth face, or
contact of bevel gear and bevel pin- at the small or big ends.
ion". a If the gears are adjusted to this
pattern, the tooth contact will be
correct when load is applied.
HD325-7, HD405-7 13
4) Tooth contact of bevel gear and bevel pin-

ion
Adjustment
If the result of the inspection shows that
the correct tooth contact is not being
obtained, adjust again as follows.
1] If bevel pinion is too far from center
line of bevel gear. Contact is at the
small end of the convex tooth face of
the bevel gear and at the big end of
the concave tooth face.
q Procedure for adjustment
Adjust the thickness of the shims at
the to move the bevel pinion in direc-
a When adjusting the bevel gear to the
tion (A), nearer to the bevel gear.
right or left, do not change the pre-
Using shims or the adjustment nut of
load of the bearing. Always turn the
the bevel gear bearing cage, move
adjustment nuts at both ends the
the bevel gear in direction (B) by the
same amount in the same direction.
same amount that the bevel pinion
5) After adjusting tooth cantact and backlash,
has moved in direction (A). Check the
install lock plate (22).
tooth contact pattern and backlash.
13. Case
2] If bevel pinion is too close to center
After completing adjustment of the tooth con-
line of bevel gear. Contact is at the
tact and backlash, coat case (11) mounting
small end of the concave tooth face of
bolts with thread tightener and tihgten fully.
3 Mounting bolt:
the bevel gear and the big end of the
convex tooth face.
245 – 310 Nm {25 – 31.5 kgm}
q Procedure for adjustment
a After tightening, rotate the bearing 20 – 30
Adjust the thickness of the shims at
turns again, and check again that the
the bevel pinion to move the bevel
bearing rotates smoothly.
pinion in direction (A), away from the
bevel gear. Using shims or the adjust-
ment nut of the bevel gear bearing
cage, move the bevel gear in direc-
tion (B) by the same amount that the
bevel pinion has moved in direction
(A). Check the tooth contact pattern
and backlash.
14 HD325-7, HD405-7
14. Caliper assembly 15. Spring cylinder assenbly

1) Install disc plate (7). 1) Install spring cylinder (3), and connect
2 Mounting bolt: Thead tightener (LT-2) forked portion of rod and lever of slack
3 Mounting bolt: adjuster (1) with pin (2).
490 – 608 Nm {50 – 62 kgm} a Apply oil pressure to the spring cylin-
der to shorten the rod.
a Port P:
2.94 – 5.88 MPa {30 – 60 kg/cm2}
2) Fit plate (4) on one side temporarily.

3) Fit pad (5) and install caliper (6).
4) Fit plate on other side and tighten fully.
a Make a clearance of 0.1 mm between 2) Adjusting clearance of caliper pad
the plate and the caliper. Rotate adjustment screw (50) of slack
2 Mounting bolt: adjuster, and measure clearance of cali-
Thead tightener (LT-2) per pad with gauge [3].
3 Mounting bolt: a Spuring cylinder stroke: 50 mm
824 – 1,030 Nm {84 – 105 kgm} a Clearance of pad:
Both ends: 0.5 mm each
When moved to one end: 1.88 ± 0.08 mm
HD325-7, HD405-7 15
Removal and installation of rear 3. Using eye bolt [2], pull out shaft (3).
final drive carrier assembly 1 4. Remove snap ring (4), then remove sun gear
(5).
Removal
1. Remove drain plug (1) and drain oil from final 5. Using eye bolt [2], remove carrier assembly
drive (both left and right). (6).
4 Carrier assembly: 100 kg
6 Final drive: Approx. 15 l (each)
a If the drain plug is not directly at the bot-
tom, use a hydraulic jack (min. 30-ton) to
jack up the machine, then rotate the hub.
2. Using guide bolt [1], remove cover (2).
16 HD325-7, HD405-7
Installation 4. Tighten drain plug (1) and add engine oil

through oil filler (12) to the specified level.
3 Drain plug:
a Clean all parts, and check for dirt or damage.
Coat sliding surfaces of all parts with engine oil 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
6 Final drive: Approx. 15 l (each)
before installing.
1. Using eye bolt [2], install carrier assembly (6).
2. Align planetary gear, install sun gear (5), then

install snap ring (4).
a If the gear cannot be aligned, use a
hydraulic jack (min. 30-ton) to jack up the
machine, then rotate the hub.
3. Using guide bolt [1], fit O-ring and install cover

(2).
3 Cover: 98 – 123 Nm {10 – 12 kgm}
HD325-7, HD405-7 17
Disassembly and assembly of 2) Remove outer bearing (7) and pull out
spacer (8).
rear final drive carrier assembly 1 3) Remove outer bearing (9) and remove
snap ring (10).
Disassembly
1. Using push tool [1], push out shaft (2) from car-
rier (1) with press.
a When pulling out the shaft, ball (3) will
come out at the same time, so remove the
shaft carefully so as not to lose the ball.
2. Pull out pinion gear assembly (4) from carrier

(1).
a When pulling out the pinion gear assem-
bly, pull out carefully so as not to drop the
inner bearing.
3. Pinion gear assembly

1) Remove bearing inner races (5) and (6).
18 HD325-7, HD405-7
Assembly 4) Assemble bearings (6) and (5) to carrier

(1).
1. Planetary gear assembly
1) Install snap ring (10) to planetary gear (4).
2) Using push tool [2], press fit outer bearing
(9) with press.
2. Push planetary gear assembly (4) into carrier

(1).
3. Press fit shaft (2) to carrier (1).

3) Install spacer (8), and using push tool [2], a Expand fit the shaft or press fit the shaft
press fit outer bearing (7). with a press.
a After the shaft has been press fitted to a
point where the groove of ball (3) is near
the top face of the carrier, assemble the
ball to the shaft, and press fit again, taking
care that the ball does not come out.
a The bearings for the planetary gear

form sets, so match the production
number and match numbers when
assembling the inner race, outer race,
and inner race spacer.
HD325-7, HD405-7 19
Disassembly and assembly of a To prevent damage to the floating

seal, always remove before remov-
rear final drive assembly 1 ing retainer (4).
2) Remove mounting bolts, then remove
Special tools
retainer (4) and shim.
a Check the number and thickness of
New/Remodel
the shims, and keep in a safe place.
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
1 792-103-1201 Fixture t 3 Q
792-520-2121 Installer t 1
J 791-580-1600 Push tool t 1
4
792-520-2110 Installer t 1
792-530-1600 Push tool t 1
1
Disassembly
1. Rear wheel assembly
For details, see "Removal of rear wheel
4. Ring gear assembly
assembly".
1) Lift off ring gear assembly (5).
4 Ring gear assembly: 40 kg
2. Final drive carrier assembly
For details, see "Removal of rear final drive
carrier assembly".
3. Retainer, shim
1) Using tool J1, secure inner gear (1) and
outer gear (2).
a To install the tool, remove bolt (3)
from the outer gear, and use the three
tool mounting tap holes in the inner
gear.
2) Disassemble ring gear assembly as fol-

lows.
1] Remove mounting bolts (6), then
remove holder (7).
2] Remove inner hub (9) from ring gear
(8).
20 HD325-7, HD405-7
5. Rear wheel hub assembly Assembly

1) Sling wheel hub assembly (10) or support
with forklift, then remove nut (11). 1. Bearing
Install bearing (15).
2) Pull out wheel hub assembly (10) partly,

remove bearing (12), then remove wheel 2. Wheel hub assembly
assembly. 1) Using push tool , press fit outer races (13)
a The bearing comes out easily, so be and (14) in wheel hub (10).
extremely careful not to let it drop. 2) Fit O-ring, then raise rear wheel hub
4 Rear wheel hub assembly: 335 kg
assembly (10), and set to inner gear.
3) Remove outer races (13) and (14) from
wheel hub assembly (10).
3) Install bearing (12), and tighten nut (11).

2 Nut thread:
6. Bearing Thread tightener (LT-2)

3 Nut: 157 – 196 Nm {16 – 20 kgm}
Remove bearing (15).
a Do not remove tool J1 until the retainer
has been completely secured.
HD325-7, HD405-7 21
3. Ring gear assembly 2) Insert shim, then fit retainer (4) and tighten
1) Assemble ring gear assembly as follows. mounting bolts.
1] Set inner hub (9) to ring gear (8). a Rotate the wheel hub 20 – 30 times
2] Fit holder (7), and tighten mounting and tighten the bolts uniformly until
bolts (6). the tightening torque is constant.
3 Bolt: 2 Bolt thread:
27 – 34 Nm {2.8 – 3.5 kgm} Thread tightener (LT-2)
2) Raise ring gear assembly (5) and install. 3 Bolt:
245 – 309 Nm {25 – 31.5 kgm}
a After tightening the bolts, rotate the
wheel hub, and check that there is no
abnormality in rotation.
4. Shim, retainer
1) Adjust preload of bearing as follows.
1] With no shim assembled, install
retainer (4) temporarily with 3 bolts.
2] Remove tool J3 from 3 places, and 5. Carrier assembly
tighten nuts. For details, see "Installation of rear final drive
3] Rotate wheel hub 20 – 30 times and carrier assembly".
tighten 3 bolts uniformly to a tighten-
ing torque of 103 ± 5 Nm (10.5 ± 0.5
kgm).
a If the bolts are tightened without
rotating the wheel hub, the bear-
ing will not settle, and the correct
preload cannot be given.
4] Using depth micrometer [1], measure
dimension (c) between end face of
shaft and retainer.
a Measure at two places and take
the average.
5] Remove retainer, and measure thick-
ness (a) of retainer. Select a shim
thickness (b = c – a) + 0.3 mm.
22 HD325-7, HD405-7
6. Rear wheel assembly

For details, see "Installation of rear wheel
assembly".
q Adjusting preload on bearing

1) Install retainer (4) without inserting any
shim and tighten 3 mounting bolts to the
following torque.
a Rotating the hub 20 – 30 turns,
tighten the bolts evenly to the speci-
fied torque.
3 Retainer mounting bolt:
103 ± 5 Nm {10.5 ± 0.5 kgm}
2) Measure distance (a) between the end of
tube (16) and end of retainer (4) with
depth micrometer [1].
a Measure at 2 places and obtain the
average.
3) Remove retainer (4) and measure its thick-
ness (b).
a Measure at 2 places and obtain the
average.
4) Calculate shim thickness (c) by the follow-
ing expression.
c (mm) = a – b + 0.3
5) Install the shim of the calculated thickness
and retainer (4) with the all mounting bolts
(6 bolts).
a Rotating the hub 20 – 30 turns,
tighten the bolts evenly to the speci-
fied torque.
3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kg}
6) Rotate the wheel hub again and check
that it revolves normally.
HD325-7, HD405-7 23
Disassembly and assembly of 4) Remove bearing (4), then remove wheel

hub assembly (2).
front wheel hub assembly 1 4 Wheel hub assembly: 225 kg
Disassembly
1. Front brake caliper assembly
For details, see "Removal and assembly of
front brake caliper assembly".
2. Cover
Remove cover (1).
3. Wheel hub assembly

1) Support wheel hub assembly (2) with fork-
lift truck.
2) Remove retainer (3).
a Check the number and thickness of
5) Disassemble wheel hub assembly as fol-
the shims, and keep in a safe place.
lows.
1] Remove mounting bolts, then remove
brake disc (5).
2] Remove oil seal (6).
3] Remove outer race (7).
4] Remove outer race (8).
4. Bearing, retainer
1) Remove bearing (10).
2) Remove retainer (11).
3) Lever wheel hub assembly (2) lightly from

rear, and push out together with bearing
(4).
24 HD325-7, HD405-7
Assembly
1. Retainer and bearing
1) Install retainer (11).
2) Install bearing (10).
2. Wheel hub assembly

1) Assemble the wheel hub assembly
according to the following procedure.
1] Using the push tool, press fit outer
race (8).
2] Using the push tool, press fit outer
race (7).
3] Using the push tool, press fit oil seal
(6).
a Degrease the sealing side of 4] Set brake disc (5) and tighten the
wheel hub A and periphery of the mounting bolts.
2 Mounting bolt:
seal.
a Degrease and dry part B. Adhesive (LT-2)
3 Mounting bolt:
2 Periphery of seal:
Adhesive: (Loctite No. 648) 490 – 608 Nm {50 – 62 kgm}
2 Part C between seal lips:
2) Support and install wheel hub assembly
Fill with grease (See Table 1). (2) with a forklift.
Table 1
No. Manufacturer Brand of grease
1 NIHON KOYU HIREX HD-2
2 SHELL OIL Super Duty Grease 2
3 ESSO OIL RONEX MP
4 BP Energrease LS-EP2
HD325-7, HD405-7 25
2 Fill the shaded parts in the follow- 4) Adjust the preload on the bearing accord-
ing figure with sufficient amount of ing to the following procedure.
grease. (Grease: 5 l for each 1] Install retainer (3) without inserting any
wheel hub assembly) shim with 3 mounting bolts. Revolving
a Take care not to damage the oil seal the hub 20 – 30 turns, tighten the bolts
on the inside of the hub. evenly to the specified torque.
a Select the grease from Table 1. 3 Mounting bolt (For adjust-
ment):
Table 1 73.5 ± 4.9 Nm {7.5 ± 0.5 kgm}
2] Measure distance c between the retainer
No. Manufacturer Brand of grease
and axle end with depth micrometer [1].
1 NIHON KOYU HIREX HD-2 a Measure at 2 places and obtain
2 SHELL OIL Super Duty Grease 2 the average.
3 ESSO OIL RONEX MP 3] Remove retainer (3) and measure its
thickness T. Add 0.3 mm to the differ-
4 BP Energrease LS-EP2
ence between above distance c and
thickness d = (c - T), then use the
a Fill the hatched space between the result as the shim thickness.
rollers of the bearing until it is pro- a Measure at 2 places and obtain
jected from the opposite side of the the average.
retainer. a Combine the shims so that their
quantity will be minimum.
a When removing the retainer, take
care that the bearing will not come
off.
3) Install bearing (4).
26 HD325-7, HD405-7
5) Install the shims and retainer (3). Revolv-

ing the hub 20 – 30 turns, tighten the bolts
evenly to the specified torque.
3 Mounting bolt:
343 – 426 Nm {35 – 43 kgm}
a After tightening the bolts, rotate the
hub and check that it rotates normally.
3. Cover
Fit the O-ring and install cover (1).
2 Fill the inside of cover (hatched
part) with grease.
a Use grease of the brand used for the
wheel hub in 2-2).
4. Front brake calipers assembly

Install the front brake calipers assembly. For
details, see "Removal and installation of front
brake calipers".
1
HD325-7, HD405-7 27

© 2007 KOMATSU
All Rights Reserved
28 HD325-7, HD405-7
SEN01958-01
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up

Steering system
Disassembly and assembly of steering cylinder assembly ............................................................................. 2
Removal and installation of emergency steering motor pump assembly ........................................................ 5
HD325-7, HD405-7 1
Disassembly and assembly of 3. Pull out cylinder head and piston rod assembly
(3) from cylinder (4) and remove.
steering cylinder assembly 1 a When the piston rod assembly is pulled
out from the cylinder, oil will come out, so
Special tools
catch it in a container.
New/Remodel
4. Remove cylinder (4) from tool U1.
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
Cylinder repair
1 790-502-1003 t 1
stand
790-102-2303
3 or Wrench assembly t 1
790-330-1100
4 790-302-1270 Socket t 1
U
790-201-1570 Plate t 1
9 790-101-5021 Grip t 1
01010-50816 Bolt t 1
796-720-1640 Ring t 1
12 5. Disassembly of piston rod assembly
07281-00909 Clamp t 1 1) Set piston rod assembly (3) in tool U1.
2) Using tool U4, remove nut (5).
Disassembly
1. Set cylinder assembly (1) in tool U1.
2. Raise lock of cylinder head nut, and using tool

U2, remove cylinder head assembly (2).
3) Remove piston assembly (6) and cylinder

head assembly (7) from rod (8).
2 HD325-7, HD405-7
6. Disassembly of piston assembly Assembly

1) Remove wear ring (9) from piston (10).
2) Remove wear ring (11) from Piston (10). a Clean all parts, and check for dirt or damage.
Coat the sliding surfaces of all parts with
engine oil before installing.
1. Assembly of cylinder head assembly

1) Using bush tool, press fit bushing (15) to
cylinder head (16).
a Take care not to deform bushing (15)
when press fitting it.
2) Install rod packing (14).
a Be careful to install the rod packing
facing in the correct direction.
3) Assemble backup ring (18) and O-ring
(17) in order.
a Do not try to force the backup ring
7. Disassembly of cylinder head assembly into position. Warm it in warm water
1) Remove snap ring (12), then remove dust (50 – 60ºC) before fitting it.
seal (13). 4) Using tool U9 install dust seal (13) to cylin-
2) Remove rod packing (14). der head (16), then install snap ring (12).
3) Remove busing (15) from cylinder head
(16).
4) Remove O-ring (17) and backup ring (18).
HD325-7, HD405-7 3
2. Assembly of piston assembly 2) Using tool U4, tighten nuts (5).

1) Using tool U10, expand piston ring (11). 2 Nut: Thread tightener (LT-2)
a Set the piston ring to tool U10 and 3 Nut:
g i v e th e ha n d l e 8 – 10 t ur ns t o 1,078.7 ± 107.9 Nm {110 ± 11.0 kgm}
expand the piston ring. 3) Remove piston rod assembly (3) from tool
2) Remove piston ring from tool U10, and U1.
assemble to piston (10).
3) Using tool U12, compress piston ring.
4) Assemble wear ring (9).
4. Set cylinder (4) in tool U1.
5. Assemble cylinder head and piston rod assem-

bly (3) in cylinder (4).
3. Assembly of piston rod assembly

1) Assemble cylinder head assembly (7) and 6. Using tool U2, tighten cylinder head assembly
piston assembly (6) to piston rod (8). (2).
3 Cylinder head nut:
568.8 ± 56.9 Nm {58 ± 5.8 kgm}
4 HD325-7, HD405-7

emergency steering motor pump q Carry out installation in the reverse order to
assembly 1 removal.
Removal q Refilling with oil (Hydraulic tank)

a
k
Refill oil to the specified level and run the
Disconnect the cable from the negative (–)
engine to circulate the oil through the system.
Then check the oil level again.
2. Disconnect motor wiring (2).
3. Disconnect ground (3).
4. Remove hose (4) and (5).
5. Disconnect emergency steering motor pump

assembly (6) together with bracket, then
remove.
HD325-7, HD405-7 5

© 2007 KOMATSU
All Rights Reserved
6 HD325-7, HD405-7
SEN01959-01
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up

Brake system
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
HD325-7, HD405-7 1
Removal and installation of front Installation

brake caliper pad 1 q Carry out installation in the reverse order to
removal.
Removal
1. For details, see "Removal and installation of [*1]
front wheel assembly". a Push in the torque pin and fix it securely with
the bolt.
2. Pull out torque pin (1). [*1] a Make the clearance between the torque pin
a Loosen pin fixing bolt (2), and pull torque and the disc 1.5 – 3 mm.
3 Pin fixing bolt:
pin (1) until the pads can be removed.
51.5 ± 2.5 Nm {5.25 ± 0.5 kgm}
a For the precautions for installing the pin fixing
bolt, see "Assembly of front brake caliper
assembly".
[*2]
a Bleed air from front brake circuit after seeing
“Air bleeding for brake circuit” of Testing and
adjusting.
3. Remove pads (3) and (4). [*2]

1) Install a vinyl hose to bleeder screw (5) so
that the brake oil can be drained out.
2) Loosen the bleeder screw, and return pis-
ton (6) to the bottom of the cylinder with a
bar.
2 HD325-7, HD405-7
Removal and installation of front Installation

brake caliper assembly 1 q Carry out installation in the reverse order to
removal.
Removal
1. Front wheel assembly [*1]
2 Mounting bolt: Thread tightener (LT-2)
a For details, see "Removal and installation
3 Mounting bolt:
of front wheel assembly".
824 – 1,030 Nm {84 – 105 kgm}
2. Disconnect tube (1). a Bleed air from front brake circuit after seeing
a Disconnect two tubes on both sides. "Air bleeding for brake circuit" of testing and
adjusting.
3. Remove caliper assemblies (2). [*1]

a Leave 2 or 3 of the 10 mounting bolts in
position, then use a forklift truck or other
equipment as support, remove the
remaining mounting bolts, and remove
caliper assembly (2).
4 Caliper assembly: 75 kg
HD325-7, HD405-7 3

front brake caliper assembly 1
Disassembly
1. Install backup ring (14), seal (13), and dust seal

(11) in groove of torque plate (15) securely.
a When installing seal (13), set the notched
1. Loosen pin fixing bolts (1) and (2), remove side facing pad (6) end, the assemble.
torque pins (3), (42), and (5), then remove
pads (6). 2. Install piston (12).
a Fit the lip of the dust seal in the groove of
2. Remove plate (7), then remove plug (8), the piston.
backup ring (9), and seal (10).
3. Fit seal (10), backup ring (9), and plug (8), and
3. Remove dust seal (11), then remove piston install plate (7).
(12).
4. Remove seal (13) and backup ring (14).

a Disassemble the other pistons in the same
way.
4 HD325-7, HD405-7
4. Fit pads (6), and install torque pins (5), (4), and 5. Install caliper assembly.
(3), then tighten with pin fixing bolts (2) and (1). For details, see "Installation and removal of
3 Pin fixing bolt: front brake caliper assembly".
51.5 ± 2.5 Nm {5.25 ± 0.25 kgm} a Install the front brake calipers assembly
so that clearance "d" between disc plate
(16) and torque pin (3) will be 1.5 to 3.0
mm.
a Lock bolts (1) and (2) are different from

the normal bolts: the tip (portion a) cuts
into the surface of the torque pin. (Cre-
ates plastic deformation.)
a hen tightening, even when resistance is
felt, it is necessary to tighten further in
order to cut into the surface. For this rea-
son, if the tightening is less than the spec-
ified tightening torque, the bolt will not cut
in sufficiently and it will not hold in posi-
tion properly.
b : Cut-in point
c : Cut-in mark
a Be sure to install short torque pin (5) of
pins (4) and (5) at the plate end.
a Istall so that clearance d between disc
(16) and torque pin (3) is 1.5 to 3.0 mm.
a Asemble the other pistons in the same
way.
HD325-7, HD405-7 5
Removal and installation of rear 6. Lift off brake assembly (6). [*1]
4 Brake assembly: 370 kg
brake assembly 1
Removal
1. Remove final drive assembly
For details, see "Removal and installation of
final drive assembly".
2. Drain oil.
6 Brake cooling tank: 90 l
3. Remove retainer (1).

a Remove floating seal (2) from the retainer.
7. Remove piston (7). [*2]

a Loosen the air bleed plug and remove pis-
ton (7).
8. Remove cylinder assembly (8). [*3]
4. Disconnect hoses (3) and (5).
5. Remove tubes (4).
Installation
removal.
[*1]
3 Mounting bolt: 157 – 196 Nm {16 – 20 kgm}
[*2]
a Install the piston seal with the grooved side
facing the side taking the pressure.
[*3]
a Install the cylinder seal with the side with the
groove facing the side taking the pressure.
3 Mounting bolt: 490 – 608 Nm {50 – 62 kgm}

a Refill oil to the specified level and check the oil
level again.
5 Brake cooling tank: 90 l
6 HD325-7, HD405-7
Disassembly and assembly of 2. Damper, disc, plate

q Remove damper (2), disc (3), and plate
rear brake assembly 1 (4) from outer gear (1).
Special tools
3. Hub
New/Remodel
1) Remove mounting bolts, then remove hub
(5) from outer gear (1).
Necessity
Sym-
Part No. Part name
Sketch
bol 2) Remove floating seal (6) and dust seal (7)
Q'ty
from hub (5).
1 792-103-1201 Fixture t 3 Q
792-520-2121 Installer t 1
J 791-580-1600 Push tool t 1
4
792-520-2110 Installer t 1
792-530-1600 Push tool t 1
Disassembly
1. Outer gear assembly
1) Remove tool J1.
2) Using eyebolts, lift off outer gear (1)
together with disc and plate.
4. Floating seals
a Be careful not to damage the floating
q Remove floating seals (9) and (10) from
seal when removing.
inner gear (8).
HD325-7, HD405-7 7
Assembly 2. Hub
1) Install oil seal (7) to hub (5).
2 Lip of oil seal: Grease (G2-LI)
a Clean all parts, and check for dirt or damage.
3 Oil seal periphery surface:
Coat the sliding surfaces of all parts with engine
oil before installing. Thread tightener (Loctite #648)
a When assembling the floating seals, use alco- 2) Using tool J4, install floating seal (6) to
hol to remove all the white powder from the O- hub (5).
ring surface before assembling. a For precautions to take after installing
the floating seal, see Item 1.
1. Floating seals
q Using tool J4, install floating seals (9) and
(10) to inner gear (8).
3) Align match marks, and install hub (5) to

outer gear (1).
3 Mounting bolt:
a After installing the floating seals, measure 98 – 123 Nm {10 – 12.5 kgm}
dimension a between the inner gear and
floating seal at four places around the cir-
cumference and check that the measure-
ment is within 1 mm.
8 HD325-7, HD405-7
3. Outer gear 4. Damper, disc, plate

1) Using eyebolts, assemble outer gear q Align notches at 6 places around the cir-
assembly (1) to inner gear. cumference of damper (2) and plate (4),
a Coat the sliding surfaces of the float- then assemble together with disc (3) to
ing seals thinly with engine oil. inner gear and outer gear assembly.
a Assemble slowly and be careful not to a If the notches are not aligned before
damage the floating seals. assembling, there will be a lack of lubrica-
tion and cooling, and this will cause sei-
zure.
2) Align center of inner gear (8) and outer

gear (1), then using tool J1, secure inner
gear (8) and outer gear (1).
HD325-7, HD405-7 9
Removal and installation of

parking brake pad 1
Removal
k Stop the machine on level ground, and put
blocks under the wheels.
k Raise the dump body and lock with the
safety pin.
a Release the parking brake.
1. Turn adjustment bolt (1) counterclockwise, and

make clearance between pad and disc larger.
2. Remove bolt (2), then remove bracket (3) and

spring (4). [*1]
a Check the mounting direction of the
spring.
3. Loosen 8 bolts (5), and sling so that caliper

does not drop. [*2]
4. Remove pads (6). [*3]

a Move plate (7) when removing the pads
(6) so that the pads do not fall.
a After removing the rear pad, move the cal-
iper to the front, and remove the front pad.
10 HD325-7, HD405-7
Installation a For details of the mounting position for each

q Carry out installation in the reverse order to spring, see Fig. 2.
removal. Fig. 2
[*1]
a Install the springs as follows.
1) Connect the slack adjuster and spring cyl-
inder and apply oil pressure of 2.94 MPa –
5.88 MPa {30 – 60 kg/cm2} to port P (M20
x 1.5) of the spring cylinder.
a Screw in mounting bolts (2) of the bracket 2 – 3

turns so that the bracket moves freely.
3) Turn adjustment bolt (1) clockwise to bring

both pads into close contact with disc,
then tighten to a point where it becomes
difficult to turn bolt.
2) Fit spring (4) in bracket (3) and install to 4) Tighten mounting bolts (2) and be careful
position shown in Fig. 1. that bracket does not come out of position.
a After installing to the machine, check
Fig. 1 that the clearance between the pad
and disc is at least 0.05 mm (each
side).
If there is not sufficient clearance,
move the bracket in the direction to
increase the clearance, install it
again, and check that the clearance is
correct.
[*2]
a Align the grooves of the pad and the caliper
with both sides of the plate securely.
2 Plate mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
[*3]
a Adjust the clearance between brake pad and
disc. For details, see "Testing and adjusting of
parking break".
HD325-7, HD405-7 11

parking brake caliper assembly 1 q Carry out installation in the reverse order to
removal.
Removal
1. Remove parking brake spring cylinder assem- [*1]
bly.
For details, see "Removal of parking brake Thread tightener (LT-2)
3
q
spring cylinder assembly". Plate mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
2. Remove plate
q For details, see "Removal of parking brake
pad assembly".
3. Remove pads (1). [*1]
4. Lift off caliper (2).

4 Caliper: 35 kg
12 HD325-7, HD405-7
Disassembly and assembly of front brake caliper pad assembly 1
Disassembly Assembly
1. Remove snap ring (1), and pull out adjuster 1. Assemble piston seal (12) to caliper (13), and
(2). insert piston (11).
2 Piston, piston seal: Grease (G2-LI)
2. Remove washer (3) and (4), and packing (6)
and bearing (7). 2. Screw piston shaft (10) into piston (11), and
install thrust bearing (8).
3. Remove bolts, then remove housing (5) and a Be careful to install the thrust bearing fac-
gasket (9). ing in the correct direction.
2 Thrust bearing: Grease (G2-LI)
4. Remove piston shaft (10) and thrust bearing
(8) from piston. 3. Fit gasket (9) and install housing (5).
5. Remove piston (11) and piston seal (12) from 4. Install packing (6), and washers (4) and (3)
caliper (13). bearing (7).
a Fit the seal securely in the groove.
2 Seal: Grease (G2-LI)
5. Assemble adjuster (2), and secure with snap

ring (1).
HD325-7, HD405-7 13

parking brake spring cylinder q Carry out installation in the reverse order to
assembly 1 removal.
Removal [*1]
a Adjust the linkage. For details, see Testing and
adjusting, "Testing and adjusting performance
blocks under the wheels.
k
of parking brake".
Raise the dump body and lock with the
safety pin.
[*2]
3 Mounting nut:
245 – 309 Nm {25 – 31.5 kgm}
1. Remove pin (1). [*1]

a With the parking brake released, turn
adjustment bolt (2) counterclockwise and
check that there is play in linkage (3).
2. Disconnect hose (4).

a When disconnecting the spring cylinder
hose, apply the parking brake.
a Check that the spring cylinder hose is
released.
3. Remove spring cylinder assembly (5). [*2]
14 HD325-7, HD405-7
Removal and installation of slack Installation

adjuster assembly 1 q Carry out installation in the reverse order to
removal.
Removal
k Stop the machine on level ground and put a Bleed the air from the brake circuit. For details,
blocks under the wheels. see Testing and adjusting, "Bleeding air from
k Raise the dump body and lock with the brake circuit".
safety pin.
k Open the drain valve of the rear air tank to
release the air inside the tank.
1. Disconnect hoses (1).
2. Remove tube (2) to (5).
3. Remove slack adjuster (6).
HD325-7, HD405-7 15

slack adjuster assembly 1 a Clean all parts and check for dirt or damage.
Coat sliding surfaces of all parts with engine
Disassembly oil, and coat surface of spring with grease (G2-
1. Remove cylinders (1), then remove pistons (3) LI) before installing.
and springs (2).
1. Fit O-ring, then install valve (7).
2. Remove seals (4) from pistons (3).
2. Install spring (6).
3. Remove cap (5), then remove spring (6) and
valve (7). 3. Fit O-ring, then install cap (5).
4. Fit seal (4) on piston (3), then install cylinder

(1).
5. Fit O-ring on body (8), then install spring (2)

and cylinder assembly.
16 HD325-7, HD405-7
HD325-7, HD405-7 17

© 2007 KOMATSU
All Rights Reserved
18 HD325-7, HD405-7
SEN01960-01
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up

Undercarriage and frame
Removal and installation of front wheel assembly .......................................................................................... 2
Removal and installation of rear wheel assembly ........................................................................................... 3
Removal and installation of front suspension cylinder assembly .................................................................... 5
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
HD325-7, HD405-7 1
Removal and installation of front

wheel assembly 1
Removal
blocks on both sides of the rear wheels.
k Put a hydraulic jack (30 ton) under the sus-
pension cylinder, and jack up the front
wheel assembly.
Installation
removal.
[*1]
a Follow the order for tightening the hub nuts
and install uniformaly.
a Tighten fully after lowering the machine to the
ground.
3 Hub nut:
1. Remove 12 hub nuts (1). [*1]
1,519 – 1,852 Nm (154.9 – 189.1 kgm)
2. Remove front wheel assembly (2). [*2]

4 Front wheel assembly:
[*2]
750 kg (Radial tire)
a Align the notched groove of the wheel hub and
a Use a forklift truck (5 ton).
the position of the air valve.
a When removing, be careful not to damage
a Be careful not to damage air valve.
the air valve of the inside wheel assembly.
k After removing the wheel assembly,
q Rotate the wheel and check that the runout is
within 5 mm.
stand it in a safe place and use blocks
q After installing the wheel assembly, drive the
to prevent it from falling over.
machine about 5 – 6 km and then check that
the bolts are tightened to the specified torque.
2 HD325-7, HD405-7
Removal and installation of rear 4. Remove wheel assembly (3).

a Using a forklift (5t), remove the wheel.
wheel assembly 1 a When removing the wheel, take care not
to break its air valve.
Removal
4 Wheel assembly: 750 kg
k Stop the machine on a level ground and put k Rest the removed wheel assembly
chocks at the front and rear of the front against a safe place and put blocks
tires. under it to prevent it from falling down.
1. Set a hydraulic jack (30 t) under either rear
axle and raise the rear wheel assembly.
5. Remove inner hub nuts (4). [*2]
2. Loosen the locknut of the air valve and remove

lock plate (1).
3. Remove outer hub nuts (2). [*1]
6. Remove wheel assembly (5) with a forklift, etc.

4 Wheel assembly: 750 kg
k Rest the removed wheel assembly
against a safe place and put blocks
under it to prevent it from falling down.
HD325-7, HD405-7 3
Installation
removal.
[*1] [*2]
a Tighten the hub nuts evenly in the diagonal
order.
a Tighten the hub nuts permanently after lower-
ing the machine.
3 Hub nut:
1,519 – 1,852 Nm {154.9 – 189.1 kgm}
a When installing, be careful not to damage the

air valve.
q Rotate the wheel and check that the runout is

within 5 mm.
q After installing the wheel assembly, drive the
machine about 5 – 6 km and then check that
the bolts are tightened to the specified torque.
4 HD325-7, HD405-7
Removal and installation of front 10. Remove 4 bolts (12).

a When removing the bolts marked q, turn
suspension cylinder assembly 1 the knuckle arm approx. 40° towards the
chassis, then remove the bolts marked w.
Removal
When doing this, return the knuckle arm to
1. Remove front wheel assembly its original position, and use a jack (30
q For details, see "Removal and installation ton) to raise the bottom of the king pin
of front wheel hub assembly" when removing.
2. Releasing nitrogen gas

q Release nitrogen gas from front suspen-
sion cylinder. For details, see "Testing and
adjusting of suspension cylinder", Releas-
ing nitrogen gas. [*1]
3. Disconnect brake hoses (1) and (2).

a Fit tags to the hoses to mark the mounting
position.
4. Remove grease tubes (3) and (4).
11. Remove pin (13) at suspension cylinder rod

end.
a Using a fork-lift (5 ton), sling the suspen-
sion cylinder assembly.
12. Remove suspension cylinder assembly (14).

a Disconnect the suspension cylinder
assembly from the knuckle arm.
4 Suspension cylinder assembly: 290 kg
5. Remove 2 elbows (5) and (6).

6. Remove lock plate (7).
7. Remove pins (8) and (9).
8. Remove tie rod (10).
9. Disconnect steering cylinder rod (11).
Installation
removal.
[*1]
3 Valve: 39.2 – 49.0 Nm {4 – 5 kgm}
q Refilling with oil, charging nitrogen gas

q Adjust front suspension cylinder. For details,
see "Testing and adjusting of front suspension
cylinder".
HD325-7, HD405-7 5
Disassembly and assembly of 1. Remove cover

front suspension cylinder
2. Remove intake valve (1) and oil level valve (2).
assembly 1
3. Cylinder rod assembly
Special tools: 1) Remove flange mounting bolts (3) and air
bleed valve (4).
New/Remodel
2) Raise cylinder rod assembly (5) with plate
Necessity
Sym-
Part No. Part name ( 6) , r eta i n er ( 7 ) an d f l an ge ( 8 ) s t i ll
Sketch
bol
installed.
Q'ty
792-103-4102 Push tool t 1 Q 4. Disassembly of flange
1 792-101-5421 Grip t 1 1) Remove plate (6), retainer (7), and flange
(8) from rod assembly (5).
01010-51240 Bolt t 1
Q 2) Remove dust seal (9) and bushing (10)
792-610-1000 Suspension tool t 1 from retainer (7).
2 790-610-1100 • Pump assembly t 1 3) Remove packing (11) and bushing (12)
792-610-1200 • Charging tool t 1 from flange (8).
5. Remove wear ring (13) from cylinder rod (5).

Disassembly
q Using a block, stand the cylinder assembly Assembly
upright.
1. Installation of wear ring
Install wear ring (13) to cylinder rod (5).
2. Assembly of flange
1) Using tool Q1, press fit bushing (12) in
flange (8), and install U-packing (11).
2) Press fit bushing (10) to retainer (7), and
install dust seal (9).
a Be careful not to deform the bushing

when press fitting.
6 HD325-7, HD405-7
3. Assembly of rod assembly 4. Assembly of cylinder rod assembly

q If stopper (14) installed to the rod is bro- 1) Install wear ring (13) to cylinder rod (5).
ken or shifted out, replace it with new one. 2) Install flange (8), retainer (7), and plate (6)
1) Place stopper (14), aligning it with rod (5). to cylinder rod.
a Place stopper (14) with the round rim 3) Using block, stand cylinder upright.
end up. a Fill inside of cylinder with engine oil.
5 Cylinder: 13.8 l (HO-MVK)
4) Raise cylinder rod assembly (5), and
assemble in cylinder.
a When assembling the rod assembly
in the cylinder, if the rod assembly is
inserted too far, the oil will spurt out,
so stop at a position where the oil
does not spurt out.
a After completely installing the sus-
pension to the machine, use tool Q2
to adjust the oil and gas levels. For
details, see "Testing and adjusting of
suspension cylinder".
5) Install flange (8), retainer (7), and plate (6)
2) Using tool [1], press fit stopper (14).
to cylinder with bolts (3).
3 Bolt:
q Press fit stopper (14) to the rod
mounting part securely.
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
6) Install air bleed valve (4).
3 Valve:
39.2 – 49.0 Nm {4 – 5 kgm}
5. Install oil level valve (2) and intake valve (1).

3 Valve: 39.2 – 49.0 Nm {4 – 5 kgm}
6. Install cover
3) Press fitting tool [1] (Reference)

[1a]: Nylon (For protection of rod)
HD325-7, HD405-7 7
Disassembly and assembly of variable damping selector valve

assembly 1
Disassembly
k Release the nitrogen gas. 5. Remove valve body assembly (6).

For details, see "Testing and adjusting,
Adjusting suspension cylinder (releasing 6. Disassemble valve body assembly.
nitrogen gas from suspension cylinder)". 1) Remove retainer assembly (8) from valve
body (7).
q Remove the air cylinder assembly. 2) Disassemble retainer assembly.
Remove dust seal (10) from retainer (9),
1. Remove bracket (1). then using push tool, remove bushing
(11).
2. Remove lever (2), then remove key (3). 3) Remove flange assembly (12).
4) Disassemble flange assembly.
3. Remove bracket (4). Remove U-packing (14), O-ring (15), and
ring (16) from flange (13).
4. Remove tube (5). 5) Remove shaft assembly (17).
k The oil inside the cylinder will come 6) Disassemble shaft assembly.
out from the tube, so prepare a con- Using push tool, remove bearing (19) from
tainer to catch it. shaft (18).
6 Front suspension cylinder:
13.8 l (each side)
8 HD325-7, HD405-7
7. Remove orifice plate assembly (20) from valve

body (7).
8. Disassemble orifice plate assembly.

1) Remove bolt (21), then remove plates
(22), to (25), and (26).
2) Remove pin (27) from plate (25).
9. Remove tube assembly (28).
10. Disassemble tube assembly.

Remove O-ring (30), ring (31), and O-ring (30)
from tube (29).
2) Install shaft assembly (17).
Assembly 3) Assembly of shaft assembly (12).
Install ring (16), O-ring (15), and U-pack-
1. Assembly of tube assembly (28) ing (14) to flange (13).
Install O-ring (30), ring (31), and O-ring (30) to 4) Install flange assembly (12).
tube (29). 5) Assembly of retainer assembly (8).
Using push tool (outside diameter: 20
2. Install tube assembly (28). mm), press fit bushing (11) in retainer (9),
then install dust seal (10).
3. Assemble orifice plate assembly (20). 6) Install retainer assembly (8) to valve body
1) Install pin (27) to plate (25). (7).
2) Assemble plates (26), to (23), and (22),
and install with bolt (21). 6. Fit O-ring and install valve body assembly (6).
a Assemble plates (25), (24), and (23)
with the chamfered side facing plate 7. Fit O-ring and install tube (5).
(26).
8. Install bracket (4).
9. Fit key (3) to shaft assembly (17), and install

lever (2).
10. Install bracket (1).

q Refilling with oil, charging with gas
a Add oil and charge the suspension cylin-
der with nitrogen gas.
For details, see "Testing and adjusting,
Adjusting suspension cylinder".
5 : 13.8 l (each side)
4. Install orifice plate assembly (20) to valve body 11. Tighten 6 mounting bolts (32) of valve assem-
(7). bly (6).
3 Mounting bolt:
5. Assemble valve body assembly (6).
1) Assembly of shaft assembly (17). 245.2 – 308.9 Nm {25 – 31.5 kgm}
Using push tool (outside diameter: 42
mm), install bearing (19) to shaft (18).
a Press fit the outer race (fixed race) of
bearing (19), then install the lip of the
holder facing the outer race (fixed
race).
HD325-7, HD405-7 9
Removal and installation of rear Installation

suspension cylinder assembly 1 q Carry out installation in the reverse order to
removal.
Removal
k Stop the truck on level ground and set the [*1]
3 Valve: 39.2 – 49.0 Nm {4 – 5 kgm}
parking brake switch to the PARK position,
then lock the wheels with blocks.
k Disconnect the cable from the negative (–) [*2]
3 Clamp: 6.31 – 7.29 Nm {0.64 – 0.74 kgm}
1. Release the nitrogen gas. [*1] [*3] [*4]

k When aligning the pin holes, never insert
q Release nitrogen gas. For details, see
"Testing and adjusting, Testing and adjust- your fingers in them.
ing rear suspension cylinder". a Refill the rear suspension cylinder with nitro-
gen gas and adjust it. For details, see "Testing
2. Remove pressure sensor connector (1). and adjusting, Testing and adjusting rear sus-
pension cylinder".
3. Remove guard (2). [*2]
4. Remove rear suspension cylinder bottom pin

(3). [*3]
a Using a forklift etc., sling the rear suspen-
sion cylinder assembly temporarily.
5. Remove rear suspension cylinder rod pin (4).

[*4]
6. Remove rear suspension cylinder assembly

(5).
4 Rear suspension cylinder assembly:
110 kg
10 HD325-7, HD405-7
Disassembly and assembly of

rear suspension cylinder
assembly 1
Special tools:
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
792-103-4102 Push tool t 1 Q
1 792-101-5421 Grip t 1
01010-51240 Bolt t 1 4. Flange
Q
792-610-1000 Suspension tool t 1 1) Remove retainer (8) and flange (9) from
2 790-610-1100 • Pump assembly t 1
rod assembly (7).
2) Remove U-packing (11), backup ring, and
792-610-1200 • Charging tool t 1 buffer ring (12), and O-ring (13) from
flange (9).
3) Remove the bushing from flange (9).
Disassembly 4) Remove seal (14) and bushing from
1. Cover retainer (8).
Hanging the cylinder assembly, loosen band
(1) and remove the button, then remove cover
(2).
2. Intake valve and oil level valve

1) Remove the protector, them remove
intake valve (3) and oil level valve (4).
2) Drain oil from the cylinder.
5. Wear ring
Remove wear ring (15) from rod (16).

Place the cylinder assembly on its end, upside
down.
1) Remove flange mounting bolt (5).
2) Slowly hang cylinder rod assembly (7)
with a crane to remove it from cylinder
(10), without removing retainer (8) and
flange (9).
HD325-7, HD405-7 11
Assembly 5. Intake valve and oil level valve

Turn the cylinder assembly in reverse.
1. Wear ring 1) Hang cylinder (10) until dimension (A)
Install wear ring (15) to rode (16). becomes 110 ± 3 mm.
2. Flange
1) Install the bushing to flange (9) with tool
Q1.
2) Install U-packing (11) to flange (9).
3) Install backup ring and buffer ring (12) and
O-ring (13) to flange (9).
2) Supply oil through oil level port with an oil

pump until bubbles do not come out from
the intake port any more.
3) After filling the oil, install intake valve (3)
and oil level valve (4).
3 Intake valve and oil level valve:
39.2 – 49.0 Nm {4 – 5 kgm}
3. Retainer
1) Install the bushing to retainer (8) with tool 6. Cover
Q1. 1) Install cover (2) and tighten band (1).
2) Install seal (14) to retainer (8). 2) Install the protector of the intake valve and
oil level valve.

1) Erect cylinder (10) by using a block.
2) Hang cylinder rod assembly (7) and install
it to cylinder (10).
3) Install plate (6), retainer (8), and flange (9)
together with mounting bolts (5).
3 Mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
12 HD325-7, HD405-7
HD325-7, HD405-7 13

© 2007 KOMATSU
All Rights Reserved
14 HD325-7, HD405-7
SEN01961-01
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up

Hydraulic system
Disassembly and assembly of hoist cylinder assembly .................................................................................. 2
HD325-7, HD405-7 1
Disassembly and assembly of 1. Set cylinder assembly to tool U1.

hoist cylinder assembly 1 2. Using tool U2, remove crown (1) from cylinder
Special tools: (2).
a After loosening the crown, remove the
New/Remodel
grease nipple from the rod head, then pull
put the crown.
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
Cylinder repair
1 790-502-1003 t 1
stand
790-101-1102 Pump t 1
2
790-102-3802 Wrench assembly t 1
790-201-1881 Push tool t 1
5 790-101-5021 Grip t 1
01010-50816 Bolt t 1
797-201-1841 Push tool t 1
6 790-101-5021 Grip t 1
01010-50816 Bolt t 1 3. Remove cylinder and rod assembly from
U 790-201-1690 Plate t 1 cylinder (2).
7 790-101-5021 Grip t 1
01010-50816 Bolt t 1
790-201-1650 Plate t 1
8 790-101-5021 Grip t 1
01010-50816 Bolt t 1
790-720-1000 Expander t 1
10 796-720-1680 Ring t 1
07281-01589 Clamp t 1
796-720-1670 Ring t 1
11
07281-01279 Clamp t 1
4. Remove piston nut (3), then lift off rod (5) from
Disassembly
cylinder (4).
q Be careful not to damage the rod packing, dust
seal, piston ring, and wear ring.
2 HD325-7, HD405-7
5. Remove cylinder head assembly (6) from cylin- q Disassembly of piston assembly
der (4). Remove piston ring (13) and wear ring (14)
from piston assembly (12).
6. Remove wear ring (7).
8. Remove snap ring (15) from cylinder (4),

q Disassembly of cylinder head assembly then remove dust seal (16), rod packing (17),
1) Remove O-ring, then remove dust seal (8) and bushing (18).
and rod packing (9).
2) Remove bushing (10).
7. Remove snap ring (11) from cylinder (4),

then remove piston assembly (12).
HD325-7, HD405-7 3
Assembly q Assembly of piston assembly

1) Using tool U10, expand piston ring (13),
a Clean all parts, and check for dirt or damage. and assemble to piston (12).
Coat the sliding surfaces of all parts with a Set the piston ring on tool U10, and
engine oil before installing. t ur n th e h an dl e 8 – 1 0 ti m e s t o
expand the ring.
1. Using tool U6, press fit bushing (18) to cylinder 2) Set tools U11 in position, and compress
(4). piston ring (13).
3) Using tools U11, install wear ring (14).
2. Install rod packing (17).

a Check the direction of assembly for the
rod packing when installing.
4. Assemble piston assembly (12) to cylinder

(4), and install snap ring (11).
3. Using tool U8 fit dust seal (16) and install snap
ring (15).
4 HD325-7, HD405-7
5. Install wear ring (7) to cylinder (4). 3) Using tool U7 install dust seal (8).
q Assembly of cylinder head assembly 6. Assemble cylinder head (6) to cylinder (4).
1) Using tool U5, press fit bushing (10).
7. Raise rod (5) and assemble to cylinder (4).

2) Assemble rod packing (9) to cylinder head a Align the stud bolt at the tip of the rod with
(6). the bolt hole in the piston assembly.
a Check the direction of assembly for
the rod packing when installing.
HD325-7, HD405-7 5
8. Tighten mounting nut (3) of piston assembly

(12).
2 Stud bolt:
Thread tightener (Loctite #262)
3 Mounting bolt:
274.6 ± 29.4 Nm {28 ± 3 kgm}
a Remove all oil and grease from the
assembly portion of the nuts and blots.
9. Assemble cylinder and rod assembly to cyl-

inder (2).
10. Using tool U2 install crown (1) to cylinder

(2), and fit grease nipple.
3 Crown:
4,413.2 ± 441.3 Nm {450 ± 45 kgm}
6 HD325-7, HD405-7
HD325-7, HD405-7 7

© 2007 KOMATSU
All Rights Reserved
8 HD325-7, HD405-7
SEN01962-01
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up

Body
Removal and installation of body assembly .................................................................................................... 2
HD325-7, HD405-7 1
Removal and installation of body 3. Disconnect body potentiometer linkage (3)

from the body side. [*2]
assembly 1
4. Remove right and left body hinge pins (4). [*3]
Special tools
a Check the thickness, quantity and posi-
tions of the inserted spaces. [*4]
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
V1 790-441-1320 Hook t 4
Removal
k Raise the poke ejector and set it in parallel
with the body.
1. Using tool V1, sling the body assembly by 4 5. Lift off body assembly (5). [*5]
4 Body assembly
parts.
HD325-7: 8,000 kg
2. Remove hoist cylinder bottom pin (1). [*1]
HD405-7: 10,100 kg
a Fix hoist cylinder (2) with a lever block etc.
so that it will not fall down when pin (1) is
removed.
a Remove the pin on the opposite side simi-
larly.
Installation
removal.
[*1]
kWhen aligning the pin holes, never insert
your fingers in the pin holes.
3 Lock plate mounting bolt:
157 – 196 Nm {16 – 20 kgm}
[*2]
a Adjust the boom positioner sensor. For details,
see Testing and adjusting, "Adjusting boom
positioner sensor".
2 HD325-7, HD405-7
[*3] q Adjusting body mount shim

kWhen aligning the pin holes, never insert 1. Adjust the body mount shim.
your fingers in the pin holes. 1) Insert 40 mm thick spacer [1] in the end of
a Insert the spacers as checked when removed. body (7). (1 place each on right and left
3 Lock plate mounting bolt: sides)
157 – 196 Nm {16 – 20 kgm} 2) Measure the clearance between each of
rubber pads (8) A, B and C installed on the
right and left sides and frame top (9).
[*4] q Shim thickness = (X - 38) mm
a After installing the body, check that difference 3) If there is any clearance, add shim (10) to
"Z" between the levels of the body assembly eliminate it.
and cab assembly is in the following range. q Standard shim thickness at A, B and
q Standard value of difference (Z): 107 ± 25 C: 2 mm
q Kinds of shim thickness:
1 mm, 3.2 mm
4) Remove spacer [1], lower the body, and
check that all of 6 rubber pads A, B and C
are in contact with the rear frame top.
3 Mounting bolt (9):
245 – 309 Nm {25 – 31.5 kgm}
a If difference (Z) is out of the standard, adjust it

with spacers (6) of the right and left body hinge
pins.
q Kinds of spacer thickness: 1 mm, 6 mm
a Clearance (Y) must be 1 mm or less.
HD325-7, HD405-7 3
2. Adjust the front mount shim.

q After adjusting the bottom mount shim,
adjust the right and left front mount shims.
1) Lower the body and measure thickness
(w) of rubber pad (11).
q Standard shim thickness: 6 mm
2) If the thickness is larger than the stan-
dard(rubber pads) or there is a clearance
between the body and rubber pad, add
shim (12) to adjust height (w) to the stan-
dard(rubber pads).
q Standard height (w): 51 mm
3 Mounting bolt (9):
245 – 309 Nm {25 – 31.5 kgm}
4 HD325-7, HD405-7
HD325-7, HD405-7 5

© 2007 KOMATSU
All Rights Reserved
6 HD325-7, HD405-7
SEN01963-01
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up

Cab and its attachments
Disassembly and assembly of operator's seat assembly................................................................................ 2
Removal and installation of air conditioner unit assembly .............................................................................11
HD325-7, HD405-7 1
Disassembly and assembly of operator's seat assembly 1

a The procedure for disassembling and assembling the operator's seat assembly (air suspension (Isring
hausen)) is shown below.
A: Headrest E: Left-hand armrest

B: Seatback F: Suspension cover
C: Seat cushion G: Rails
D: Right-hand armrest
Disassembly
1. Headrest
1) Referring to the figure, check the positions
of the 2 clips (2) of headrest stay (1) on
both sides.
2 HD325-7, HD405-7
2) Apply force b to part a of each clip (2) in 2. Seatback

the direction of the arrow to turn the clip. 1) Disconnect 3 air hoses (5) from the rear
Release headrest stay (1) from part d of left of seatback (4).
the clip and pull out up headrest (3). a Before disconnecting the air hoses,
check their types.
2) Remove seatback hinge mounting bolt (6)

(M8 bolt).
a Pushing in both clips (2) simultaneously,

remove headrest (3).
3) Bring seatback (4) down forward.
HD325-7, HD405-7 3
4) Apply force E to the right side of seatback 2) Push cushion stopper wire (9) down with
(4) in the direction of the arrow. screwdriver [1], etc.
5) Applying the force to seatback (4), pull its 3) Pull out seat cushion (8) forward and
right side up. remove it.
6) Slide seatback (4) sideway and remove it.
4. Armrest
3. Seat cushion q The procedure for disassembling right-hand
1) Push cushion adjuster lever (7) inward armrest (10) is shown below. (Disassemble
and slide seat cushion (8) to the front end. left-hand armrest (11) similarly.)
4 HD325-7, HD405-7
1) Remove plastic cap (12) from the armrest 6) Remove right-hand armrest (10).
hinge. a There are 2 position adjustment
a Use a flat-head screwdriver, etc. to washers (16) installed to each bolt
remove the cap. between the armrest and seatback.
2) Loosen armrest hinge mounting bolt (13). Take care not to lose them.
3) Remove plastic cap (14), and then remove 5. Suspension cover

lower mounting bolt (15A) (M8 bolt) of 1) Remove right-hand hinge cover (17).
right-hand armrest (10). 2) Remove plastic plate (18) from the rear
with screwdriver [1], etc.
a Take care not to damage the plastic
plate by prying it off forcibly with a
screwdriver, etc.
4) Turn right-hand armrest (10) up by 180

degrees.
a If the armrest is not turned, you can-
not apply the tool to upper mounting
bolt (15B).
5) Remove plastic cap (14) and upper
mounting bolt (15B)
HD325-7, HD405-7 5
3) Remove 4 suspension cover fixing rings 6) Remove 6 plastic suspension cover clips
(19). (small) (25) and 2 plastic suspension
cover clips (large) (26).
a Clips (small) (25):
Front upper part; 2 places
Each side; 1 place
Rear lower part; 2 places
Clips (large) (26):
Front lower part; 2 places
7) Remove suspension cover (27).
a If you remove the suspension cover
without performing the work in steps
5) and 6), the suspension cover may
be broken.
4) Remove 4 mounting bolts (20), cushion

rear fixing plate (21), 2 cushion rails (22),
and 4 bushings (23).
6. Rails
1) Turn over the seat assembly to set rails
(28) on the upside.
5) Remove 3 metallic suspension cover clips

(24).
6 HD325-7, HD405-7
2) Slide rails (28) to the rear end. Assembly

3) Remove 1 hexagon socket head bolt (29)
and 1 lock washer (30) from the front part 1. Slide rails
of each rail. [*6] 1) Put height adjustment washers (31)
between slide rails (28) and suspension,
and then set slide rails (28) in position.
4) Slide rails (28) to the front end.

5) Remove 1 hexagon socket head bolt (29)
and 1 lock washer (30) from the rear part 2) Set slide rails (28) to the front end and
of each rail, and then remove rails (28). install 1 lock washer (30) and 1 hexagon
socket head bolt (29) to each slide rail.
3 Hexagon socket head bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
a Take care not to lose height adjust-

ment washers (31) between the rails
and suspension.
3) Set slide rails (28) to the rear end and
install 1 lock washer (30) and 1 hexagon
socket head bolt (29) to each slide rail.
3 Hexagon socket head bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
HD325-7, HD405-7 7
2. Suspension cover 3) Set 4 bushings (23) and 2 cushion rails

1) Set suspension cover (27) in position and (22), and then install cushion rear fixing
install 6 plastic suspension cover clips plate (21), and 4 mounting bolts (20).
(small) (25) and 2 plastic suspension 3 Cushion rail mounting bolt:
cover clips (large) (26). 21.4 – 27.6 Nm {2.18 – 2.82 kgm}
a Clips (small) (25):
Front upper part; 2 places
Each side; 1 place
Rear lower part; 2 places
Clips (large) (26):
Front lower part; 2 places
4) Install 4 suspension cover fixing rings

(19).
2) Install 3 metallic suspension cover clips

(24).
5) Install plastic plate (18) to the rear.

6) Install right-hand hinge cover (17).
8 HD325-7, HD405-7
3. Armrest 6) Tighten armrest hinge mounting bolt (13).

q The procedure for assembling right-hand a Tighten the bolt so that the arm will
armrest (10) is shown below. (Assemble move smoothly.
left-hand armrest (11) similarly.) q Operating effort at armrest end:
49 – 78.4 N {5 – 8 kg}
7) Install plastic cap (12).
1) Install 2 position adjustment washers (16)

for each bolt and set right-hand armrest
(10) in position. 4. Seat cushion
1) Slide in the seat cushion from the front of
the fitting position.
a If seat cushion (8) is slid to the rear, it
is locked by cushion stopper wire (9).
2) Tighten lower mounting bolt (15A) lightly

and turn armrest (10) by 180 degrees.
3) Tighten upper mounting bolt (15B) lightly.
4) Tighten lower mounting bolt (15A) and
upper mounting bolt (15A) permanently.
3 Upper and lower armrest mounting
bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
5) Install 2 plastic caps (14).
HD325-7, HD405-7 9
5. Seatback 3) Connect 3 air hoses (5) to the rear left of

1) Insert the left side of seatback (4), and the seatback (4).
then lower and set the right side.
6. Headrest
1) Insert headrest (3) in seatback (4).
a Check that 2 clips (2) on both sides are
locked securely.
2) Install seatback hinge mounting bolt (6).

3 Seatback hinge mounting bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
10 HD325-7, HD405-7
Removal and installation of air 3. Disconnect hose (5).

conditioner unit assembly 1 4. Remove duct (6) – (8). [*1]
Special tools
5. Remove covers (9) and (10).
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
Vacuum pump
799-703-1100 t 1
(100 V)
Vacuum pump
X 1 799-703-1111 t 1
(220 V)
Vacuum pump
799-703-1121 t 1
(240 V)
799-703-1401 Gas leak detector t 1
6. Remove dashboard cover (11).
Removal
k If the coolant temperature in the radiator is
high, you may be scalded. In this case, wait
until the coolant temperature lowers and
then disconnect the heater hoses.
k Collect the air conditioner refrigerant
(R134a) in advance.
k If refrigerant (R134a) gets in your eyes, you
may lose your sight. 7. Disconnect air conditioner hose and tube (12)
Accordingly, you must be qualified for han- – (15).
dling the refrigerant and put on protective
goggles while you are collecting the refrig-
erant or charging the air conditioner with
refrigerant.
1. Remove floor mat.
2. Remove covers (1) – (4).
HD325-7, HD405-7 11
8. Disconnect connector (16), connector CG1 Installation

(17), and connector TCHET (18), connector
AC1 (19) and connector AS1(20). q Carry out installation in the reverse order to
removal.
q Charging air conditioner with refrigerant
gas
with refrigerant (R134a).
a Quantity of refrigerant: 1.10 kg
[*1]
Assembly procedure for air duct
1. Install vent duct (1) and foot duct (2) to the
dashboard bracket (Make up the sub-assem-
bly).
2. Couple the air duct sub-assembly with the air

9. Removal air conditioner unit assembly. conditioner unit.
a Be sure to check that faucet joint portion
(a) is assembled normally.
a If faucet joint portion (a) is not inserted
normally, the dashboard mounting portion
floats.
a If the dashboard is assembled while it is
floating, the air conditioner opening is
deformed.
1. Vent damper
2. Foot damper
3. Face damper
4. Air conditioner unit
Check that faucet joint portion: a
q Refilling with coolant

specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
12 HD325-7, HD405-7
HD325-7, HD405-7 13

© 2007 KOMATSU
All Rights Reserved
14 HD325-7, HD405-7
SEN01964-01
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up

Electrical system
Removal and installation of engine controller assembly ................................................................................. 2
Removal and installation of transmission controller assembly........................................................................ 3
Removal and installation of retarder controller assembly ............................................................................... 4
HD325-7, HD405-7 1

engine controller assembly 1
Removal
the parking brake, and then lock the tires
with chocks.
1. Remove left engine side cover.
2. Remove engine controller (1).
3. Disconnect connectors J3P (2) and connector

ENG (3) and connector J2P (4) engine control-
ler.
4. Remove engine controller (5).
Installation
removal.
2 HD325-7, HD405-7

transmission controller assembly1
Removal
with chocks.
1. Remove seat rear cover.
2. Disconnect connectors (2) from transmission

controller (1).
q Connector, ATC1, ATC2, ATC3
3. Remove transmission controller (1).
Installation
removal.
HD325-7, HD405-7 3

retarder controller assembly 1
Removal
with chocks.
1. Remove seat rear cover.
2. Disconnect connectors (4) from retarder con-

troller (3).
q Connector, BRC1, BRC2, BRC3
3. Remove retarder controller (3).
Installation
removal.
4 HD325-7, HD405-7
HD325-7, HD405-7 5

© 2007 KOMATSU
All Rights Reserved
6 HD325-7, HD405-7
SEN00763-03
DUMP TRUCK
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up
90 Diagrams and drawings 1

Hydraulic diagrams and drawings
Power train hydraulic circuit diagram .............................................................................................................. 2
HD325-7 Serial No. 7001 – 7025, 7101 – 7522
HD405-7 Serial No. 3001 – 3035, 7101 – 7522........................................................................................... 3
HD405-7 Serial No. 7253 –.......................................................................................................................... 5
Brake hydraulic circuit diagram....................................................................................................................... 7
HD325-7, HD405-7 1
SEN00763-03 90 Diagrams and drawings
Power train hydraulic circuit diagram 1
2 HD325-7, HD405-7
Steering and hoist hydraulic circuit diagram Steering and hoist hydraulic circuit diagram
HD325-7 Serial No. 7001 – 7025, 7101 – 7522 HD325-7
HD325-7,Serial No. 7001 – 7025, 7101 – 7522
HD405-7
HD405-7 Serial No. 3001 – 3035, 7101 – 7522 HD405-7 Serial No. 3001 – 3035, 7101 – 7522
HD325-7, HD405-7 3
Steering and hoist hydraulic circuit diagram Steering and hoist hydraulic circuit diagram
HD325-7 Serial No. 7253 – HD325-7
HD325-7,Serial No. 7523 –
HD405-7
HD405-7 Serial No. 7523 – HD405-7 Serial No. 7523 –
HD325-7, HD405-7 5
Brake hydraulic circuit diagram Brake hydraulic circuit diagram

HD325-7, HD405-7
HD325-7, HD405-7 7
HD325-7, HD405-7 9

© 2008 KOMATSU
All Rights Reserved
10 HD325-7, HD405-7
SEN00764-03
DUMP TRUCK
HD325-7
HD405-7

HD325-7 7001 – 7025
HD325-7 7101 and up
HD405-7 3001 – 3035
HD405-7 7101 and up
90 Diagrams and drawings 1

Electrical diagrams and drawings
Electrical circuit diagram for inside cab (1/5) .................................................................................................. 3
HD325-7 Serial No. 7001 – 7025, 7101 – 7161
HD405-7 Serial No. 3001 – 3035, 7101 – 7157......................................................................................... 5
HD405-7 Serial No. 7158 – ......................................................................................................................... 7
HD325-7 Serial No. 7001 – 7025, 7101 – 7161
HD405-7 Serial No. 3001 – 3035, 7101 – 7157........................................................................................... 9
HD405-7 Serial No. 7158 – ........................................................................................................................11
Electrical circuit diagram for inside cab (4/5) ................................................................................................ 13
Electrical circuit diagram for inside cab (5/5) ................................................................................................ 15
HD325-7, HD405-7 1
Electrical circuit diagram for outside cab (1/3) ..................................................................................................17

Connectors table and arrangement drawing .....................................................................................................23
2 HD325-7, HD405-7
Electrical circuit diagram for inside cab (1/5) Electrical circuit diagram for inside cab (1/5) 1
HD325-7, HD405-7
SEN00764-03
HD325-7, HD405-7 3
Electrical circuit diagram for inside cab (2/5) 1
SEN00764-03
HD325-7, HD405-7 5
SEN00764-03
HD325-7, HD405-7 7
SEN00764-03
HD325-7, HD405-7 9
SEN00764-03
HD325-7, HD405-7 11
Electrical circuit diagram for inside cab (4/5) Electrical circuit diagram for inside cab (4/5)
HD325-7, HD405-7
HD325-7, HD405-7 13
Electrical circuit diagram for inside cab (5/5) Electrical circuit diagram for inside cab (5/5)
HD325-7, HD405-7
HD325-7, HD405-7 15
Electrical circuit diagram for outside cab (1/3) Electrical circuit diagram for outside cab (1/3) 1
HD325-7, HD405-7
SEN00764-03
HD325-7, HD405-7 17
HD325-7, HD405-7
SEN00764-03
HD325-7, HD405-7 19
HD325-7, HD405-7
SEN00764-03
HD325-7, HD405-7 21
Connectors table and arrangement drawing HD325/405-7 Connectors table and arrangement drawing
ÎThe address column in the following table shows the addresses in the connector arrangement drawing. HD325/405-7
Connector No. Connector type Number Location Address Connector No. Connector type Number Location Address Connector No. Connector type Number Location Address Connector No. Connector type Number Location Address
of pins of pins of pins of pins
53 Terminal 1 Emergency steering relay B-8 CJL DT2 6 Joint connector M-3 FUA2 — — Circuit breaker (30A) B-7 R11 Relay 5 Horn relay AF-3
54 Terminal 1 Emergency steering relay B-7 CJN DT2 6 Joint connector L-3 FUB1 — — Circuit breaker (80A) A-6 R16 Relay 5 Hazard lamp relay 1 AF-4
55 Terminal 1 Emergency steering relay C-7 CJP DT2 6 Joint connector N-7 FUB2 — — Circuit breaker (80A) A-6 R17 Relay 5 Hazard lamp relay 2 AF-4
56 Terminal 1 Emergency steering relay C-7 CJP1 DT2 6 Joint connector — FUEL DT2 2 Fuel level gauge sensor H-9 R19 Relay 5 Parking brake safety relay AF-3
60 Terminal 1 Battery relay C-8 CJP2 DT2 6 Joint connector — G SUMITOMO 3 Gsensor AJ-5 R21 Relay 5 Side lamp relay AF-2
61 Terminal 1 Battery relay D-8 CJPR DT2 6 Joint connector — GND Terminal 1 Ground D-7 R22 Relay 5 Rotary lamp relay AF-2
70 Terminal 1 Emergency steering relay B-8 CJR DT2 6 Joint connector L-9 GS Terminal 1 Ground AM-5 R25 — 11 Power window relay X-9
71 Terminal 1 Emergency steering relay B-8 CJV DT2 6 Joint connector L-9 H01 DT2 3 Steering pressure switch L-3 R29 Relay 5 Headlamp relay (high) (PASS) AF-4
72 Terminal 1 Emergency steering relay B-9 CK1 M 6 Bulb breakage check switch AA-3 HAZ M 6 Hazard lamp switch Q-9 R30 Relay 5 Headlamp relay (high) AF-4
73 Terminal 1 Emergency steering relay B-9 CM DT2C 8 Lighting switch, passing switch, turn switch U-1 HEPC DT2 2 Hoist EPC valve K-3 R31 Relay 5 Headlamp relay (low) AG-4
76 Terminal 1 Battery relay B-9 CN1 — 2 Injector AI-7 HN — 1 Horn switch Q-6 R32 Relay 5 Dust indicator relay AF-2
77 Terminal 1 Battery relay C-9 CN10 DT2 2 3rd clutch ECMV AE-9 HN1 DT2 2 Horn valve D-2 R33 M 6 Parking brake manual switch T-8
81 Terminal 1 Fuse D-9 CN11 DT2 2 3rd fill switch AE-9 HN2 DT2 2 Horn valve D-2 R34 M 7 Power window switch (right) U-9
83 Terminal 1 Fuse D-9 CN12 DT2 2 R clutch ECMV AE-9 HSOL DT2 3 Hoist selector valve K-3 R35 M 7 Power window switch (left) U-9
250 — 2 Resistor(male) R-2 CN13 DT2 2 R fill switch AE-9 HSL DT2 4 Hoist lever potentiometer X-2 R37 Relay 5 Auto preheater relay AF-2
1020 — 2 Resistor(male) S-1 CN14 DT2 2 4th clutch ECMV AE-9 HSL DT2 4 Intermediate connector — R38 — 5 Engine cut relay —
A1_F — 1 Emergency escape switch AE-3 CN15 DT2 2 4th fill switch AD-9 J01 HD 9 Intermediate connector AA-4 R40 Relay 5 Payload meter relay (if equipped) AG-4
A1_M — 1 Emergency escape switch AE-3 CN16 DT2 2 Torque converter lockup solenoid AD-8 JM01 — 6 Joint connector AN-8 R43 Relay 5 Payload meter external indicator lamp blue relay AG-4
ABS M 6 AB Ssystem switch Q-7 CN17 DT2 2 Low clutch ECMV AD-8 J02 DRC 70 Intermediate connector AA-4 R44 Relay 5 Payload meter external indicator lamp yellow relay AG-4
ABS1 DRC 24 ABS controller — CN18 DT2 2 Low fill switch AD-8 JM02 — 6 Joint connector AN-6 R45 Relay 5 Payload meter external indicator lamp red relay AG-2
ABS2 DRC 40 ABS controller — CN19 DT2 2 High clutch ECMV AC-8 J03 DRC 70 Intermediate connector Y-3 R46 — 5 Small lamp relay AG-2
ABS3 DRC 40 ABS controller — CN2 — 2 Injector AJ-8 JM03 — 4 Joint connector AN-6 RAD — 9 Cassette stereo AM/FM radio O-8
ABS6 — 4 Intermediate connector — CN20 DT2 2 High fill switch AC-8 J04 DRC 70 Intermediate connector AA-4 RE1 — 2 Resistor AF-2
ABS7 DT2C 12 Intermediate connector AC-2 CN21 DT2 3 Torque converter intermediate pressure sensor AD-5 JM04 — 4 Joint connector AM-6 RE3 — 2 Resistor (female) R-2
ABS8 DT2B 12 Intermediate connector AC-2 CN22 DT2 2 Torque converter oil temperature sensor AF-5 J05 DRC 70 Intermediate connector Z-3 RE4 — 2 Resistor (female) S-1
ABS9 DT2A 12 Intermediate connector AC-2 CN23 DT2 2 Transmission oil temperature sensor AG-6 JM05 — 3 Joint connector AM-9 RES DT2 2 Resistor AK-9
AC1 M 6 Intermediate connector Q-2 CN3 DT2 2 Input shaft speed sensor AC-7 J06 DT06 4 Intermediate connector Z-3 RESW DT2 2 Retarder switch J-9
ACC Terminal 1 Starting switch ACC terminal O-8 CN3 — 2 Injector AK-9 JM06 — 3 Joint connector AL-9 REVR DT2 2 Retarder valve B-6
ACCF DT2 3 ACC oil pressure sensor (front) C-2 CN4 DT2 2 Inter mediate shaft speed sensor AC-7 J07 DT2B 12 Intermediate connector L-8 RL M 2 Room lamp F-8
ACCR DT2 3 ACC oil pressure sensor (front) C-3 CN4 — 2 Injector AK-9 JM07 — 4 Joint connector AK-9 RL2 — 2 Room lamp 2 G-9
AISS M 6 AISS switch (If equipped) P-9 CN5 DT2 2 Output shaft speed sensor AG-9 J08 DT2A 12 Intermediate connector M-8 RLY Terminal 1 Heater relay C-9
ARC M 3 ARSC set switch R-2 CN5 — 2 Injector AL-9 JM08 — 6 Joint connector AM-9 RP DT2 5 Intermediate connector B-6
ARSC M 6 ARSC system switch P-7 CN6 DT2 2 1stclutch ECMV AF-9 J1939 DT2 3 Connector AL-9 RP1 DT2B 8 Intermediate connector C-7
AS1 DT2 6 Accele ration sensor Q-4 CN6 — 2 Injector AM-9 J2P DRC 50 Engine controller AN-7 RTL DT2 6 Retarder lever potentiometer S-1
AS3 DT2 3 Pitch angle sensor AG-2 CN7 DT2 2 1st fill switch AF-9 J3P DT06 4 Engine controller AL-5 RTR DT2 2 Retarder oil temperature sensor (right) AL-1
ASR M 6 ASR system switch Q-8 CN8 DT2 2 2nd clutch ECMV AF-9 JCA SWP 16 Joint connector AF-1 S01 DT2 2 Service brake switch —
ASS DT2 2 Pneumatic suspension seat X-2 CN9 DT2 2 2nd fill switch AE-9 JCB SWP 8 Joint connector AF-1 S04 DT2 2 Auto suspension solenoid 1 (if equipped) I-9
ATC1 DRC 24 Transmission controller AF-2 CNS1 DT2D 12 Intermediate connector U-8 JCC SWP 16 Joint connector U-1 S05 DT2 2 Auto suspension solenoid 2 (if equipped) I-9
ATC2 DRC 40 Transmission controller AE-2 CNS2 DT2C 12 Intermediate connector U-8 JCD SWP 16 Joint connector V-1 SBP DT2 4 Bypass valve position sensor AI-7
ATC3 DRC 40 Transmission controller AE-2 CNS3 DT2B 12 Intermediate connector T-8 JCF SWP 16 Joint connector AF-1 SBS DT2 2 Seat belt switch Y-3
ATC6 X 4 Intermediate connector AF-1 CUTF — 5 ABS cut valve relay (front) — LKO DT2 2 Lever kick-out solenoid X-2 SDE M 6 Side lamp switch (if equipped) AB-2
B Terminal 1 Starting switch B terminal P-7 CUTR — 5 ABS cu tvalve relay (rear) — LKO DT2 2 Intermediate connector — SEC DT2 2 Secondary brake pressure switch H-9
B01 DT2 6 Intermediate connector L-9 D01 AMP 2 Diode AC-3 LP1 DT2 12 Intermediate connector H-1 SEGR DT2 4 EGR valve position sensor AJ-9
B02 DT2 6 Intermediate connector M-8 D04 AMP 2 Diode AC-1 LP3 DT2 8 Intermediate connector E-1 SF1 DT2 12 Gearshift lever T-8
B03 DT2 6 Winker tail stop lamp (left) L-9 D05 AMP 2 Diode AC-1 LP4 DT2 8 Intermediate connector B-5 SF2 DT2 2 Gearshift lever T-8
B04 M 2 Backup lamp (70W) — D06 AMP 2 Diode AC-3 LS — 3 Rheostat W-1 SL HRN 4 Intermediate connector D-2
B05 Terminal 1 Backup alarm buzzer K-9 D07 AMP 2 Diode T-1 M Terminal 1 Emergency steering motor G-1 SL DT2 4 Intermediate connector L-2
B06 Terminal 1 Backup alarm buzzer K-9 D08 AMP 2 Diode AC-3 MON AMP 4 Intermediate connector P-9 SLL M 2 Side lamp (left) (if equipped) J-2
B07 DT2 3 Body position sensor J-9 D09 AMP 2 Diode AC-3 NE FRAMATOME 3 Ne sensor AN-7 SLR M 2 Side lamp (right) (if equipped) E-8
B1 DT2 2 Lamp G (right) (for payload meter) (if equipped) D-7 D10 AMP 2 Diode AC-2 OP7_F — 1 Connector V-1 SPARE X 4 Intermediate connector AD-3
B10 Terminal 1 Ground M-8 D11 AMP 2 Diode AC-1 OP7_M — 1 Connector W-1 SPL — 2 Speaker (left) G-9
B1L DT2 2 Lamp G (left) (for payload meter) (if equipped) J-2 DL DT2A 12 Intermediate connector AF-2 OPS DT2 2 Operator's seat heater — SPR — 2 Speaker (right) G-9
B2 DT2 2 Lamp A (right) (for payload meter) (ife quipped) D-7 DPC1 AMP070 20 Monitor panel S-7 PAMB FRAMATOME 3 Ambient pressure sensor AM-6 SR3 X 3 Steering speed sensor T-1
B2L DT2 2 Lamp A (left) (for payload meter) (ife quipped) J-2 DPC2A AMP070 18 Monitor panel S-7 PCV1 SUMITOMO 2 Supply pump control valve AI-5 ST1 Terminal 1 Emergency steering switch R-9
B3 DT2 2 Lamp R (right) (for payload meter) (ife quipped) D-7 DPC2B AMP070 12 Monitor panel S-7 PCV2 SUMITOMO 2 Supply pump control valve AI-6 ST2 Terminal 1 Emergency steering switch R-8
B3L DT2 2 Lamp R (left) (for payload meter) (if equipped) K-3 DPC3A AMP070 18 Monitor panel R-7 PEVA FRAMATOME 3 EGR valve pressure sensor AI-8 ST3 Terminal 1 Emergency steering switch R-8
BCVR DT2 2 BCV solenoid (right) G-9 DPC4 AMP070 12 Monitor panel S-7 PFUEL AMP 3 Common rail pressure sensor AL-5 ST4 Terminal 1 Emergency steering switch S-8
BLS M 6 Rotary lamp switch AA-1 DPC6 AMP070 8 Monitor panel R-7 PIM CANNON 3 Boost pressure sensor AN-8 STR DT2 2 Steering oil temperature sensor (if equipped) I-2
BP DT2 2 BP valve AI-6 DPC7 X 4 Monitor panel S-1 PL01 M 2 Headlamp (high) (left) F-1 SUFL DT2 3 Suspension oil pressure sensor (front, left) (if equipped) —
BR Terminal 1 Starting switch BR terminal O-7 DSL — 1 Door switch (left) H-1 PL02 M 2 Headlamp (low) (left) F-1 SUFR DT2 3 Suspension oil pressure sensor (front, right) (if equipped) —
BRC1 DRC 24 Retarder controller AD-3 DSR — 1 Door switch (right) E-8 PL03 M 3 Front combination lamp (left) F-1 SURL DT2 3 Suspension oil pressure sensor (rear, left) M-8
BRC2 DRC 40 Retarder controller AD-3 DT7 DT2 12 Intermediate connector X-2 PL04 Plug connector 1 Beacon lamp (left) (if equipped) — SURR DT2 3 Suspension oil pressure sensor (rear, right) K-9
BRC3 DRC 40 Retarder controller AD-3 DT8 DT2 4 Intermediate connector W-2 PL06 M 2 Fog lamp (left) (if equipped) E-1 T05 Terminal 1 Ground N-6
BRC6 X 4 Intermediate connector AF-1 E Terminal 1 Emergency steeringmotor G-1 PL07 Terminal 1 Ground G-1 T1 Terminal 1 Transmission ground AG-7
BT DT2B 8 Intermediate connector D-8 E01 Terminal 1 Alternator R terminal AM-2 PM DT2A 12 Intermediate connector M-2 TC200 — 40 KOMTRAX controller —
BT1 — Fusebox AH-3 E02A DT2 2 Starting motor AL-1 PM1 MIC 21 Intermediate connector V-9 TCHET X 4 Tachograph and heater unit —
BT-1A Terminal 1 Battery 1 (+) F-8 E04 DT2 2 Engine oil level switch AL-5 PM3 DT2 3 Pitch angle sensor AH-1 TEL DT2D 12 Intermediate connector —
BT-1B Terminal 1 Battery 1 (-) F-9 E05 Terminal 1 Oil filter switch AM-9 PM4 S 16 Intermediate connector V-9 TEST_F — 1 ASR test switch AE-3
BT2 — Fuse box AH-3 E06 Terminal 1 Alternator E terminal AN-3 PM5 — 13 Payload meter controller (if equipped) — TEST_M — 1 ASR test switch AE-2
BT-2A Terminal 1 Battery 2 (-) F-8 E07 X 2 Ai rcompressor C-2 PM6 — 12 Payload meter controller (if equipped) — TFUEL PACKARD 2 Fuel temperature sensor AN-9
BT-2B Terminal 1 Battery 2 (+) F-8 E09 Terminal 1 Alternator B terminal AM-2 PM7 — 9 Payload meter controller (if equipped) — TIM PACKARD 2 Boost temperature sensor AM-9
BT3 — Fuse box AG-3 E11B Terminal 1 Heater relay C-9 PM8 — 5 Intermediate connector — TM2 HD 23 Intermediate connector AH-8
BT4 — Fuse box AH-3 E12B Terminal 1 Heater relay D-9 POIL FRAMATOME 3 Engine oil pressure sensor AL-5 TM3 HD 31 Intermediate connector AH-8
BTL DT2 2 Battery fluid level sensor B-7 E14 Terminal 1 Startingmotor B terminal AK-1 PR01 M 2 Headlamp (low) (right) B-4 TMF1 DT2 2 Transmission oil filter switch J-2
BZ2 M 2 Buzzer V-1 E15 Terminal 1 Ground AM-2 PR02 M 2 Headlamp (high) (right) B-4 TWTR PACKARD 2 Engine coolant temperature sensor AJ-2
C Terminal 1 Starting switch C terminal P-7 E16B Terminal 1 Ground C-9 PR03 M 3 Front combination lamp (right) B-5 WFM — 6 Wiper motor (front) T-1
CAB1 DT2A 8 Intermediate connector U-9 E17B DT2 2 Diode C-9 PR04 Plug connector 1 Beacon lamp (right) (if equipped) — WFR — 6 Wiper relay (front) V-1
CAB2 DT2B 8 Intermediate connector V-9 EGR DT2 2 EGR valve AI-9 PR06 M 2 Fog lamp (right) (if equipped) B-4 WPS DT2B 12 Wiper switch S-1
CAN2 DT2 3 Resistor U-1 EM — 6 Emergency steering timer AH-2 PR07 Terminal 1 Ground B-5 ÎDetails of colored connectors
CAN2 — 3 Terminal resistor (120z) AM-6 EMPR — 2 Emergency steering fuse D-8 PSOLR DT2 2 Parking brake solenoid (rear) J-9 DT2A:Gr(Gray), DT2B:B(Black), DT2C:G(Green), DT2D:Br (Brown)
CG1 — 2 Cigarette lighter Q-6 ENG DRC 60 Engine controller AN-7 PSWR DT2 2 Parking brake switch N-8
CH1 M 8 Mode selector switch 1 Z-2 ER1 Terminal 1 Ground X-9 PWL_F Plug connector 1 Power window motor (left) I-1
CH2 M 8 Mode selector switch 2 Z-2 ER1 Terminal 1 Ground C-7 PWL_M Plug connector 1 Power window motor (left) H-1
CHECK M 6 ABS check switch AA-3 ER2 Terminal 1 Ground D-7 PWM M 6 Power mode switch P-9
CHK-1 — 1 Intermediate connector — ER2 Terminal 1 Ground — PWR_F Plug connector 1 Power window motor (right) E-8
CHK-2 — 1 Intermediate connector — ER3 Terminal 1 Ground — PWR_M Plug connector 1 Power window motor (right) E-8
CJA DT2 6 Joint connector L-2 FB DT2 2 Front brake cut valve H-9 R_L2 — 1 Intermediate connector —
CJB DT2 6 Joint connector L-2 FBC M 6 Front brake cut switch P-9 R01 Relay 5 Engine starting relay AF-4
CJD DT2 6 Joint connector D-2 FL04 — 2 Washer motor C-6 R02 Relay 5 Transmission neutral relay AF-4
CJE3 DT2 6 Joint connector M-3 FLS — 4 Flasher W-2 R03 Relay 5 Parking brake relay AF-4
CJE4 DT2B 8 Joint connector AM-6 FOG M 6 Fog lamp switch (if equipped) Z-1 R04 Relay 5 Stop lamp relay AF-3
CJG DT2 6 Joint connector N-7 FR01 DT2 2 Air cleaner clogging sensor D-7 R05 Relay 5 Backup lamp/buzzer relay AF-3
CJH1 DT2B 8 Joint connector C-6 FR02 DT2 2 Radiator coolant level sensor B-3 R06 Relay 5 Fog lamp relay AF-4
CJK DT2 6 Joint connector B-7 FUA1 — — Circuit breaker (30A) B-7 R08 Relay 5 Stop lamp relay AF-4
SEN00764-03
HD325/405-7 23
HD325-7, HD405-7 25

© 2008 KOMATSU
All Rights Reserved
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SEN00486-07

DUMP TRUCK HD325 -7

DUMP TRUCK 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN00486-07

00 Index and foreword SEN00743-07

10 Structure, function and maintenance standard SEN00748-04

20 Standard value table SEN00758-02

30 Testing and adjusting SEN00759-02

Troubleshooting by failure code, Part 2 SEN01188-01

50 Disassembly and assembly SEN00761-01

90 Diagrams and drawings SEN00762-05

Foreword and general information SEN00745-04

10 Structure, function and maintenance standard

20 Standard value table

30 Testing and adjusting

Testing compression pressure..................................................................................................... 16

Troubleshooting by failure code, General SEN01186-01

Failure code [CA145] (Coolant temperature sensor too low) ...................................................... 20

Failure code [CA2555] (Intake air heater relay disconnection) ................................................... 24

S-13 Oil level rises (Entry of coolant/fuel) ................................................................................... 26

50 Disassembly and assembly

Disassembly and assembly of rear suspension cylinder assembly ............................................ 11

90 Diagrams and drawings

HD325-7, HD405-7 Dump truck

DUMP TRUCK 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

1. General precautions 7) If welding repairs are needed, always

2. Preparations for work 6) When removing a cover which is under

4. Precautions for sling work and making

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value or allow-

Handling of electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector