Komatsu HD325-7, HD405-7 Dump Truck Service Manual
1,406 pages · Publication SEN00486-16
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What's inside
From the manual's own table of contents: 227 sections, 466 entries. See sample pages (PDF, 757 KB)
Show all 227 sections
Accumulator charge valve42 topics
- Accumulator
- Slack adjuster
- Brake
- Proportional reducing valve
- Parking brake
- Parking brake solenoid
- Hand brake (retarder)
- Suspension
- Suspension cylinder
- Rear axle support
- Steering, hoist oil pressure piping diagram
- Dump body control
- Hydraulic tank
- Steering valve
- Cross-over relief valve
- Steering control valve
- Hoist valve
- Dump control valve (EPC valve)
- Steering cylinder
- Hoist cylinder
- Work equipment and steering pump
- ROPS cab
- Air conditioner
- Rear view monitor
- Machine monitor system
- Automatic shift control system
- Transmission controller
- External power supply heater
- Auto emergency steering system
- Retarder control system
- Battery disconnector switch
- Dump control lever
- Auto suspension system
- Payload meter (card type)
- Sensors, switches
- KOMTRAX terminal system (If equipped)
- Standard value table for engine
- Standard value table for machine
- Tools for testing, adjusting, and troubleshooting
- Testing engine speed
- Testing intake air pressure (boost pressure)
- Testing exhaust temperature
Testing brake oil pressure1 topic
- with nitrogen gas
Connection table for connector pin numbers54 topics
- T- branch box and T- branch adapter table
- Failure codes table
- Before troubleshooting by failure codes
- Contents of troubleshooting table
- Failure code [1500L0] (Dual engagement)
- Failure code [15B0NX] (Transmission oil filter: Clogging)
- Failure code [15F0KM] (R o F shifting abuse 1: Mistake in operation)
- Failure code [15F0MB] (R o F shifting abuse 2: Mistake in operation)
- Failure code [15F7KM] (Forward clutch disk abuse: Mistake in operation or setting)
- Failure code [15G0MW] (R clutch: Slipping)
- Failure code [15G7KM] (Reverse clutch disk abuse: Mistake in operation or setting)
- Failure code [15H0MW] (Hi clutch: Slipping)
- Failure code [15J0MW] ( Lo clutch: Slipping)
- Failure code [15K0MW] (1st clutch: Slipping)
- Failure code [15L0MW] (2nd clutch: Slipping)
- Failure code [15M0MW] (3rd clutch: Slipping)
- Failure code [15N0MW] (4th clutch: Slipping)
- Failure code [15SBL1] (R clutch solenoid: Fill signal is ON when command current is OFF)
- Failure code [15SBMA] (R clutch solenoid: Malfunction)
- Failure code [15SCL1] (Hi clutch solenoid: Fill signal is ON when command current is OFF)
- Failure code [15SCMA] (Hi clutch solenoid: Malfunction)
- Failure code [15SDL1] (Lo clutch solenoid: Fill signal is ON when command current is OFF)
- Failure code [15SDMA] (Lo clutch solenoid: Malfunction)
- Failure code [15SEL1] (1st clutch solenoid: Fill signal is ON when command current is OFF)
- Failure code [15SEMA] (1st clutch solenoid: Malfunction)
- Failure code [15SFL1] (2nd clutch solenoid: Fill signal is ON when command current is OFF)
- Failure code [15SFMA] (2nd clutch solenoid: Malfunction)
- Failure code [15SGL1] (3rd clutch solenoid: Fill signal is ON when command current is OFF)
- Failure code [15SGMA] (3rd clutch solenoid: Malfunction)
- Failure code [15SHL1] (4th clutch solenoid: Command current is OFF and fill signal is ON)
- Failure code [15SHMA] (4th clutch solenoid: Malfunction)
- Failure code [15SJMA] (Lockup clutch solenoid: Malfunction)
- Failure code [989A00] (Engine over run prevention command signal: Operating)
- Failure code [989D00] (Rear section tipping over alarm: Alarm is activated)
- Failure code [2F00KM] (Parking brake: Mistake in operation or setting)
- Failure code [2G42ZG] (Front accumulator: Lowering of oil pressure)
- Failure code [2G43ZG] (Rear accumulator: Lowering of oil pressure)
- Failure code [A570NX] (Engine oil filter: Clogging)
- Failure code [AA10NX] (Air cleaner element: Clogging)
- Failure code [AB00MA] (Alternator: Malfunction)
- Failure code [B@BAZG] (Abnormal lowering of engine oil pressure: Lowering of oil pressure)
- Failure code [B@BAZK] (Engine oil: Level too low)
- Failure code [B@BCZK] (Lowering of radiator coolant: Lowering of level)
- Failure code [B@BCNS] (Engine: Overheat)
- Failure code [B@C7NS] (Rear brake oil: Overheat)
- Failure code [B@CENS] (Torque converter oil: Overheat)
- Failure code [B@GAZK] (Battery electrolyte level: Lowering of level)
- Failure code [B@JANS] (Steering oil: Overheat)
- Failure code [CA111] (Abnormality in engine controller)
- Failure code [CA115] (Abnormal engine Ne and Bkup sensors)
- Failure code [CA122] (Charge pressure sensor too high)
- Failure code [CA123] (Charge pressure sensor too low)
- Failure code [CA131] (Throttle sensor too high)
- Failure code [CA132] (Throttle sensor too low)
Failure code [CA2271] (EGR valve lift sensor too high)48 topics
- Failure code [CA2272] (EGR valve lift sensor too low)
- Failure code [CA2351] (EGR valve solenoid drive short circuit)
- Failure code [CA2352] (EGR valve solenoid drive disconnection)
- Failure code [CA2555] (Intake air heater relay disconnection)
- Failure code [CA2556] (Intake air heater relay short circuit)
- Failure code [D19HKB] (Stop lamp relay output system: Short circuit)
- Failure code [D5ZKKZ] (Front brake cut-off solenoid valve: Disconnection or short circuit)
- Failure code [DAF9KM] Wrong connection of connector
- Abnormal communication)
- Lowering of source voltage)
- Abnormality in controller)
- Power source voltage too low)
- Failure code [DAQ9KQ] (Transmission controller: Disagreement of model selection)
- Failure code [DAQRKR] (Communication lost: Defect communication)
- Failure code [DAQRMA] (Transmission controller option setting: Malfunction)
- Failure code [DB10KT] (Retarder controller nonvolatile memory: Abnormality in controller)
- Power source voltage too low)
- Failure code [DB19KQ] Disagreement of model selection (Retarder controller)
- Failure code [DB1RKR] (CAN communication (retarder controller): Communication disabled)
- Failure code [DB1RMA] Disagreement of option setting (Retarder controller)
- Failure code [DB1SKQ] (Model selection: Wrong information)
- Failure code [DB2RKR] (CAN communication (engine controller): Communication disabled)
- Failure code [DBC9KQ] Disagreement of model selection (ABS controller)
- Failure code [DBCRMA] Disagreement of option setting (ABS controller)
- Out of input signal range) (If equipped)
- Failure code [DDD8KA] (ARSC system switch system: Disconnection)
- Failure code [DDD8KB] (ARSC system switch system: Short circuit)
- Failure code [DDDAKA] (ASR system switch: Disconnection) (If equipped)
- Failure code [DDDAKB] (ASR system switch: Short circuit)
- Failure code [DDTHKA] (Hi clutch fill switch: Disconnection)
- Failure code [DDTJKA] (Lo clutch fill switch: Disconnection)
- Failure code [DDTKKA] (1st clutch fill switch: Disconnection)
- Failure code [DDTLKA] (2nd clutch fill switch: Disconnection)
- Failure code [DDTMKA] (3rd clutch fill switch: Disconnection)
- Failure code [DDTNKA] (R clutch fill switch: Disconnection)
- Failure code [DDTPKA] (4th clutch fill switch : Disconnection)
- Failure code [DF10KA] (Gear shift lever: Disconnection)
- Failure code [DF10KB] (Gear shift lever: Short circuit)
- Failure code [DGF1KX] (Transmission oil temperature sensor: Out of input signal range)
- Failure code [DGR2KZ] (Retarder oil temperature sensor : Disconnection or short circuit)
- Failure code [DGR6KX] (Steering oil temperature sensor: Input signal out of range)
- Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)
- Failure code [DHP6KA] (Suspension pressure sensor system (Rear right): Disconnection)
- (Rear right): Out of input signal range)
- Failure code [DHP7KA] (Suspension pressure sensor system (Rear left): Disconnection)
- (Rear left): Out of input signal range)
- Failure code [DHT5KX] (Torque converter oil pressure sensor: Out of input signal range)
- Disagreement of run and stop condition with signal)
Failure code [DK30KX] Trouble in steering angle potentiometer1 topic
- Potentiometer signal is inconsistent with swich signal)
Failure code [DK52KX] (Failure in hoist lever potentiometer 1: Out of input signal range)1 topic
- Disagreement of analog signal)
Failure code [DK54KX] (Body positioner sensor: Out of input signal range)1 topic
- Disagreement of run and stop condition with signal) (If equipped)
Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection)1 topic
- Disagreement of revolution speed signal)
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)3 topics
- Disagreement of revolution speed signal) (If equipped)
- (If equipped)
- Defective function (If equipped)
Failure code [DV00KB] Short circuit in buzzer output2 topics
- Disconnection or short circuit) (If equipped)
- Disconnection or short circuit)
Failure code [DWNBMA] Trouble in ASR shut-off valve (Valve does not operate)40 topics
- Out of control)
- output circuit: Disconnection)
- Short circuit)
- Short circuit to power source line)
- Malfunction)
- Failure code [DX13KA] (Output circuit of hoist EPC valve: Disconnection)
- Failure code [DX13KB] (Output circuit of hoist EPC valve: Short circuit)
- Short circuit with power source line)
- (right) (Valve keeps operating)
- (right) output circuit
- (right) (Valve does not operate)
- (left) (Valve keeps operating)
- (left) output circuit
- (left) (Valve does not operate)
- Failure code [DXH1KA] (Lockup clutch solenoid output circuit: Disconnection)
- Failure code [DXH1KB] (Lock-up clutch solenoid output circuit: Short circuit)
- Short circuit to power source line)
- Failure code [DXH2KA] (Hi clutch solenoid output circuit: Disconnection)
- Failure code [DXH2KB] (Hi clutch solenoid output circuit: Short circuit)
- Failure code [DXH2KY] (Hi clutch solenoid output circuit: Short circuit to power source line)
- Failure code [DXH3KA] (Lo clutch solenoid output circuit: Disconnection)
- Failure code [DXH3KB] (Lo clutch solenoid output circuit: Short circuit)
- Failure code [DXH3KY] (Lo clutch solenoid output circuit: Short circuit in power source line)
- Failure code [DXH4KA] (1st clutch solenoid output circuit: Disconnection)
- Failure code [DXH4KB] (1st clutch solenoid output circuit: Short circuit)
- Failure code [DXH4KY] (1st clutch solenoid output circuit: Short circuit to power source line)
- Failure code [DXH5KA] (2nd clutch solenoid output circuit: Disconnection)
- Failure code [DXH5KB] (2nd clutch solenoid output circuit: Short circuit)
- Short circuit in power source line)
- Failure code [DXH6KA] (3rd clutch solenoid output circuit: Disconnection)
- Failure code [DXH6KB] (3rd clutch solenoid output circuit: Short circuit)
- Failure code [DXH6KY] (3rd clutch solenoid output circuit: Short circuit to power source line)
- Failure code [DXH7KA] (R clutch solenoid output circuit: Disconnection)
- Failure code [DXH7KB] (R clutch solenoid output circuit: Short circuit)
- Failure code [DXH7KY] (R clutch solenoid output circuit: Short circuit to power source line)
- Failure code [DXHHKA] (4th clutch solenoid output circuit: Disconnection)
- Failure code [DXHHKB] (4th clutch solenoid output circuit: Short circuit)
- Failure code [DXHHKY] (4th clutch solenoid output circuit: Short circuit to power source line)
- Before troubleshooting of electric system
- Engine does not start
Alarm buzzer does not stop sounding1 topic
- section do not display properly
Sketches of special tools44 topics
- Removal and installation of engine assembly
- Removal and installation of radiator assembly
- Removal and installation of output shaft assembly
- Disassembly and assembly of output shaft assembly
- Removal and installation of fuel supply pump assembly
- Removal and installation of cylinder head assembly
- Removal and installation of fuel injector assembly
- Removal and installation of engine front seal
- Removal and installation of engine rear seal
- Removal and installation of torque converter and transmission assembly
- Disassembly and assembly of torque converter and control valve assembly
- Disassembly and assembly of torque converter assembly
- Disassembly and assembly of PTO Assembly
- Disassembly and assembly of transmission assembly
- Removal and installation of transmission control valve assembly (ECMV assembly)
- Disassembly and assembly of transmission control valve assembly (ECMV assembly)
- Removal and installation of differential assembly
- Disassembly and assembly of differential assembly
- Removal and installation of rear final drive carrier assembly
- Disassembly and assembly of rear final drive carrier assembly
- Disassembly and assembly of rear final drive assembly
- Disassembly and assembly of front wheel hub assembly
- Disassembly and assembly of steering cylinder assembly
- Removal and installation of emergency steering motor pump assembly
- Removal and installation of front brake caliper pad
- Removal and installation of front brake caliper assembly
- Disassembly and assembly of front brake caliper assembly
- Removal and installation of parking brake pad
- Removal and installation of parking brake caliper assembly
- Disassembly and assembly of front brake caliper pad assembly
- Removal and installation of parking brake spring cylinder assembly
- Removal and installation of slack adjuster assembly
- Disassembly and assembly of slack adjuster assembly
- Removal and installation of front wheel assembly
- Removal and installation of rear wheel assembly
- Removal and installation of front suspension cylinder assembly
- Disassembly and assembly of front suspension cylinder assembly
- Disassembly and assembly of variable damping selector valve Disassembly
- Removal and installation of rear suspension cylinder assembly
- Disassembly and assembly of rear suspension cylinder assembly
- Disassembly and assembly of hoist cylinder assembly
- Removal and installation of body assembly
- Disassembly and assembly of operator's seat assembly
- Removal and installation of air conditioner unit assembly
Inside this manual
Real pages from this service manual (1,406 pages). Open the sample pages (PDF, 757 KB)
- Specifications, page 332: 10 Structure, function and maintenance standard
- Troubleshooting, page 689: Failure code [2G42ZG] (Front accumulator: Lowering of oil pressure)
- Diagram, page 1,088: Circuit diagram related
- Foldout diagram, page 1,392: Electrical circuit diagram for inside cab (2/5)
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the HD325-7, HD405-7 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
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This is a service manual
Here's how it compares to the other manual types.
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 1,406 pages
Quantity one is the manual described above.
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