Manual de Oficina Sebm015114 - HD325 - 405-5 - 0502

SEBM015114
MACHINE MODEL SERIAL NUMBER

HD325-6 (2WD) 5680 and up
HD325-6W (4WD) 5706 and up
HD405-6 1055 and up
• This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may re-
quire.
Materials and specifications are subject to change without notice.
• HD325-6, HD405-6 mounts the SAA6D140E-2 or SAA6D140E-3 engine.

For details of the engine, see the 6D140-2 or 140-3 Series Engine Shop Manual.
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Printed in Japan 10-03(02) (14)
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30-26-1 (9) 30-53 (2) 30-102 (2) 30-153 (2) b 30-174 (14)
30-27 (9) 30-54 (3) 30-103 (2) 30-154 (2) b 30-175 (14)
30-27-1 (9) 30-55 (3) 30-104 (2) 30-155 (2) c 30-175-1 (14)
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30-34-1 (9) 30-66 (2) 30-118 (2) 30-155-14 (3) 30-189 (2)
30-34-2 (9) 30-67 (2) 30-119 (2) 30-155-15 (3) 30-190 (2)
30-34-3 (9) 30-68 (2) 30-120 (2) 30-155-16 (3) 30-191 (2)
30-35 (2) 30-69 (2) 30-121 (2) 30-155-17 (3) 30-192 (3)
30-36 (2) 30-70 (3) 30-122 (2) 30-155-18 (3) 30-193 (2)
30-37 (2) 30-71 (3) 30-123 (2) 30-155-19 (3) 30-194 (2)
30-37-1 (9) 30-72 (2) 30-124 (2) 30-155-20 (3) 30-195 (2)
30-37-2 (9) 30-72-1 (3) 30-125 (2) 30-155-21 (3) 30-196 (2)
30-37-3 (9) 30-72-2 (3) 30-126 (2) 30-155-22 (3) 30-197 (2)
30-38 (9) 30-73 (2) 30-127 (2) 30-155-23 (3) 30-198 (2)
30-39 (2) 30-74 (2) 30-128 (2) 30-155-24 (3) 30-199 (2)
30-40 (2) 30-75 (2) 30-129 (2) 30-155-25 (3) 30-200 (2)
30-41 (9) 30-76 (2) 30-130 (2) 30-155-26 (3) 30-201 (2)
30-41-1 (9) 30-77 (2) 30-131 (2) 30-155-27 (3) 30-202 (2)
30-41-2 (9) 30-78 (2) 30-132 (2) 30-155-28 (3) 30-203 (2)
30-41-3 (9) 30-79 (2) 30-133 (2) 30-155-29 (3) 30-204 (2)
30-41-4 (9) 30-80 (2) 30-134 (2) 30-155-30 (3) 30-205 (2)
HD325-6 00-2-5
(14)
30-206 (2) 40-8 90-201 (7)

30-207 (3) 40-9 90-203 (7)
30-208 (3) 40-10 90-205 (7)
30-208-1 (3) 40-11 (3) 90-205-2 (13)
30-208-2 (3) 40-12 (3) 90-207 (10)
30-209 (2) 40-13 (3) 90-209 (10)
30-209-1 (3) 40-14 (3) 90-211 (10)
30-209-2 (3) 40-14-1 (3) 90-213 (10)
30-210 (2) 40-14-2 (3)
30-210-1 (3) 40-15 (3)
30-210-2 (3) 40-15-1 (3)
30-210-3 (3) 40-16
30-210-4 (3) 40-17
30-210-5 (3) 40-18
30-211 (2) 40-19
30-212 (2) 40-20
30-213 (2) 40-21
30-214 (2) 40-22 (3)
30-215 (2) 40-23
30-216 (2) 40-24
30-217 (2) 40-25
30-218 (2) 40-26
30-219 (2) 40-27
30-220 (2) 40-28
30-221 (2) 40-29
30-222 (2) 40-30
30-223 (2) 40-31
30-224 (2)
30-225 (2) 90-1 (13)
30-226 (2) 90-1-2 (10)
30-227 (2) 90-1-4 (10)
30-228 (2) 90-1-6 (10)
30-229 (2) 90-1-8 (10)
30-230 (2) 90-1-10 (10)
30-231 (2) 90-3 (7)
30-232 (2) 90-5 (7)
30-233 (2) 90-7 (7)
30-234 (2) 90-7-2 (7)
30-235 (2) 90-7-4 (7)
30-236 (2) 90-7-6 (7)
30-237 (2) 90-7-8 (7)
30-238 (2) 90-9 (7)
30-239 (2) 90-11 (7)
30-240 (2) 90-11-2 (7)
30-241 (2) 90-11-4 (7)
30-242 (3) 90-13
90-15 (7)
40-1 (3) 90-15-2 (7)
40-2 90-17 (7)
40-3 90-19 (7)
40-4 (12) 90-19-2 (7)
40-5 90-21 (7)
40-6 (3) 90-23 (7)
40-7 90-23-2 (7)
00-2-6 HD325-6
(14)
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is 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 ¤ is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.
TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
W h en a m an u a l is r e vis ed , a n e d itio n ma rk
VOLUMES
Shop manuals are issued as a guide to carrying out 123
( ....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Revised pages are shown in the LIST OF REVISED
}
Electrical volume: Each issued as one
PAGES next to the CONTENTS page.
Attachments volume: · volume to cover all
models
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
¤ Safety
Special safety precautions
are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order.
2. Following examples show how to read the page s Caution
tions or other precautions
for preserving standards
are necessary when per-
4
number.
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3 tems. Caution necessary
Weight when selecting hoisting
3
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
Places that require special
2
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
Places to be coated with
5
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
6
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
item. Places where oil or water
Drain m u s t b e d r a i n e d , a nd
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
¤ Heavy parts (25 kg or more) must be lifted

Slinging near the edge of the hook may cause
the rope to slip off the hook during hoisting, and
4
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.
¤
but sling with two or more ropes symmetrically
wound onto the load.
WIRE ROPES
Slinging with one rope may cause turning
1) Use adequate ropes depending on the
of the load during hoisting, untwisting of
weight of parts to be hoisted, referring to
the rope, or slipping of the rope from its
the table below:
original winding position on the load, which
can result in a dangerous accident.
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
When hoisting a load with two or more ropes,
Rope diameter Allowable load the force subjected to each rope will increase
mm kN tons
with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6 vertically, at various hanging angles.
14 21.6 2.2 When two ropes sling a load vertically, up to
16 27.5 2.8 19.6 kN {2000 kg} of total weight can be sus-
18 35.3 3.6
pended. This weight becomes 9.8 kN {1000 kg}
20 43.1 4.4
22.4 54.9 5.6
when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.
★ The allowable load value is estimated to be one-

sixth or one-seventh of the breaking strength of
the rope used.
2) Sling wire ropes from the middle portion of the

hook.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
¤ Before carrying out the following work, release

the residual pressure from the hydraulic tank.
Type 1
For details, see TESTING AND ADJUSTING,

Releasing residual pressure from hydraulic
¤
tank.
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.
Disconnection
1) Release the residual pressure from the hydrau-
lic tan k. Fo r d e tails , se e TES TIN G AN D
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
★ The adapter can be pushed in about 3.5
mm.
★ Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
★ Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
★ 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. (See Fig. 5)
★ When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
• Used to prevent rubber gaskets,

LT-1A 790-129-9030 150 g Tube rubber cushions, and cock plug
from coming out.
• Used in places requiring an imme-

diately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyeth-
LT-1B 790-129-9050
(2 pcs.) container ylene, polyprophylene, tetrafluor-
oet hl ene and vi nyl chl oride),
rubber, metal and non-metal.
• Features: Resistance to heat and

LT-2 09940-00030 50 g Polyethylene chemicals
container • Used for anti-loosening and seal-
ant purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for

790-129-9060 metal, glass and plastic.
(Set of 1 kg
Hardenin
LT-3 adhesive and Can
hardening g
agent:
agent)
500 g
Adhesives
Polyethylene • Used as sealant for machined

LT-4 790-129-9040 250 g holes.
container
Holtz • Used as heat-resisting sealant for

MH 705 790-126-9120 75 g Tube repairing engine.
• Quick hardening type adhesive

Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of met-
als, rubbers, plastics and woods.
• Quick hardening type adhesive

• Quick cure type (max. strength af-
Aron-alpha Polyethylene
201 790-129-9130 2g container ter 30 minutes)
• Used mainly for adhesion of rub-
bers, plastics and metals.
Loctite Polyethylene • Resistance to heat, chemicals

79A-129-9110 50 cc • Used at joint portions subject to
648-50 container
high temperatures.
• Used as adhesive or sealant for

LG-1 790-129-9010 200 g Tube gaskets and packing of power
train case, etc.
• Used as sealant for various

threads, pipe joints, flanges.
LG-5 790-129-9070 1 kg Can • Used as sealant for tapered
Gasket plugs, elbows, nipples of hydrau-
sealant lic piping.
• Features: Silicon based, resist-

ance to heat, cold
• Used as sealant for flange sur-
LG-6 790-129-9020 200 g Tube
face, tread.
• mab Used as sealant for oil pan,
final drive case, etc.
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
• Ftures: Silicon based, quick hard-

ening type
LG-7 790-129-9070 1g Tube • Used as sealant for flywheel
housing, intake manifold, oil an,
Adhesives thermostat housing, etc.
Three bond • Used as heat-resisting sealant for

790-129-9090 100 g Tube repairing engine.
1211
• Used as lubricant for sliding por-

LM-G 09940-00051 60 g Can
tion (to prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuf-
lubricant fling of the thread when press fit-
LM-P 09940-00040 200 g Tube ting or shrink fitting.
• Used as lubricant for linkage,
bearings, etc.
SYG2-400LI • General purpose type

SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature,

Grease SYG2-350CA light load bearing at places in con-
G2-CA SYG2-400CA-A Various Various tact with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum 400 g • Used for places with heavy load

disulphide SYG2-400M (10 per Belows type
lubricant case)
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Thread diameter Width across

of bolt flats
mm mm Nm kgm
6 10 13.2 0 1.4 1.35 0 0.15

8 13 31 03 3.2 0 0.3
10 17 66 07 6.7 0 0.7
12 19 113 0 10 11.501
14 22 177 0 19 1802
16 24 279 0 30 28.5 0 3
18 27 382 0 39 39 0 4
20 30 549 0 59 56 0 6
22 32 745 0 83 76 0 8.5
24 36 927 0 103 94.5 0 10.5
27 41 1320 0 140 135 0 15

30 46 1720 0 190 175 0 20
33 50 2210 0 240 225 0 25
36 55 2750 0 290 280 0 30
39 60 3290 0 340 335 0 35
Thread diameter Width across

of bolt flats
mm mm Nm kgm
6 10 0
7.85 1.95 0.8 0 0.2
8 13 0
18.6 4.9 1.9 0 0.5
10 14 0
40.2 5.9 4.1 0 0.6
12 27 0
82.35 7.85 8.4 0 0.8
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

★ In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
SAD00483
the table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 0
24.5 4.9 0
2.5 0.5
18 24 0
49 19.6 5 2 0
22 27 0
78.5 19.6 8 2 0
24 32 0
137.3 29.4 14 3 0
30 36 0
176.5 29.4 18 3 0
33 41 0
196.1 49 20 5 0
36 46 0
245.2 49 25 5 0
42 55 0
294.2 49 30 5 0
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
mm mm Nm kgm
10 14 0
65.7 6.8 0
6.7 0.7
12 17 112 9.80 11.5 1 0
16 22 279 290 28.5 3 0
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Norminal No.
mm mm Nm kgm
02 14 0
34.3 4.9 3.5 0 0.5
03, 04 20 Varies depending 0
93.1 9.8 9.5 01
05, 06 24 on type of 0
142.1 19.6 14.5 02
10, 12 33 connector. 0
421.4 58.8 43 06
14 42 0
877.1 132.3 89.5 0 13.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Norminal No.
mm mm Nm kgm
08 08 14 0
7.35 1.47 0.75 0.15 0
10 10 17 0
11.27 1.47 1.15 0.15 0
12 12 19 0
17.64 1.96 1.8 0.2 0
14 14 22 0
22.54 1.96 2.3 0.2 0
16 16 24 0
29.4 4.9 3 0.5 0
18 18 27 0
39.2 4.9 4 0.5 0
20 20 30 0
49 4.9 5 0.5 0
24 24 32 0
68.6 9.8 7 1 0
30 30 32 0
107.8 14.7 11 1.5 0
33 33 n 0
127.4 19.6 13 2 0
36 36 36 0
151.9 24.5 15.5 2.5 0
42 42 n 0
210.7 29.4 21.5 3 0
52 52 n 0
323.4 44.1 33 4.5 0
00-13
TIGHTENING TORQUE FOR 102 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 0
10 2 1.02 0 0.20
8 0
24 4 2.45 0 0.41
10 0
43 6 4.38 0 0.61
12 0
77 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 8 20 0.81 0 0.20
8 0
10 2 1.02 0 0.20
10 0
12 2 1.22 0 0.20
12 0
24 4 2.45 0 0.41
14 0
36 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 3 10 0.31 0 0.10
1/8 8 20 0.81 0 0.20
1/4 0
12 2 1.22 0 0.20
3/8 0
15 2 1.53 0 0.41
1/2 0
24 4 2.45 0 0.41
3/4 0
36 5 3.67 0 0.51
1 0
60 9 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) type Face seal type
Nominal size Width across
of hose flats Nominal thread
Range Target Thread size size - Threads per Root diameter
(mm) (mm) (Reference)
inch, Thread series
9
02 19 35 - 63 {3.5 - 6.5} 44 {4.5} 14 – - 18UNF 14.3
16
11
22 54 - 93 {5.5 - 9.5} 74 {4.5} – – - 16UN 17.5
03 16
24 59 - 98 {6.0 - 10.0} 78 {8.0} 18 – –
13
04 27 84 - 132 {8.5 - 13.5} 103 {10.5} 22 – - 16UN 20.7
16
05 32 128 - 186 {13.0 - 19.0} 157 {16.0} 24 1 - 14UNS 25.4
3
06 36 177 - 245 {18.0 - 25.0} 216 {22.0} 30 1 – - 12UNF 30.3
16
(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 – –
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm 2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori-
ty Classi- Charging Ground Starting Lighting Instrument Signal Other
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR n BW RW YR GW LW
2
Color White & Red n White & Black Red & White Rellow & Red Green & White Blue & White
Code WB n BY RB YB GR LR
3
Color White & Black n Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL n BR RY YG GY LY
4 Auxi-
liary
Color White & Blue n Black & Red Red & Yellow
Yellow &
Green
Green &
Yellow
Blue & Yellow
Code WG n n RG YL GB LB
5
Color White & Green n n Red & Green Yellow & Blue Green & Black Blue & Black
Code n n n RL YW GL n
6
Color n n n Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
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.
A
(1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line
A
from .
B
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down
B
from .
C
(3) Take the point where the two lines cross as . This point C gives the value when converting from mil-
limeters 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 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.
B
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
C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
A 50
60
1.969
2.362
2.008
2.402
2.047
2.441
2.087
2.480
2.126
2.520
2.165
2.559
2.205
2.598
2.244
2.638
2.283
2.677
2.323
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
00-16
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
00-17
Liter to U.S. Gallon

1l = 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
Liter to U.K. Gallon

1l = 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 7.969 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
00-18
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
00-19
kg/cm2 to lb/in2
1kg/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 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade 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 81 117.8

– 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 0 140.0 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
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22
01 GENERAL
General assembly drawing ........................... .Ol-2

Specifications ................................................. 01-3
Weight table .................................................... 01-6
List of lubricant and water ............................. 01-7
HD325-6 01-l
GENERAL GENERAL ASSEMBLY DRAWING
GENERAL ASSEMBLY DRAWING

HD325-6 : Serial No. 5680 – 6000
HD325-6W : Serial No. 5706 – 6000
¡ : The figures in [ ] are for the HD325-6W.
HD405-6 : Serial No. 1055 – 2000
01-2 HD325-6
7
GENERAL GENERAL ASSEMBLY DRAWING
HD325-6 : Serial No. 6001 and up

HD325-6W : Serial No. 6001 and up
¡ : The figures in [ ] are for the HD325-6W.
HD325-6 01-2-1
7
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model HD325-6 HD325-6W HD405-6
Serial No. 5680 – 6000 5706 – 6000 1055 – 2000
Empty kg 28,700 30,740 32,050

Max. load kg k 36,500 36,800 40,000
Gross weight kg 60,775 67,615 72,125
Weight
Empty (front) kg 13,780 (48%) 15,790 (49.6%) 14,290 (45%)

distribution
Weight
(rear) kg 14,920 (52%) 16,060 (50.4%) 17,760 (55%)

Gross (front) kg 19,450 (32%) 21,210 (33.2%) 22,850 (32%)
(rear) kg 41,325 (68%) 42,715 (66.8%) 49,275 (68%)
Struck m3 18 18 20
Dump body capacity
3
Heaped (2 :1) m 24 24 27.3
Performance
Max. travel speed km/h 70 68 70

Gradeability % 35 40 35
Min. turning radius m 7.2 7.2 7.2
Dumping angle (angle to ground) deg 48 48 48
Overall length mm 8,365 8,365 8,365

Overall width mm 3,660 3,690 6,660
Overall height mm 4,000 4,000 4,000
Dimensions
Wheel base mm 3,750 3,750 2,550
Front wheel mm 3,150 3,190 3,150

Tread
Rear wheel mm 2,550 2,550 2,550
Ground clearance mm 500
Model KOMATSU SAA6D140E-2

Type 4-cycle, water-cooled, in-line 6-cylinder,
direct injection, with turbocharger and
air-cooler after-cooler
No. of cylinders – Bore × stroke mm 6 – 140 × 165
Piston displacement l {cc} 15,230 {15,230}
Engine
Flywheel horsepower (Net) kW/rpm {HP/rpm} 364/2,000 {488/2,000}

Max. torque Nm/rpm {kgm/rpm} 2,167/1,400 {221/1,400}
Fuel consumption (Min.) g/kW h {g/HPh} 211 {157}
Stating motor 11 kW
Alternator 24V, 50A
Battery 12V,170Ah × 2
k : For machines equipped with tire size, 18.00-33-32PR or 18.00 R33.
HD325-6 01-3
7
GENERAL LIST OF LUBRICANT AND WATER
LIST OF LUBRICANT AND WATER

HD325-6 : Serial No. 5680 – 6000
HD325-6W : Serial No. 5706 – 6000
HD405-6 : Serial No. 1055 – 2000
AMBIENT TEMPERATURE CAPACITY
RESERVOIR KIND OF
FLUID –22 –4 14 32 50 68 86 104°F
Specified (l) Refill (l)
–30 –20 –10 0 10 20 30 40°C
SAE 30
SAE 10W
Engine oil pan 41 37
SAE 15W-40
SAE 10W-30
Transmission case SAE 30

(including front 195 90
drive case) SAE 10W
Engine oil
Front brake oil tank 2 —
Hydraulic tank 165 129

SAE 10W
Front suspension 13.8 (each) —
Rear suspension 9.2 (each) —
(Front drive oil tank)
Differeneial case 50 45
SAE 30
Final drive case 17 (each) 13 (each)
ASTM D975 No. 2

Fuel tank Diesel fuel 500 —
k
Cooling system Water Add antifreeze 106 110
k ASTM D975 No. 1
Fuel and oil ¡ The specified capacity means the total amount
Select fuel and oil according to the above table. of oil including oil for components and oil in
piping. The refill capacity means the amount
Cooling water of oil needed to refill the system during nor-
Since Komatsu genuine Supercoolant (AF-ACL) is mal inspection and maintenance.
added to the cooling water, the latter does not
need to be replaced while the atmospheric tem- ¡ When starting the engine in an atmospheric
perature is above – 10°C. If the atmospheric tem- temperature of lower than 0°C, be sure to use
perature drops below – 10°C, adjust the concen- engine oil of SAE10W, SAE 10W-30 or
tration of AF-ACL according to the operation and SAE15W-40, even through the atmospheric
maintenance manual. temperature goes up to 10°C or above during
the day.
HD325-6 01-7
7
GENERAL LIST OF LUBRICANT AND WATER

AMBIENT TEMPERATURE CAPACITY
RESERVOIR KIND OF
FLUID –22 –4 14 32 50 68 86 104°F
Specified (l) Refill (l)
–30 –20 –10 0 10 20 30 40°C
SAE 30
SAE 10W
Engine oil pan 56 52
SAE 15W-40
SAE 10W-30
Transmission case SAE 30

(including front 195 90
drive case) SAE 10W
Engine oil
Front brake oil tank 2 —

Hydraulic tank 165 129
SAE 10W
Front suspension 13.8 (each) —
Rear suspension 8.1 (each) —
(Front drive oil tank)
Differeneial case 50 45
SAE 30
Final drive case 17 (each) 13 (each)
ASTM D975 No. 2

Fuel tank Diesel fuel 500 —
k k
Cooling system Water Add antifreeze 89 89
k ASTM D975 No. 1
Fuel and oil maintenance manual.

Select fuel and oil according to the above table. ¡ The specified capacity means the total amount
k Never use kerosene as fuel. of oil including oil for components and oil in
piping. The refill capacity means the amount
Cooling water of oil needed to refill the system during nor-
Since Komatsu genuine Supercoolant (AF-ACL) is mal inspection and maintenance.
added to the cooling water, the latter does not
need to be replaced while the atmospheric tem- ¡ When starting the engine in an atmospheric
perature is above – 10°C. If the atmospheric tem- temperature of lower than 0°C, be sure to use
perature drops below – 10°C, adjust the concen- engine oil of SAE10W, SAE 10W-30 or
tration of AF-ACL according to the operation and SAE15W-40, even through the atmospheric
temperature goes up to 10°C or above during
the day.
01-7-1 HD325-6
7
10 STRUCTURE AND FUNCTION
Radiator, torque converter, oil cooler, Hand brake valve ........................................ IO- 63
after cooler.. ................................................ IO- 3 Brake valve.. ................................................ IO- 65
Power train skeleton.. ................................... IO- 4 Emergency brake control valve ................. IO- 68
Output shaft .................................................. IO- 7 Parking brake control valve ...................... IO- 71
Drive shaft ..................................................... IO- 8 Relay valve .................................................. IO- 73
Torque converter, transmission and brake Parking brake relay valve .......................... IO- 76
cooling hydraulic piping ............................ IO- 9 Front brake chamber .................................. IO- 78
Hydraulic circuit diagram for torque Rear brake chamber ................................... IO- 79
converter, transmission and brake Parking brake chamber .............................. IO- 82
cooling.. ....................................................... IO-I 0 Slack adjuster.. ............................................ IO- 83
Torque converter, transmission and brake Front drive hydraulic circuit diagram ...... 10-84-2
cooling hydraulic circuit schematics.. ....... IO-I 1 Front drive piston pump .......................... 10-84-5
Torque converter .......................................... IO-I 2 Front drive piston motor .......................... 10-84-7
Torque converter valve ................................ IO-14 Charge pump oil Filter .............................. 10-84-g
Lockup solenoid valve.. ................................ IO-19 Hydraulic piping ......................................... IO- 85
Transmission ................................................. IO-21 Hydraulic circuit diagram.. ......................... IO- 86
Transmission valve ....................................... IO-25 Hydraulic circuit schematics.. .................... IO- 87
ECMV Dump body control .................................... IO- 88
(Electronic Control Modulation Valve). .... IO-26 Hydraulic tank, filter ................................... IO- 89
Front axle ...................................................... IO-31 Demand valve ............................................. IO- 90
Rear axle ....................................................... IO-32 Steering control valve ................................ IO- 94
Differential.. ................................................... IO-33 Cross-over relief valve ............................... IO- 98
Final drive ..................................................... IO-35 Hoist valve .................................................. IO- 99
Front brake .................................................... IO-36 Diagram for electrical circuit
Rear brake ..................................................... IO-37 inside cab .................................................. IO-100
Parking brake ................................................ IO-38 Diagram for electrical circuit
Wheels.. ......................................................... IO-39 outside cab.. .............................................. IO-101
Rear axle support ......................................... IO-40 Front brake cut-off valve ............................ IO-I 02
Steering system ............................................ 1O-41 Overrun prevention valve .......................... IO-I 03
Steering wheel .............................................. IO-42 Exhaust brake valve ................................... IO-103
Steering linkage.. .......................................... IO-43 Horn valve ................................................... IO-I 04
Suspension system ...................................... IO-45 Wiper switch ............................................... IO-104
Suspension cylinder.. ................................... IO-47 Wiper relay.. ................................................ IO-105
Air piping ...................................................... IO-52 Air conditioner ............................................ IO-106
Air circuit diagram ........................................ IO-54 Piping diagram ......................................... IO-106
Air governor.. ................................................ IO-56 Electrical circuit diagram ......................... IO-108
Air dryer ........................................................ IO-58 Refrigerant circuit diagram ...................... 10-l 10
Safety valve.. ................................................. 1 O-61 Unit ............................................................ IO-I 11
Check valve ................................................... IO-61 Receiver dryer.. ......................................... IO-I 11
Double check valve ....................................... IO-62 Condenser.. ............................................... IO-I 12
HD325-6 10-l
0
Receiver dryer .......................................... 10-111 4. Lamp drive relay ................................ 10-156
Condenser ................................................. 10-112 Self-diagnostic function ........................... 10-157
Compressor .............................................. 10-112 Payload meter II (Card type) ..................... 10-158
Engine control system ............................... 10-113 Structure of system .................................. 10-158
Exhaust brake ............................................. 10-114 Electrical circuit diagram ......................... 10-159
System diagram ....................................... 10-114 Payload meter block diagram ................. 10-159
Automatic retard speed control Principle of measurement ....................... 10-160
system (OP) .............................................. 10-117 Features of each device ......................... 10-161
System diagram ....................................... 10-117 1. Payload meter II ................................ 10-161
Structure of system .................................. 10-118 Left face .............................................. 10-162
Electrical circuit diagram ......................... 10-119 2. Pressure sensor ................................. 10-189
Air circuit diagram ................................... 10-120 3. Clinometer .......................................... 10-190
Automatic retard speed control .............. 10-121 4. Lamp drive relay ................................ 10-190
Automatic retard speed controller .......... 10-122 5. Self diagnostic function .................... 10-192
Automatic shift control system ................. 10-123 Machine monitor system ........................... 10-198
System diagram ....................................... 10-123 System drawing ....................................... 10-198
Electrical circuit diagram ......................... 10-125 Monitor panel diagram ............................ 10-200
Transmission controller ........................... 10-126 Machine monitor normal display
Connector signals .................................... 10-128 functions ................................................. 10-201
Shift lever positions and automatic Self-diagnostic function when starting
gear shifting ranges ............................... 10-129 switch is operated .................................. 10-208
Automatic gear shift line graph .............. 10-130 Travel speed compensation
Shift lever switch ...................................... 10-132 Rotary switch .......................................... 10-208
Sensors, switches .................................... 10-133 Engine oil pressure ............................... 10-209
Engine speed sensor ............................. 10-133 Engine water temperature sensor ........ 10-210
Transmission speed sensor ................... 10-133 Retarder oil temperature sensor ........... 10-210
Transmission oil temperature sensor ... 10-133 Torque converter oil temperature
Fill switch ................................................ 10-134 sensor .................................................... 10-210
Accelerator sensor ................................. 10-134 Air pressure sensor ................................ 10-210
Mode selector switch ............................. 10-135 Fuel level sensor ................................... 10-211
Self-diagnostic function ........................ 10-135 Tilt switch ................................................ 10-212
Automatic emergency steering system .... 10-136 Transmission oil filter sensor ................ 10-213
System diagram ....................................... 10-136 Radiator water level sensor .................. 10-213
Electrical circuit diagram ......................... 10-137 Body seated switch ................................ 10-214
Flow switch ............................................... 10-138 Steering oil temperature sensor ........... 10-215
Relay timer ................................................ 10-140 Brake stroke sensor ............................... 10-215
Automatic suspension system .................. 10-141 Oil filter caution system (if equipped) ........ 10-216
Structure of system .................................. 10-142 Front drive system ..................................... 10-217
System circuit diagram ............................ 10-143 System diagram ....................................... 10-217
Automatic suspension mode selection 4-wheel drive controller ............................. 10-218
control ..................................................... 10-144 ECMV ........................................................... 10-219
Suspension controller .............................. 10-145 Sensors, switches ....................................... 10-220
Sensors, switches .................................... 10-146 Steering angle sensor
Steering angle sensor ............................ 10-146 (Potentiometer) ................................... 10-220-1
Pressure sensor ...................................... 10-146 High-pressure oil pressure sensor .......... 10-221
Self-diagnostic function ........................ 10-147 Clutch oil pressure sensor ....................... 10-222
Payload meter (Printer type) .................... 10-148 Wheel speed sensor ................................. 10-223
Structure of system ............................... 10-148
Electrical circuit diagram ......................... 10-149
Principle of calculation ............................ 10-150
Features of equipment ............................. 10-152
1. Payload meter .................................... 10-152
2. Pressure sensor .................................. 10-155
3. Clinometer .......................................... 10-156
10-2 HD325-6
C
STRUCTURE AND FUNCTION RADIATOR, TORQUE CONVERTER, OIL COOLER, AFTER COOLER
RADIATOR, TORQUE CONVERTER, OIL COOLER, AFTER
SOH00316
Reservoir
tank
1.
2.
Upper tank
Water filter Drain
I
3. Core
CoolinQ svstm SOH00396
4. Net
5. Lower tank
(torque converter brake oil cooler)
6. Drain valve
7. After cooler
HD325-6 SPECIFICATIONS
HD325-6W Radiator
! HD405-6 Core type: CD-5
8. Shroud Total heat dissipation area 82.84m2
Oil cooler
A: From thermostat
Element type: Shell, tube
B: To water pump
Heat dissipation area: 7.87m2
C: From rear brake
D: To oil filter After cooler
E: From water pump Total heat dissipation area: 32.68m2
HD325-6 1o-3
0
STRUCTURE AND FUNCTION POWER TRAIN SKELETON
POWER TRAIN SKELETON

HD325-6
H D405-6
’ 0
L0
0
566FO6004
1o-4 HD3256
0
1. Engine
2. Output shaft
3. Front drive shaft
4. Brake cooling pump (SAR(3)-063+063)
5. Torque converter transmission charge pump
and brake cooling pump (SAR(3)-80)
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
15. Parking brake
16. Steering, hoist pump (SAR(3)-063+050)
HD325-6 1o-5
0
HD325-6W
0
0
6.
I kc
rL_____
17
16’ L
13 12 11 10
666FO6221
1O-6 HD325-6
0
1. Engine (SAGD140) OUTLINE

2. Output shaft . The power generated by engine (I) passes
3. Front drive shaft through torque converter (7) and transmission
4. Brake cooling pump (8), and drives the rear wheels. Part of the
(SAR(3)-063+063) power drives front drive pump (17) installed
5. Torque converter to torque converter (7).
transmission charge . The front drive unit consists of front drive
pump and brake cooling pump (variable displacement swash-plate-
pump (SAR(3)-80) type axial piston pump) (17) and front drive
6. PTO motor (variable displacement swash- plate-
7. Torque converter type piston motor) (22).
8. Transmission . The power from the engine is converted to
9. Rear drive shaft fluid energy by front drive pump (17) and is
10. Differential gear restored to mechanical energy by front drive
11. Drive shaft motor (22).
12. Rear brake . The capacity of front drive pump (17) and left
13. Rear tire and right motors (22) is controlled to the opti-
14. Final drive (Rear) mum for the condition of the machine by the
15. Parking brake 4WD controller.
16. Steering, hoist pump . The desired drive force is transmitted to clutch
(SAR(3)-063+050) (19) through the gear connected to the out-
17. Front drive pump put shaft of the motor by the combination of
18. Front tire the front drive pump and motor.
19. Clutch Clutch (19) is engaged when 4-wheel drive is
20. Final drive (Front) selected, and disengaged when rear-wheel
21. Front brake drive is selected.
22. Front drive motor Clutch (19) is engaged to final drive (20), and
the power transmitted to the clutch has its
speed reduced by the 2- stage planetary gear
mechanism and drives the front wheels.
. The front wheels are driven when the speed
range of transmission (8) is Fl, F2, F3, or R,
and pressure is generated in the hydraulic cir-
cuit at the same time that the clutch is en-
gaged.
. The drive system is switched between 4-wheel
drive and rear-wheel drive by the signal from
the selector switch inside the cab input to the
4WD controller.
HD325-6 1O-6 1
0
STRUCTURE AND FUNCTION OUTPUT SHFT
OUTPUT SHFT
A-A '9
566FO6005
FUNCTION 1. Rubber cushion 6. Shaft

The output shaft is installed to the engine flywheel, 2. Outer body 7. Coupling
and absorbs the twisting vibration caused by 3. Flange 8. Inner body
changes in the engine torque. 4. Breather 9. Cover
5. Bearing
HD325-6 1o-7
STRUCTURE AND FUNCTION DRIVE SHAFT
DRIVE SHAFT
I /
1. Output shaft
2. Front drive shaft
3. Torque converter
4. Transmission
5. Rear drive shaft
6. Differential
1O-8 HD325-6
TORQUE CONVERTER, TRANSMISSION AND
STRUCTURE AND FUNCTION BRAKE COOLING HYDRAULIC PIPING
TORQUE CONVERTER, TRANSMISSION AND BRAKE COOLING

HYDRAULIC PIPING
HD325-6 : Serial No. 5680 – 6000
HD325-6W : Serial No. 5706 – 6000
HD405-6 : Serial No. 1055 – 2000
1. Hydraulic piping (SAR(3)-063+063)

2. Torque converter
3. Transmission valve
4. Hydraulic tank (transmission filter)
5. Transmission
6. Hydraulic pump (SAR(3)-80)
7. Oil cooler (radiator lower tank in built)
HD325-6 10-9
7
STRUCTURE AND FUNCTION TORQUE CONVERTER
HD325-6W
566FO6222
1. PTO gear SPECIFICATIONS

2. Torque converter valve . Model: TCA48- 1 OA
l Type: 3 element, I stage, 2 phase
a: Torque converter oil outlet port With lockup clutch
b: To transmission lubrication . Lockup clutch: Oil-cooled single disc clutch
c: To transmission control valve Hydraulic control
(with modulation valve)
HD325-6 10-12-l
0
STRUCTURE AND FUNCTION TORQUE CONVERTER VALVE
TORQUE CONVERTER VALVE
566FO6012
1. Piston 8. Spool A: From hydraulic pump

2. Torque converter valve (torque converter relief valve) a: Plug for measuring hydraulic
3. Spool (lockup valve) 9. Piston pressure of load piston
4. Spool (main relief valve) 10. Spring b: Plug for measuring lockup
5. Piston 11. Piston pressure
6. Spring 12. Spring c: Plug for measuring main
7. Body 13. Spring pressure
d: Plug for measuring torque
converter inlet pressure
10-14 HD3256
MAIN RELIEF VALVE

FUNCTION To lock-up valve
. This valve acts to ensure the main hydraulic
pressure of the transmission valve, the main
hydraulic pressure of the lockup valve, and
the pilot pressure
OPERATION
. The oil from the hydraulic pump enters port
A, then passes through orifice a and goes to
port c.
When the hydraulic pressure in the circuit
rises, the pressure at port C also rises and
pushes main relief spool (I) to the left in the
direction of the arrow. The oil at port A passes
through port B and flows to the torque con- relief valve
verter circuit.
SWH00754
l Actuating pressure:
3.58 f 0.15 MPa (36.5 f 1.5kg/cm2}
(engine at 2,100 rpm)
TORQUE CONVERTER RELIEF VALVE

FUNCTION From main relief
This valve acts to protect the torque converter cir-
cuit from abnormally high pressure.
OPERATION
The oil from the main relief valve enters port D
and then passes through orifice b and goes to port
F. When the pressure in the circuit rises, the pres-
sure at port F also rises, and moves torque con-
verter relief spool (2) to the right in the direction
of the arrow. The oil port D flows to port E and
goes to the transmission lubrication circuit.
. Actuating pressure : / pi F\_
0.90 f 0.10 MPa (9.2 f 1 kg/cm*) F
2
(engine at 2,100 rpm) @8 E
To torque To toransmission
converter lubrication
SWH00755
HD325-6 10-15
Driving in direct range Lockup

clutch Torque
(torque converter range -+ direct range) \ converter _
1) When the machine travels in the direct range
(lockup), solenoid valve (5) is switched ON by
the electrical signal, and valve (5a) is pushed
to the left in the direction of the arrow, so port
B is closed, and port P and port C are opened.
As a result, the oil port D flows from port P of
solenoid valve (51, passes through port C and
is drained. Lockup valve (6) and piston (8)
are pushed to the right by spring (41, and port
A and port E are opened.
0
To To From To
drain drain Pump drain
SWH00756
2) When port A and port E are opened, the oil Lockup

clutch Toraue
from the pump is sent to the lockup clutch. In
addition, the oil at port E flows to port F and
applies back pressure to load piston (2).
8 aEAf3 t
To To From To
drain drain PUMP drain
SWH00759
3) As the hydraulic pressure of the lockup clutch LockuP

clutch Toraue
rises, the pressure of the passing through ori- \ converter _
fice a and entering port G also rises, and
pushes piston (7).
Because of the reaction force, lockup valve
(6) compresses spring (4) and pushes it to the
left in the direction of the arrow to throttle port
A and port E. .a
,7
To To From To
drain drain Pump drain
SWH00760
HD325-6 10-17
4) The oil from port E to port F applies pressure Lockup

clutch Toraue
to load piston (21, and pushes piston (2) to converter
k- II
the right in the direction of the arrow to com-
press spring (4).
Compressed spring (4) pushes lock up valve
(6) to the right in the direction of the arrow,
and opens port A and port E. When this hap-
pens, the increase in hydraulic pressure to
the lockup clutch starts again.
To To From To
drain drain PUMP drain
SWH00761
5) By repeating the actions in Steps 3) and 41,

clutch Torque
the load on spring (4) is increased, and the
hydraulic pressure gradually rises.
Finally, when load piston (2) contacts stopper
(31, the rise in hydraulic pressure stops. The
pressure at this point is the set pressure of
the lockup valve.
l Set pressure: 1.86 MPa I19 kg/cm*)
To To From To
drain drain Puma drain
SWH00762
lo-18 HD325-6
STRUCTURE AND FUNCTION LOCKUP SOLENOID VALVE
LOCKUP SOLENOID VALVE
4
11
$0 0 n II
\
\a
9
561FO3012
1. Cover A: From pump

2. Coil B: To piston
3. Spring C: To drain
4. Plunger
5. Valve seat holder
6. Valve seat
7. Spring
8. Valve seat
9. Cap
IO. Cable
11. Connector
HD3256
10-19
STRUCTURE AND FUNCTION TRANSMISSION
TRANSMISSION
HD325-6 : Serial No. 5680 – 6000
HD325-6W : Serial No. 5706 – 6000
HD405-6 : Serial No. 1055 – 2000
A: High clutch port

B: Low clutch port
C: 3rd clutch port
D: R clutch port
E: 1st clutch port
F: 2nd clutch port
G: 4th clutch port
H: From filter
(transmission lubrication)
I: From torque converter
(transmission lubrication)
HD325-6 10-21
7
10-22 HD325-6
1. Input shaft
2. Speedometer cable pickup port
3. Oil pan
4. Strainer
5. Transmission lubrication relief valve
28 29 30 31 32 33 34 6. Brake cooling of relief valve
7. No.1 sun gear (No. of teeth: 34)
8. No.1 clutch hub
9. No.1 clutch
IO. No.1 planetary pinion (No. of teeth: 32)
11. No.1 planetary carrier
12. No. 2 clutch hub
13. No. 2 clutch
14. No. 2 ring gear (No. of teeth 98)
15. No. 2 clutch housing
17. No. 4 sun gear (No. of teeth: 49)
18. No. 3 clutch
19. No. 3 clutch hub
20. No. 3 clutch drum
21. No. 4 planetary pinion (No. of teeth: 21)
22. No. 4 clutch
23. No. 4 ring gear (No. of teeth: 91)
25. No. 5 clutch
28. No. 6 clutch
32. No. 7 clutch
34. No. 6, 7 planetary carrier
35. Output shaft
37. No. 7 clutch piston
39. Intermediate shaft (No. 7 sun gear: 24 teeth)
43. No. 4, 5 planetary carrier
+ SWH00764 46. No. 1 clutch piston
HD325-6 1o-23
OUTLINE
. The transmission consists of an F7 RI plan- Planetary gear
Group Clutch pack
etary gear type transmission with a control
valve. No. 1 clutch (High)
Front
. The transmission and torque converter are group No. 2 clutch (Low) No. 1 planetary gear
connected at the transmission input shaft.
. Gear shifting is carried out automatically by No. 3 clutch (4th)
the automatic transmission according to No. 4 clutch (3rd) No. 4 planetary gear
changes in engine speed. Rear
No. 5 clutch (RI No. 5 planetary gear
group
GEAR SHIFTING FUNCTION No. 6 clutch (2nd) No. 6 planetary gear
1. The inside of the transmission consists of 7
clutch packs and 5 sets of planetary gears. No. 7 clutch (1st) No. 7 planetary gear
These are divided into the front group and rear
pump.
2. One clutch pack in the front group and one Speed Reduction
Clutches engaged ration
clutch pack in the rear group are actuated si- range
multaneously by oil pressure sent from the Fl No. 2- No. 7 (Low - 1st) 4.750
transmission valve to give the speed range F2 No. 2- No. 6 (Low - 2nd) 3.368
and reduction ratio. F3 No. I- No. 6 (High - 2nd) 2.501
F4 No. 2- No. 4 (Low - 3rd) 1.842
F5 No. 1- No. 4 (High - 3rd) 1.367
F6 No. 2- No. 3 (Low - 4th) 1.ooo
F7 No. 1- No. 3 (High -4th) 0.742
R No. 2- No. 5 (Low - RI 4.339
/
1o-24 HD325-6
STRUCTURE AND FUNCTION ECMV
STRUCTURE OF ECMV A I E_,_D
. The ECMV (Electronic Control Modulation

Valve) consists of two valves: a pressure con-
trol valve and a flow sensor valve.
. Pressure control valve
The pressure valve contains a proportional
solenoid which takes the current sent from the
transmission controller and the pressure con-
trol valve converts this current into hydraulic
pressure.
. Flow sensor valve
This valve is actuated by a trigger from the
pressure control valve, and has the following
functions.
1) The valve is opened until the clutch is filled
with oil, thereby reducing the time (filling
time) taken for oil to fill the clutch.
(See)
2) When the clutch becomes full of oil, the valve Time
closes, and seends a signal (full signal) to the

controller to inform that filling is completed.
3) While there is hydraulic pressure applied to
--o
the clutch, it outputs a signal (full signal) to OFF 1 ON
;;;0 bed
Time
the controller to inform whether there is hy-
draulic pressure or not. SVH00638
A range: Before gear shifting (drained)
B range: Filling starts (trigger issued)
C range: Filling completed
D range: Regulation
E range: Filling
ECMV AND PROPORTIONAL SOLENOID Characteristics of proportional solenoid

current and proaulsion force
. Each ECMV is equipped with one proportional
solenoid.
The propulsion force shown in the diagram
on the right is generated according to the
command current from the controller.
. The propulsion force generated by the pro-
portional solenoid acts on the pressure con-
trol valve spool and generates the hydraulic 0' (A)
pressure shown in the diagram on the right. - Current
In this way, by controlling the command cur-

Characteristics of proportional solenoid
rent, the propulsion force is changed and this Prorwlsion force and hydraulic Pressure
acts on the pressure control valve and con-
trol the oil flow and oil hydraulic pressure.
ECMV AND FILL SWITCH

. Each ECMV is equipped with one fill switch.
When the clutch is completely filled, the flow
sensor valve acts to switch the fill switch on.
As a result of this signal, the oil pressure starts Ntkd
to build up. - Propulsion force
SVH00639
HD3256 1O-27
ACTUATION OF ECMV
. The ECMV is controlled by the command cur-
rent from the transmission controller to the
proportional solenoid, and the output signal
of the fill switch. The relationship between
the ECMV proportional solenoid command
current and the clutch input pressure and the
output signal of the fill switch is as shown in :z
%P
the diagram on the right. ;z
0 * bed
MPa(ko/cm*l I t Time
A range: Before gear shifting (drained)
B range: Filling starts (trigger issued)
C range: Filling completed
D range: Regulation
E range: Filling
bed
Time
SVH00636
1. Before shifting gear (drained) (A range of

graph)
When no current is being sent to propor-
tional solenoid (6), the reaction force for
spring (9) of the pressure control valve pushes
pressure control valve spool (7). As a result,
proportional solenoid (6) is pushed back, so
pressure control valve spool (7) connects the
oil at clutch port C to drain port E and drains
the oil.
In this condition, there is no hydraulic force
acting on spool (3) of the flow sensor valve,
so the reaction force of spring (4) for the fill
switch moves flow sensor valve spool (3)
away from fill switch (5), and stops it in a po-
sition where it is in balanced with return
spring (2) of the flow sensor valve.
561FO3026
1 O-28 HD325-6
2. Starting to fill (trigger command input to

pressure control valve) (B range of graph)
1) When there is no oil inside the clutch and
the trigger current is sent (maximum cur-
rent is applied) to proportional solenoid
(61, the proportional solenoid moves the
full stroke and pressure control valve
spool (7) moves to the left. As a result of
this, pump port A and pressure control
valve output port B are opened, and oil
passes through orifice “a” of flow sensor
valve spool (3) and starts to fill the clutch.
561 FO3027
2) When this happen, a pressure difference

is created between the upstream and
downstream sides of orifice “a” of flow
sensor valve spool (3). Because of this
difference in pressure, flow sensor valve
spool (3) moves to the left and com-
presses sensor valve return spring (2).
As a result, flow sensor valve spool (3)
opens pump port D, and oil flows from
here through orifice “a” and goes to the
clutch port.
3. Filling completed (pressure control set to

initial pressure)(C range of graph)
1) When pump port D of the flow sensor
561 FO3028
valve opens, and the oil flows out from
here, a difference in pressure is created
between the upstream and downstream
sides of orifice “a” of flow sensor valve
spool (3). This continues to push flow
sensor valve spool (3) to the left. When
this happens, and the current of propor-
tional solenoid (6) is lowered momentarily
to the initial pressure level, almost the
complete pump pressure comes to bear
on load piston (8). As a result, pressure
control valve spool (7) is pushed back to
the right, and a small amount of oil leaks
from pressure control valve outlet port B
to drain port E. However, only a small
amount of oil leaks, so almost all the oil
from the pump flows to the clutch, and
flow sensor valve spool (3) continues to
be pushed to the left. 561 FO3029
HD325-6 lo-29
2) When the clutch is filled with oil, the flow

of oil from pump port D to clutch port C
stops. The size of areas receiving pres-
sure on the left and right sides of flow
sensor valve spool (3) is different (the area
on the left side is larger), so when the pres-
sure on both sides becomes the same, the
spool is moved by hydraulic force to the
right. When this happens, pump port D
and clutch port C are closed. Because of
this difference in area on the left and right
sides, and the force of return spring (2) of
the pressure control valve, flow sensor
valve (3) compresses fill switch spring (4)
and is pushed to the right. It then con-
tacts fill switch (5) and transmits the clutch
filling completed signal to the shift con-
troller. At this point, the current for the
561 FO3030
initial pressure level is flowing to propor-
tional solenoid (61, so the hydraulic pres-
sure is set to the initial pressure by pres-
sure control valve spool (7).
4. Regulating (D range of graph)

When current is sent to proportional solenoid
(6), the solenoid generates a force propor-
tional to the current. This propulsion force of
the solenoid, and the sum of the propulsion
force by the hydraulic pressure at the clutch
port applied to load piston (81, and the reac-
tion force of pressure control valve spring (9)
are regulated so that they are in balanced.
The difference in hydraulic pressure applied
to both sides of flow sensor valve spool (3)
pushes the spool to the right, and the fill sig-
nal continues to be sent to the transmission
controller.
561 FO3031
1O-30 HD325-6
STRUCTURE AND FUNCTION
FRONT AXLE
FRONT AXLE
HD3256
HD405-6
566~06018
1. Cover
2. Holder
3. Wheel hub
4. Retainer
HD325-6
10-31
0
STRUCTURE AND FUNCTION FRONT AXLE
HD325-6W +
1. Wheel hub
2. No. 2 planetary gear (No. of teeth: 31)
3. No. 2 planetary gear shaft
4. No. 1 planetary gear (No. of teeth: 34)
5. No. 1 planetary gear shaft
6. Cover
7. Spacer
9. Button
11. Spacer
12. No. 1 carrier
13. No. 2 carrier
14. Ring gear (No. of teeth: 81)
. 15. Clutch (drive selector)
16. Holder
17. Inner hub
18. Oil seal
19. Hub
20. Damper
21. Plate
22. Spring
23. Disc
24. Outer gear
25. Piston
26. Floating seal
27. Inner gear
28. Cylinder
29. Drive shaft
30. Gear
31. Front drive motor
+
SVH00878
10-31-l HD325-6
0
STRUCTURE AND FUNCTION FRONT AXLE
25 2k 23 22 21 20 if 18 17 IC
SVHOO879
HD325-6 10-31-2
0
STRUCTURE AND FUNCTION REAR AXLE
REAR AXLE
A -A
566FO6019
1. Parking brake SPECIFICATIONS

2. Differential Reduction ratio
3. Axle housing Differential: 3.125
4. Brake Final drive: 4.737
5. Final drive Oil
Differential: E0030-CD (45 liters)
Final drive: E0030-CD (13 liters each side)
Tire size: 08.00 - 33
Rim size: 13.00 x 33
1 O-32 HD325-6
STRUCTURE AND FUNCTION DIFFERENTIAL
DIFFERENTIAL
(Standard differential)
HD325-6
HD325-6W
HD405-6
17’
SDH00317
1. Coupling SPECIFICATIONS
2. Cage Type: Spiral bevel gear, splash-type lubrication
3. Cage Reduction ratio: 3.125
4. Case Differential: Straight bevel gear, splash-type
5. Nut lubrication
6. Cap Oil: E030-CD (45 liters)
7. Differential gear case
8. Cross shaft
9. Bevel gear (No. of teeth: 50)
10. Differential 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
HD325-6 1o-33
0
STRUCTURE AND FUNCTION DIFFERENTIAL
DIFFERENTIAL
(with differential lock)
HD325-6
HD325-6W
HD405-6
20-
19 IS 1!
i i I I SOH00318
1. Coupling SPECIFICATIONS
2. Cage Type: Spiral bevel gear, splash-type lubrication
3. Cage Reduction ratio: 3.125
4. Case Differential: Straight bevel gear, splash-type
5. Nut lubrication
6. Cap Oil: E030-CD (45 liters)
7. Differential gear case Differential lock type: Wet type, multiple disc
8. Piston clutch type
9. Plate
IO. Disc
11. Cross shaft
12. Bevel gear (No. of teeth: 50)
13. Differential gear case
14. Side gear (No. of teeth: 24)
15. Washer
16. Pinion gear (No. of teeth: 17)
17. Bevel pinion (No. of teeth: 16)
18. Spacer
19. Collar
20. Holder
1o-34 HD325-6
0
STRUCTURE AND FUNCTION FINAL DRIVE
FINAL DRIVE
1. Ring gear (No. of teeth: 71) SPECIFICATION

2. Cover Type: Planetary gear, splash-type lubrication
3. Sun gear (No. of teeth: 19) Reduction ratio: 4.737
4. Button Oil: E030-CD (13 liters each side)
5. Planet gear shaft
6. Planet gear (No. of teeth: 25)
7. Carrier
8. Spacer
9. Holder
10. Inner hub
11. Drive shaft
12. Wheel hub
13. Retainer
HD325-6 1o-35
STRUCTURE AND FUNCTION FRONT BRAKE
FRONT BRAKE
HD325-6
HD405-6
566FO6022
1. Plate 6. Pad SPECIFICATIONS

2. Pin 7. Disc Type: Air over hydraulic, caliper disc type
3. Plate 8. Seal
4. Bleeder 9. Ring
5. Piston 10. Seal
lo-36 HD325-6
0
STRUCTURE AND FUNCTION REAR BRAKE
REAR BRAKE
i r-’
12 li lb ‘7 ‘6
566FO6023
1. Inner gear SPECIFICATIONS

2. Floating seal Type: Air over hydraulic, oil-cooled, multiple-disc
3. Floating seal brake (acts also as retarder)
4. Retainer Oil: Brake oil E030-CD
5. Oil seal Cooling oil E030-CD
6. Hub
7. Plate
8. Disc
9. Outer gear
10. Damper
11. Piston
12. Cylinder
HD325-6 1o-37
STRUCTURE AND FUNCTION PARKING BRAKE
PARKING BRAKE
”\
“..L _.__
1
L_
566FO6024
1. Brake caliper assembly SPECIFICATION

2. Spring Spring-boosted type
3. Parking brake chamber Type: Caliper disc brake
4. Pad
5. Disc
6. Cover
7. Plate
1O-38 HD325-6
STRUCTURE AND FUNCTION WHEELS
WHEELS
FRONT WHEEL
1. Tire
2. Clampx6
3. Nutx12
4. Studx12
5. Valve
6. Rim assembly
SPECIFICATIONS
Tire size: 18.00 - 33 I
566FO6025
REAR WHEEL
1. Spacer
2. Tire
3. Rim assembly
4. Valve
5. Extension
6. Nut (inside and outside wheel, x16)
7. Clamp (outside wheel, x8)
8. Stud (outside wheel, x16)
9. Wedge ring
10. Nut (inside wheel, x3)
11. Clamp (inside wheel, x3)
12. Stud (inside wheel, x3)
SPECIFICATIONS
Tire size: 18.00 - 33 12 11 10
566FO6026
HD325-6 1o-39
STRUCTURE AND FUNCTION REAR AXLE SUPPORT
REAR AXLE SUPPORT
F-F
E -E
I
“3
i H
G -G
I -I
H -H
566FO6027
1. Rod
2. Rod
3. Axle
4. Suspension cylinder
1O-40 HD3256
STRUCTURE AND FUNCTION STEERING SYSTEM
STEERING SYSTEM
566F1034
1. Tire OUTLINE
2. Steering cylinder The steering system is of the self-metering power
3. Tie rod steering type. When the steering wheel is manipu-
4. Crossover relief valve lated, the steering valve is actuated, the oil to flow
5. Steering valve into the steering cylinder. By extending or con-
6. Demand valve tracting this steering cylinder, a truck can be
7. Knuckle steered as desired.
8. Arm (A-frame) If the steering wheel rotation is stopped before
the stroke end, the steering valve will instantly
be returned to neutral position and stopping the
steering cylinder at once.
HD325-6 10-41
STRUCTURE AND FUNCTION STEERING WHEEL
STEERING WHEEL
569FO5031
1. Steering wheel SPECIFICATIONS

2. Steering shaft l Tilting range: 94 mm
3. Steering column . Telescoping range: 50 mm
4. Steering post
5. Lock lever
6. Yoke
7. Joint shaft
8. Steering valve
1 O-42 HD325-6
STRUCTURE AND FUNCTION STEERING LINKAGE
STEERING LINKAGE
1. Center lever
2. Tie rod
3. Arm (A-frame)
4. Knuckle arm 566FO6028
HD325-6 1o-43
STRUCTURE AND FUNCTION STEERING LINKAGE
D-D
E-E F-F
566FO6029
1o-44 HD3256
STRUCTURE AND FUNCTION SUSPENSION SYSTEM
SUSPENSION SYSTEM
566FO6030
1. Front suspension cylinder

2. Rear axle support
3. Rear suspension cylinder
4. Radius rod
5. Arm (A-frame)
OUTLINE
The suspension system supports the weight of hydropneumatic cylinders, the suspension cylin-
the chassis, and absorbs the shock from uneven der is charged (sealed) with oil and nitrogen gas.
road surfaces to provide a comfortable ride for This acts as a shock absorber (spring and damper)
the operator. At the same time, it maintains the by contracting and expanding the nitrogen gas
stability of the machine by ensuring that all four and oil to absorb the load from the road surface.
wheels are always in contact with the ground sur- In addition to these functions, the front suspen-
face. In this way, it allows the machine to demon- sion employs an automatic suspension system.
strate its full performance in items such as accel- In this system, the force of the suspension is au-
eration, braking, and turning, even when travel- tomatically changed by selecting the dumping
ing at high speed. force to match the travel conditions and load con-
Hydropneumatic cylinders are used for the sus- ditions. This further increases the stability and
pension cylinders to reduce the shock. With riding comfort of the machine.
HD325-6 1o-45
STRUCTURE AND FUNCTION SUSPENSION SYSTEM
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 wheels move up
and down in accordance with the retraction
and extension of the suspension cylinder to
maintain the proper alignment for the wheels
and to improve the stability of the machine.
561 FO3048
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 inverted-V-shaped link im-
proves the rolling steering characteristics.
561 FO3049
1 O-46 HD3256
STRUCTURE AND FUNCTION SUSPENSION CYLINDER
SUSPENSION CYLINDER
FRONT SUSPENSION CYLINDER
A-A
B-B
566FO6031
1. Feed valve IO. Tube A: Port

2. Retainer 11. Air cylinder B: Port
3. Flange 12. Valve assembly
4. Cylinder 13. Orifice plate
5. Rod 14. Leaf spring
6. Stopper 15. Damping force selector valve
7. Wear ring 16. Damping force selector valve
8. Valve (for bleeding air) lever
9. Air bleed valve
HD325-6 16-47
Structure and operation

The suspension cylinder acts as a shock absorber
and spring. The inside of the cylinder is divided
into gas chamber A which is charged with nitro-
gen gas, and oil chamber B which is filled with
oil. Oil chamber B and oil chamber C are
conmected by tube (1 I) and valve body (12).
a Nitrogen gas
When the machine is traveling, the whees fol-
low the unevenness of the road surface, and
an external force in the updown direction is
applied to the suspension cylinder. When this
happens, the volume of the nitrogen in gas
chamber A changes elastically under the in-
put force, and absorbs the external force. The
nitrogen gas is sealed by a rod and oil, so it is
always subjucted to a pressure correspond-
ing to the external force, and acts as an air
spring.
b Principle of generation of damping force
Inside valve body (12) are orifice plate (8) and
leaf springs (9a) and (9b). They restrict the
flow of oil between oil chamber B and oil 561 FO3210
chamber C, and create a damping force.

Action when retracting
When the nitrogen gas is compressed by
the extenal force from the road surface,
the oil in oil chamber B flows from oil
chamber Bthrough thevalve (12) and tube
(II) to oil chamber C. The oil flowing
throgh the valve from direction Z to ori-
fice plate (8) is throttled by orifices in four
places to generate a damping force.
Action when extending
When the external force from the road
surface weaken, the pressure of the nitro-
gen gas extends the rod, and the oil in oil
chamber C passes through tube (11) and
valve (12) and flows to oil chamber B. The /It \
oil inside the valve flows from direction X !a jb z 8
and passes through two orifices from
orfice plate (8) to generate a damping
force.
Orifice Orifice
X Z
SWH00765
1 O-48 HD3256
c. Variable shaft mechanism

In the valve body, bypass circuit D is provided
before and after orifice plate (8), so the oil flow
is divided into oil flowing through orifice plate
(8) 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 air cylinder driven
by a signal from the suspension 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 9a 9b
the orifices through which the oil is passing.
561FO3054
(Orifice-small) MEDIUM
D
.?1:
;_
d
DamPins characteristics of each mode
SVH00644 (Orifice-large) SOFT SVH00643
HD325-6 1o-49
REAR SUSPENSION CYLINDER

HD325-6
HD325-6W
HD405-6
SDH00319
1. Feed valve
2. Cylinder
3. Rod
4. Flange
5. Retainer
6. Oil level valve
(For air bleed and pressure sensor mount)
7. Ball
1O-50 HD325-6
0
The operation of the rear suspension cylin-

der is explained by using the illustration of
HD325-6, serial No. 5001 - 5484. It is basically
common, however, to the other models and
serial No.
Structure and operation
The suspension cylinder has the function of
both a shock absorber and spring.
When a fixed amount of oil is sent from oil
chamber (7) through orifices (5) and (6) to
cavity (31, the oil is throttled by the orifices
and a shock-absorbing effect is obtained.
a) Retracting action
When the machine is traveling and it hits
a bump or object on the road, the wheels
are pushed up, and the cylinder rod is
pushed inside the cylinder.
When this happens, the nitrogen gas in-
side chamber (8) is compressed, the oil in
chamber (7) is sent through both orifices
(5) and (6) to cavity (31, and cavity (3) is
filled more quickly than when extending.
b) Extending action
When the machine has passed any bump
or object on the road surface, the cylin-
der rod is pushed up by the weight of the SWH00766
wheels and axle and the pressure of the
nitrogen inside chamber (8).
As a result, the amount of oil in cavity (3)
is reduced, and pressure is applied to the
oil remaining in cavity (3).
This pressurized oil closes orifice (5) with
check ball (4), and is sent to chamber (7) 1. Air bleed 8. Nitrogen gas chamber
through only orifice (61, so the flow of oil 2. Air bleed valve 9. Cylinder rod
passing through the orifice is controlled 3. Cavity 10. Cylinder
so that it is less than during retraction. 4. Check ball 11. Feed valve
In this way, the amount of oil returning to 5. Orifice
chamber (7) is restricted to provide a 6. Orifice a: When extending
shock absorbing effect. 7. Oil chamber b: When retracting
HD325-6 1o-51
STRUCTURE AND FUNCTION AIR CIRCUIT DIAGRAM
TO AIR CIRCUIT 1. Air cylinder (for suspension control)

DIAGRAM (l/2)
2. Front brake
‘-----l 3. Front brake chamber
5 4. Double check valve
r
5. Air compressor
6. Air governor
7. Check valve
8. Air tank (dry)
9. Safety valve
10. Front brake relay valve (with emergency)
11. Rear brake relay valve (with emergency)
3 ..a
12. Rear brake relay valve (wrtn emergency)
13. front brake relay valve (with emergency)
14. Air tank (dry)
15. Air tank (dry)
16. Air tank (pilot)
17. Air charge socket
18. Drain valve
19. Brake oil tank (rear)
20. Parking brake relay valve
21. Parking brake chamber
22. Rear brake chamber
23. Slack adjuster
24. Rear brake
25. Brake cooling circuit
26. Transmission oil tank
27. Exhaust brake cylinder
28. Horn
29. Muffler
30. Muffler
31. Air pressure sensor
32. Exhaust brake switch
33. Emergency brake switch
34. Brake lamp switch
35. Parking brake switch
36. Retarder lamp switch
37. Muffler
38. Brake valve
39. Retarder valve
40. Parking brake valve
41. Emergency brake valve
42. Front brake cut-off solenoid valve
43. Exhaust brake solenoid valve
44. Auto-retarder solenoid valve
45. Suspension control solenoid valve
46. Brake oil tank (front)
a: NYLON TUBE
b: STEEL TUBE
C: RUBBER HOSE
SWHOO 770
HD325-6 1o-55
STRUCTURE AND FUNCTION AIR GOVERNOR
AIR GOVERNOR
1. Spring
2. Exhaust port
3. Piston
4. Under port
5. Exhaust stem
6. Inlet valve
7. Tank port
8. Filter
SPECIFICATIONS
l Cut-out pressure: 814f 29 kPa (8.3 + 0.3kg/cm21
l Cut-in pressure: 687 * 29 kPa (7.0 + 0.3kg/cm2)
\ a
423FhlA
FUNCTION
. The air governor maintains the pressure in
the air circuit to the range.
OPERATION
Compressor working
. The air pressure in the wet tank (9) passes
from the tank port (7) through the filter (8) and
acts on the bottom of the piston (3). When
the air pressure in the tank (9) is below the
specified pressure (cut-out pressure) the pis-
ton (3) pushed down by the spring (1).
. When this happens, the air at the unloader
port (4) passes through the exhaust stem (5)
to the atmosphere and the compressor is ac-
tuated.
SWH00771
1O-56 HD325-6
STRUCTURE AND FUNCTION AIR GOVERNOR
Compressor stopped
When the pressure in the wet tank (9) rises,
and reaches the set pressure (cut-out pres-
sure), the piston (3) is pushed up against the
spring (I).
When the piston (3) is pushed up, the exhaust
stem (5) is closed and the inlet valve (6) opens.
The pressure from the tank passes through
the inlet valve (6) and unloader port (4), and
acts on the unloader valve of the compres-
sor. This puts the compressor in a no-load
condition.
When the air pressure inside the tank drops,
the piston (3) is pushed down by the spring
(1). Check valve
When the pressure drops below the specified
pressure (cut-in pressure), the inlet valve (6)
closes and the exhaust stem (5) opens. The
pressure at the unloader port (4) passes
through the exhaust stem (5) and is released Drain valve
in the atmosphere, so the compressor starts
to work again.
SWH00772
HD325-6 1o-57
STRUCTURE AND FUNCTION AIR DRYER
The air dryer is used to remove water, oil carbon,

dust, etc. from the compressed air supplied by
the air compressor and send clean dry air to the
air tank.
The removed water, etc. is automatically dis-
charged out of the system each time the air com-
pressor is unloaded.
27
4
7
14
v26
-25
16
I4
I3
16
I4
-23
I8
29
28
27
23. 24 i3 35 34 SWH00773
1 O-58 HD325-6
1. Safety valve
2. Top cap
3. Gasket
4. Filter cap
5. Filter
6. Spring
7. Strainer
8. V-spring
9. Packing
10. Body
11. Support plate
12. Deflector
13. Rod
14. Nut
15. Washer
16. Washer
17. End cap
18. Bolt
19. Unloader nut
20. Sleeve
21. Piston
22. O-ring
23. U-cap
24. Spring
25. Retainer ring
26. Spring
27. Seat ring
28. Spindle
29. Gasket
30. Nut
31. Gasket
32. Elbow
33. Check valve
34. Heater
35. Thermostat
A: Outlet port
B: Exhaust port
C: Governor unload port
HD325-6 1o-59
OPERATION
Air compressed and heated in the compressor The air dryed and cleaned in this way is sent
flows in the bottom of the air dryer, then it ex- through check valve (33) to the air tank.
pands adiabatically and cools itself, then the mois- If the pressure in the air tank reaches the speci-
ture in it is condensed into water and accumu- fied level, the governor works to unload the air
lated in end cap (17). compressor.
Since the body (IO) of the air dryer is made of The unloading pipe is connected to the unloaded
aluminum and has many fins on its outer cylin- port of the air dryer, and air in the air dryer flows
der and is cooled while the dump truck is runout each time the compressor is unloaded. At this
ning, it is not heated by the air from the compres- time, the water, oil, etc. accumulated in cap (17)
sor. The dryed air is filtrated by filter (5) to re- are discharged.
move oil, carbon and dust.
Air circuit diagram
Wet air tank
SDH00339
1 O-60 HD325-6
STRUCTURE AND FUNCTION SAFETY VALVE, CHECK VALVE
SAFETY VALVE
7 6 5 2 1
1. Valve seat FUNCTION

2. Ball l The safety valve is installed to the wet air tank,
3. Release pin and if pressure of more than 932 * 39 kPa {9.5
4. Spring + 0.4 kg/cm21 is generated in the air circuit, it
5. Spring gauge acts to release the compressed air inside the
6. Adjusting nut air tankto the atmosphere to ensure the safety
7. Locknut of the circuit.
CHECK VALVE
b
-
51F037A
1. Body FUNCTION
2. Disc valve . This acts to prevent the air from flowing back
3. Spring in the opposite direction.
4. Screw cap It is installed to the air tank, and when air en-
ters the check valve from the direction of port
a: High-pressure side a, disc valve (2) separates, so the air can flow
b: Low-pressure side to port b without obstruction.
HD325-6 1O-61
STRUCTURE AND FUNCTION DOUBLE CHECK VALVE
DOUBLE CHECK VALVE
566F127
1. Body FUNCTION
2. Shuttle guide l The double check valve acts to send either the
3. Shuttle air from the auto retarder valve or the air from
4. Gasket the retarder control valve (hand brake) to the
5. Cap rear brakes.
6. Plug
OPERATION
l When the hand brake is applied, compressed To rear brake relay valve
air moves shuttle (3) of the double checkvalve 4%

and blocks the air intake hole at the auto re-
tarder valve end.
As a result, the compressed air changes di-
From m From auto
rection and flows to the rear brake relay valve. brake retarder valve
Also when the auto retarder valve is actuated,
@ @
the shuttle blocks the air intake hole of the
brake valve, and the compressed air flows to
the rear brake relay valve.
SWH00774
1 O-62 HD325-6
STRUCTURE AND FUNCTION HAND BRAKE VALVE
HAND BRAKE VALVE
\
B-B
+
z
13’ A-A
561 FO3060
1. Clamp 11. Body OUTLINE

2. Pin 12. Stem l The hand brake valve is an air valve for the
3. Handle 13. Spring retarder control, and is installed to the steer-
4. Plunger 14. Head ing column.
5. Spring 15. Ring . The air discharge pressure changes accord-
6. Lock washer 16. Spring ing to the angle that the valve handle is ro-
7. Cam follower 17. Piston tated, so the retarder can be controlled as de-
8. Cam 18. Spring sired.
9. Cover 19. Valve
IO. Valve guide 20. Valve seat
HD325-6 1O-63
STRUCTURE AND FUNCTION HAND BRAKE VALVE
FUNCTION
When the handle is placed in “BRAKE” position,
then piston (5) will be pushed down by cam (I)
through spring (2).
The exhaust valve seat provided at piston (5) will
be pushed against exhaust valve (4) to close the
valve. The inlet valve (6) and exhaust valve (4)
from onebody. After the exhaust valve (4) is
closed, inlet valve (6) is opened. Compressed air
is fed to the relay valve through the inlet valve,
actuating the rear brake chamber cylinder and ap-
plying the retarder brake.
To relay From
valve air tank SWH00775
Air balancing position with the spring force

When the air pressure impressed on the under-
side of piston (5) balances with the force of spring
(2). piston (5) will be raised slightly, closing the
inletvalve (6). In this condition, the valve seat (3)
remains closed, keeping the air pressure at the
relay valve constant. In this manner, the brake
valve is kept in a balanced condition, holding the
air pressure constant depending on the position
of the handle.
II II Drain
To relay From
valve air tank SWH00776
Brake releasing position

When the handle (7) is moved to the brake “RE-
LEASE” position, the force of spring (2) will be
reduced, Then, position (5) will be raised by the
air pressure on the underside of the piston, caus-
ing the exhaust valve to open, which will, in turn,
cause the pressurized air at the relay valve to flow
out into the atmosphere trough the exhaust valve.
If the air pressure on the piston underside bal-
ances with the force spring (21, the exhaust valve
will be closed again to hold the balanced condi-
tion, and the air pressure at the relay valve will
be kept constant. When the handle (7) is moved
to the “COMPLETE RELEASE” position, the force
on spring (2) will be removed causing piston (5)
to be pushed up, which, in turn, will cause all of
the pressurized air to flow out into the atmo-
sphere. Thus, the brake will be completely
leased.
re-
Front
a
To drain
relay valve SWH00777
1O-64 HD325-6
STRUCTURE AND FUNCTION BRAKE VAWE
11. li i3 F56903014A
1. Plunger 11. Lower valve guide a: From dry air tank

2. Seat 12. Check valve b: To relay valve
3. Pedal 13. Lower valve return spring c: From dry air tank
4. Piston 14. Relay piston return spring d: To relay valve
5. Stop bolt 15. Upper ring retainer
6. Piston return spring 16. Upper valve return spring
7. Upper valve (upper inlet valve) 17. Inner relay piston
8. Outer relay piston 18. Valve body
9. Lower valve (lower inlet valve) 19. Rubber spring
10. Cover
HD325-6 1 O-65
STRUCTURE AND FUNCTION BRAKE VALVE
FUNCTION
A. In normal action
(when the braking effect begins to be given.)
If the pedal (3) is depressed, the pedal move-
ment will be transmitted to the position (4)
through the rubber spring (191, causing the
piston (4) to move downward. Then, the ex-
haust port (A) will be closed and the upper
inlet valve (7) will be opened. Thus, the pres-
surized air from the air tank will flow to the
relay valve of upper side, causing the appli-
cation on the brake to start.
If the upper inlet valve (7) is opened, the pres-
surized air will flow to the relay piston (8)
through passage (B), pushing inner relay pis-
ton (17) down ward, witch, in turn, will open
the lower inlet valve.
Then, pressurized air from the air tank will
flow to the relay valve of lower side, to the @
om the
start applying the brake.
Actually, the force required to move the relay
piston (8) is very small and therefore, there is
little difference in timing for the upper and
lower inlet valves to begin opening. Ii 3 SWH00778
B. When balancing is made between air

pressure and spring force
(When the brake pedal (3) is depressed to
the held at a certain point on its stroke.)
If the air pressure in the relay valve of upper
side acting on the lower part of piston (4) is
equal to the force of the rubber spring push-
ing piston (4) downward, the upper inletvalve
will close, stopping the flow of pressurized air
from the air tank to the relay valve. The ex-
haust port remains closed. Then, the air pres-
sure in the relay valve will be kept constant
and consequently, the braking force will be
maintained at the same value.
If the upper and lower air pressure values in
the relay piston are equal to each other, the
piston return spring (14) will move the relay
piston (8) slightly upward, and the lower inlet
valve will be closed by the action of spring
(13). However, the exhaust valve (C) remains
closed and the air acting on the front relay
valve cannot escape, thus the braking force
is kept constant.
Ir If pedal (3) is depressed to the end of its
stroke, the upper and lower inlet valves
(7) and (9) will remain opened equalizing SWH00779
the air pressure in the relay valve with that
in the air tank.
10-66 HD3256
STRUCTURE AND FUNCTION BRAKE VALVE
C. When the brake is released

When the effort depressing pedal (3) is re-
duced, the force on the upper part of piston
(4) will be eliminated, and piston (4) will be
pushed up by the air pressure and spring force
acting on its lower part. Exhaust port (A) will
be opened, to allow escape of the pressurized
air in the relay valve into the atmosphere. As
a result, the force acting the brake will be re-
duced.
Consequently, the air pressure acting on the
upper part of relay piston (8) will also be re-
duced. Since relay piston (8) is also pushed
up by the air pressure and spring force acting
on its lower part the exhaust valve (C) will be
opened. Then, the pressure at the relay valve
actuating the brake will be reduced, causing
release of the brakes.
relay valve
HD3256 1 O-67
STRUCTURE AND FUNCTION EMERGENCY BRAKE CONTROL VALVE
EMERGENCY BRAKE CONTROL VALVE
MPa ( kdcm'l
0 lOf3 20 30 40 45 50 55
Handle turning
561 FO3061 Actuation characteristics graph angle
(tank messure:O. 78181 btm(ko/cdl SVH00648
1. Handle A: Outlet port (to emergency brake valve)

2. Cam ring B: Inlet port (from air tank)
3. Handle head C: Exhaust port
4. Body
5. Piston FUNCTION
6. Cover l This valve allows manual actuation of the
7. Valve spring emergency brake.
8. Main spring The emergency brake can be controlled by
9. Feed valve operating the handle.
10. Feed valve seat * When traveling, the handle is set at a handle
11. Return spring angle of 55” (position 0).
12. Exhaust valve seat
1O-68 HD325-6
OPERATION
1 Braking position (handle turning angle at 0’)

At the braking position, the inlet port is con-
nected to the tank, but the air is shut off by From emergency
4= relay valve
feed valve (9). The exhaust port is open, so
the air at the exhaust port is all released. As
4= From air tank
a result, the emergency relay valve is actu- 9
ated to brake the machine.
Exhaust air
SVH00649
2 Actuation at air supply end (handle turning

angle 0’ + 55”)
When the handle is turned, the exhaust valve
seat (12) is pressed down by a cam. It con-
tacts feed valve (9) and closes the exhaust To emeroency
relay valve
port. If the handle is turned further, feed valve
(9) is pushed down, so the inlet port and out-
From air tank
let port are connected and air flows.
SVH00650
3 Balancing effect (handle turning angle

between IO” and 45”)
If the handle is stopped at a midway position
(any desired position), the air pressure in
chamber B acts also on the top surface of pis- To emergency
+ relay valve
ton (5).
If this force becomes greater than the force of
From air tank
main spring (81, piston (5) is pushed down and
feed valve (9) is closed. When this happens,
exhaust valve seat (12) is also closed, so the II tiL
pressure at the outlet port is maintained at a 8’ SVH00651

constant pressure.
HD325-6 lo-69
4 Travel position (full stroke: handle turning

angle 55”)
If the handle is turned further, piston (5) con-
tacts the stopper surface of cover (61, so feed
valve (9) is opened and the pressure at the To emergency
relay valve
outlet port rises to the tank pressure. As a
result, the emergency relay valve releases the
emergency brake, and the machine is placed
in the travel condition.
5 Actuation at exhaust end (handle turning

angle 55” + 0”)
If the handle is turned in the 0” direction, the
cam rises, and exhaust valve seat (12) rises
because of return spring (II). It separates From emeroencv
from feed valve (9), so the air at the outler

port is drained.
From air tank
SVH00653
1O-70 HD325-6
STRUCTURE AND FUNCTION PARKING BRAKE CONTROL VALVE
PARKING BRAKE CONTROL VALVE
561 FO3068
1. Body FUNCTION
2. Plunger . This valve controls the switching ON/OFF of
3. Plunger spring the parking brake.
4. Valve
5. Lever OPERATION
6. Pin . If lever (5) is set to position @I (parking brake
7. Valve spring applied), air passes from the inlet portto out-
let port; when lever (5) is at position @ (park-
A: Exhaust port ing brake released), the air is exhausted.
B: Outlet port
C: inlet port
HD325-6 10-71
STRUCTURE AND FUNCTION PARKING BRAKE CONTROL VALVE
OPERATION
1. Supplying air
When lever (1) is set to the TRAVEL position,
valve seat (4) is pushed up by plunger (5) and
compressed air is supplied to the parking
brake relay valve.
,kino
IY va
ft
From the air tank SWH00781
2. Exhausting air
When lever (I) is set to the PARKING, plunger
(5) is moved back up by spring (61, valve seat
(4) is seated to body (31, and plunger (5) sepa-
rates from valve seat (4). As a result, the com-
pressed air supplied to the parking brake
control line passes through the small hole in
the center of plunger (5) and is exhausted to
the atmosphere. When the air inside the re-
lay valve is exhausted, the parking brake is
applied by the force of the spring.
From the Parkino
brake relay valve
SWH00782
1o-72 HD325-6
STRUCTURE AND FUNCTION RELAY VALVE
RELAY VALVE (Acts also as emergency relay)
7
a
566F136A
1. Cover A: From air tank OUTLINE

2. Spring B: From brake valve In normal operation, when the brake pedal is de-
3. Exhaust valve seat C: From emergency pressed, it moves the relay valve and the air in
4. Inlet exhaust valve brake valve the air reservoir is sent to the brake chamber.
seat D: To brake chamber If any failure in the air pressure in the wet tank to
5. Body E: To brake chamber drop below the specified pressure 0.31 MPa (3.2
6. Relay piston kg/cm*), it also acts as emergency relay valve.
7. Valve guide
8. Emergency piston
HD325-6 1o-73
STRUCTURE AND FUNCTION RELAY VALUE
OPERATION
1. When not operated (compressed air supplied
to dry air tank)
When the emergency brake valve is at the
TRAVELING position and the brake pedal is To dry
not being depressed, the compressed air in air ta
*
the wet air tank passes through filter (I),
pushes down check valve (21, and is supplied
to the dry air tank. The pressure in the dry air
tank rises until it is almost the same as the
pressure in the wet air tank. SWH00763
At the same time, emergency position (3) is
pushed down by the compressed air from the
emergency brake valve.
The air is supplied directly from the wet air
tank to the dry tank. \ \ / From brake
2. When brake pedal is depressed

Compressed air enters top position A of the
relay piston and pushes the piston down. Ex-
haust valve seat (4) closes exhaust port C and From
pushes valve (5) open. emeroenw
.
oralievalve
When the valve opens, the compressed air
from the dry air tank and emergency brake
valve passes through the valve and is sup- 5 + SWH00764
plied to the brake chamber.
3. When pedal is kept in same position

(balanced condition)
From brake
The pressure at top position A and bottom
position B of the piston becomes equal, so
piston return spring (6) moves and relay pis-
ton (7) is pushed up. Moreover, in this posi-
tion, exhaust port C remains closed, so the
pressure at bottom portion B is maintained a9
From emeroencv
at the same pressure. air t brake valve
‘C
SWH00785
4. When pedal is released

The compressed air at top position A of the
piston is released from the brake valve. When rake
e
the pressure at position A goes down, relay
position (7) is pushed up by the compressed From brake
air in bottom position B, the exhaust port chamber
*
opens, and the air in position B is released.
emeroenw
brake valve
SWH00786
1o-74 HD325-6
STRUCTURE AND FUNCTION RELAY VALUE
5. When emergency brake is actuated

(1) Automatic operation
i) If there is damage to the air circuit and
the pressure at the emergency brake
valve end (wet air tank end) drops
below approx. 0.31MPa {3.2kg/cm2),
emergency piston return spring (8) is
actuated, and emergency piston (3) is
pushed up, so exhaust valve seat (5) to
closes exhaust port C and opens valve air circuit.

(4). When the valve opens, com- 0~ operation
of emergency
pressed air from the dry air tank brake valve
passes through the valve and is sup- 5 0 SWHOOBZS
plied to the brake chamber. In this
way, if the pressure in the emergency
brake valve air circuit goes below
0.31 MPa {3.2kg/cm2), the emergency
brake starts to be applied.
ii) If the air pressure in the emergency
brake valve air circuit is between
approx. 0.46 MPa {4.7kg/cm21, and
0.31 MPa {3.2kg/cm21, the emergency
brake is not applied automatically.
However, in this condition, if the brake
valve is depressed, even if the brake
valve is kept in the same position, the
remaining pressure inside the brake
valve causes the emergency brake to
be actuated.
iii) To release the emergency brake, open
the drain valve of the air tank, or raise
the air pressure in the wet air tank to
above 0.55MPa {5_6kg/cm*I.
(2) Manual operation

i) If the emergency brake valve is moved
from the TRAVELING position to the
BRAKING position, the compressed
air between the emergency brake
valve and the emergency relay valve
is released to the atmosphere.
If this happens, the circuit is set to the
same condition as in i) above, so the
emergency relay valve is actuated.
ii) To release the emergency brake, set
the emergency brake valve to the
TRAVELING position.
HD325-6 1o-75
STRUCTURE AND FUNCTION PARKING BRAKE RELAY VALVE
PARKING BRAKE RELAY VALVE
566F129
1. Cover FUNCTION
2. Relay piston l The parking brake relay valve is in the park-
3. Valve body ing brake circuit. When the parking brake
4. Exhaust cover valve is set to PARKING, the parking brake
relay valve is actuated, the air in the parking
A: From parking brake pilot valve brake chamber is released, and the machine
B: From air tank is stopped from moving.
C: To parking brake chamber
1 O-76 HD3256
STRUCTURE AND FUNCTION PARKING BRAKE RELAY VALVE
FUNCTION
1. When the parking brake valve in

“TRAVELING”
Pressurized air will enter A, the upper section parkino brake
of the relay piston, causing the piston to lower.

Then, the exhaust valve seat (I) will close the
exhaust port C and open the valve (2).
If the valve is opened, the pressurized air will
be fed to the parking brake chamber through
the valve.
SWH00787
2. When the parking brake valve in “PARKING” A B

The pressurized air in the piston upper sec-
parkino brake
tion A will be exhausted through the parking
brake valve, reducing the pressure A.
Consequently, the relay piston will be thrusted
up by the pressurized air in the section B, caus-
ing the exhaust port to open. Thus, the air in
the section B will be exhaled.
C SWH00788
HD325-6 1o-77
STRUCTURE AND FUNCTION FRONT BRAKE CHAMBER
HD325-6
HD405-6
561 FO3069
1. Piston SPECIFICATIONS
2. Push rod Air cylinder
3. Air cylinder Fluid used: Air
4. Master cylinder Effective area: 314 cm2
5. Piston Stroke: 100 mm
Max. operating pressure: 0.88 MPa 19 kg/cm21
Normal operating pressure:
0.81 MPa (8.3 kg/cm21
Master cylinder
Fluid used: Engine oil (SAEIOW)
Effective area: 12.6 cm2
Delivery oil quantity: 120 cc
(at stroke 97 mm)
Max. operating pressure:
20.3 MPa I207 kg/cm21
Normal operating pressure:
19.6 MPa I200 kg/cm21
lo-78 HD325-6
0
STRUCTURE AND FUNCTION REAR BRAKE CHAMBER
REAR BRAKE CHAMBER

HD325-6
HD325-6W
HD405-6
SEH00326
1. Air cylinder SPECIFICATIONS

2. Air piston 1. Air cylinder
3. Spring Cylinder bore: 180 mm
4. Rod Stroke: 133.5 mm
5. Breather Cylinder capacity: 3,600 cc
6. Piston
2. Master cylinder
7. Master cylinder
Cylinder bore: 68 mm
8. Piston valve
Stroke: 132.5 mm
9. Body
Cylinder capacity: 472 cc
10. Brake line failure sensor
3. Boosting ratio: 7.0 : 1
HD325-6 1o-79
0
OPERATION
Brake operated
When the brake pedal is depressed, compressed
air is supplied from the brake valve to the brake
chamber. Air piston (2) moves rod (4) and pushes
piston (6) of master cylinder (7) to the right. Brake
oil is sent by piston (6) to the brake piston to ac-
tuate the brake.
From
Q
brake
valye
Brake held in position

When the brake pedal is kept depressed at a con-
stant force, the hydraulic pressure is kept con-
stant, so the brake is kept applied.
From
valve
Brake released
When the operating force on the brake pedal is
partly released, the compressed air supplied to
the back of piston (2) of the brake chamber is re-
leased from the brake valve, and the hydraulic
pressure inside master cylinder (7) drops.
If the brake pedal is released further, the brake oil ilack
set to the piston of the brake is sent back to the er
inside of master cylinder (7) by the force of the
brake return spring.
>?? m SDW01705
1 O-80 HD325-6
OPERATION OF BRAKE LINE FAILURE SENSOR

HD325-6
HD325-6W
HD405-6
SVH00509
When air piston (I) moves more than 93% of its

stroke, it pushes brake line failure pin (2), and
brake line failure sensor (3) is actuated.
When brake line failure sensor (3) is actuated, the
rear brake caution lamp inside the cab lights up.
At the same time, the central warning lamp flashes
and the alarm buzzer sounds intermittently.
HD325-6 1O-81
0
STRUCTURE AND FUNCTION PARKING BRAKE CHAMBER
PARKING BRAKE CHAMBER
A-A
426FO92
1. Spring FUNCTION
2. Piston The air pressure from the parking brake valve
3. Cylinder pushes the spring (I 1and compresses it to release
4. Boot the parking brake.
5. Rod Usuallythe parking brake is kept applied by spring
(I), so the machine is prevented from moving.
1O-82 HD325-6
STRUCTURE AND FUNCTION SLACK ADJUSTER
SLACK ADJUSTER
5S9FOO9
1. Check valve FUNCTION

2. Piston l When the brake disc becomes worn, it takes
3. Valve body longer for the braking force to take effect (time
4. Piston lag), so the slack adjuster acts to keep the time
5. Check valve lag constant even when the brake disc is worn.
A: From rear brake chamber SPEClFlCATlONS

B: From rear brake chamber Effective area: 50.3 cm2
C: To rear brake Discharge oil: 115.6 cc (each side)
D: To rear brake Pressure normally used: 5.20 MPa (53 kg/cm2}
(when governor is 0.81 MPa (8.3 kg/cm21
Stroke: 23 mm
Check valve cracking pressure:
0.93 f 0.15 MPa 19.5 * 1.5 kg/cm21
Check valve closing pressure:
0.59 f 0.05 MPa (6.0 ? 0.5 kg/cm21
HD325-6 1O-83
STRUCTURE AND FUNCTION SLACK ADJUSTER
FUNCTION
1. When brake pedal is depressed:

The oil discharged from the brake chamber
flows into each cylinder, causing piston (4) to
move by stroke S. Thereby, the oil equivalent
to stroke S flows into the brake. At this time,
no clearance exists between the brake piston
To brake
and discs, and the braking force does not oc-
cur. When the oil pressure, in the chamber
exceeds the specified pressure. Poppet valve
(5) opens, allowing the oil to flow through the
pilot-operated circuit. Thereby, the oil pres- B
From brake chamber SWH00789
sure is imposed on brake piston, creating the
brake force.
2. When the brake pedal is released:

When the brake is released, the back pressure
is imposed on the brake piston by the brake
cooling oil pressure, causing a returning pres-
sure to occur between the adjuster and the
brake chamber. Thereby, the piston (4) is
moved back by stroke S and the clearance
between the disc and the brake piston is kept
at a dimension equivalent to the adjuster vol-
ume.
8
To brake chamber SWH00790
3. Adjuster function:
(when the brake piston volume is large than
the adjuster volume.) When the brake pedal
is depressed, oil in a volume equal to stroke
S will be discharged by piston (4). The oil
equal to the shortage in the brake piston vol-
To brake
ume will be supplied through poppet valve,
creating pressure in the brake chamber. Con-
sequently, the braking effect will be the same
as when the brake piston volume and the ad-
juster volume are equal.
SWH00791
1 O-84 HD325-6
STRUCTURE AND FUNCTION FRONT DRIVE HYDRAULIC CIRCUIT DIAGRAM
FRONT DRIVE HYDRAULIC CIRCUIT DIAGRAM

HD325-6W
0.54tdpa
(5. Skg/cm*l
r-
From brake 011 cooler outlet
SVH00880
1 O-84-2 HD325-6
0
1. Front drive oil tank

2. Charging pump
3. Piston pump
4. Filter
5. Bypass valve
6. Low-pressure relief valve
7. Servo cylinder
8. Regulator
9. High-pressure relief valve
Cut-off valve
11. Flushing valve
12. Piston motor
13. Regulator
14. Oil cooler
15. Relief valve
16. :Strainer
17. Transmission oil tank
18. IFront drive selector clutch
solenoid valve
19. Front drive selector clutch
I -- .----
-_I
a I
I I
aLi___ 1 - S
HD325-6 1 O-84-3
0
fi~325-6~
SEH00327
1. Oil cooler
2. Piston motor (right)
3. Flushing valve
4. Front drive selector clutch solenoid valve
5. Piston motor (left)
6. Front drive oil tank
7. Filter
8. Relief valve
1 O-84-4 HD325-6
0
STRUCTURE AND FUNCTION FRONT DRIVE PISTON PUMP
FRONT DRIVE PISTON PUMP

HD325-6W
566FO6229
1. Drive shaft SPECIFICATIONS

2. Swash plate Model: A4VG125EP2D1/31 RNSF-001 D-985-O
3. Servo cylinder Type: Variable capacity swash plate piston pump
4. Regulator Theoretical delivery: 0 - 125 cc/rev
5. Cut-off valve Set pressure for high-pressure cut-off valve:
6. High-pressure relief valve 37.3 MPa (380 kg/cm*1
7. Low-pressure relief valve Set pressure for high-pressure relief valve:
8. Housing 39.2 MPa (400 kg/cm*)
9. Piston Set pressure for low-pressure relief valve:
2.5 MPa I25 kg/cm21
HD325-6 1 O-84-5
0
OPERATION OF PISTON PUMP

Flow of motive force
l The piston pump is installed to the PTO.
l The motive force from the engine passes from
the flywheel through the torque converter and
PTO, and goes to the piston pump.
. Regulator (4) and servo cylinder (3) are in-
stalled to the piston pump. The regulator is
actuated by the signal from the controller, and
swash plate (2) inside the piston pump
changes its angle to send the flow of oil in
the normal or reverse direction.
. Piston (9) inside the housing rotates together
with drive shaft (I), and the tip of the piston
slides along the surface of swash plate (21,
which does not rotate. There are nine pis-
tons installed in the pump.
88 i ‘6
566FO6229
Flow of oil
. Piston (9) which, is in contact with the sur-
face of the swash plate, carries out a recipro-
Suction
cal movement according to the angle of swash
plate (2). The piston pump is actuated by the
reciprocal movement to suck in or discharge
Discharge
oil continuously inside housing (8).
. Because of this discharge operation, high-
pressure oil forms and oil flow in a constant
direction, and flows to the piston motor.
. When the angle of swash plate (2) is reversed,
the suction and discharge are also reversed,
to the direction of the flow of oil is reversed.
. As the angle of swash plate (2) becomes larger
or smaller, the stroke of the piston changes
and the travel speed is controlled.
. Because of leakage from the piston motor,
piston pump, and control valve, there is loss
of oil in the low-pressure circuit (the return
circuit from the motor to the pump). Com-
pensation is made for the lack of by supply-
ing oil from the charge pump through the
check valve of high-pressure relief valve (7).
Neutral (Diston dose not ‘move. so no
oil is discharged) SVHOOBEZ
1 O-84-6 HD325-6
0
FRONT DRIVE PISTON MOTOR

HD325-6W
566FO6230
1. Drive shaft SPECIFICATIONS

2. Piston . Model: A6VM80EP2/60W0420-PZO2OA-978-0
3. Cylinder block l Type: Variable capacity swash plate piston
4. Regulator motor
5. Port plate l Theoretical delivery: 23 - 80 cc/rev
HD325-6 1 O-84-7
0
OPERATION OF PISTON MOTOR

Principle
. Let us suppose that the shaft of a disc is sup-
ported to allow the disc to rotate freely.
If force F is applied to this disc at an angle,
this force F can be divided into force Fl ap-
plied at a right angle to the face of the disc
and force F2 applied in the direction of the
circumference of the disc. Force Fl pushes
the disc in the axial direction, and force F2 208F I 42
rotates the disc in a clock wise direction.
. If force F’ is applied to the disc instead of force
F, the-force can be divided in the same way
into forces F’l and F’2, will rotate the disc in a
counterclockwise direction.
Outline of structure
l Seven pistons (2) are installed to the disc of
drive shaft (I 1with ball joints. Pistons (2) are
at a certain angle to drive shaft (I), and are
built into cylinder block (3).
. The angle of cylinder block (3) and pistons (2)
is changed by the action of regulator (41, which
is actuated by the signal from the controller.
Operation
l The oil sent under pressure from the piston
pump enters the inlet port of the piston mo-
tor. Oil pressure is formed at the back of pis-
tons (2), and drive shaft (I) is rotated in ac-
cordance with the angle of pistons (2) and the
cylinder block.
566FO6230
362FO5029
1 O-84-8 HD325-6
0
STRUCTURE AND FUNCTION CHARGE PUMP OIL FILTER
CHARGE PUMP OIL FILTER

HD325-6W
T
A
B-B
1. Indicator
2. Bypass valve
3. Element
4. Case
A-A
566FO6231
OPERATION
. The oil from the front drive charge pump en-
ters from tube a, enters filters A and B, which
are connected in parallel, passes from the
outside of element (3) through to the inside,
then flows to tube b.
l When element (3) becomes clogged with dirt 566FO6232
and the pressure on the outside of element
(3) rises, indicator (I) is actuated to send a SPECIFICATIONS
warning to the controller. . Filtering size: 1Ou
If the pressure rises further, the oil from tube . Filtering area: 1,100 cm* x 2
a opens bypass valve (2), flows through port . Bypass pressure: 0.54 MPa I5.5 kg/cm*}
b, and returns to the tank to avoid damaging . Indicator actuation pressure:
the pump or element (3). 0.44 MPa 14.5 kg/cm*}
HD325-6 1 O-84-9
0
STRUCTURE AND FUNCTION HYDRAULIC PIPING
HYDRAULIC PIPING (Steering and hoist)

HD325-6 : Serial No. 5680 – 6000
HD325-6W : Serial No. 5706 – 6000
HD405-6 : Serial No. 1055 – 2000
1. R.H. steering cylinder

2. Hydraulic and steering pump
(SAR(3)-063+050)
3. R.H. hoist cylinder
4. L.H. hoist cylinder
5. Hydraulic tank
6. Slow return valve
7. Hoist control valve
8. Demand valve
9. L.H. steering cylinder
10. Steering valve
11. Crossover relief valve
HD325-6 10-85
7
STRUCTURE AND FUNCTION HYDRAULIC PIPING
HYDRAULIC PIPING (Steering and hoist)

1. R.H. steering cylinder

2. Hydraulic and steering pump
(SAR(3)-063+050)
3. R.H. hoist cylinder
4. L.H. hoist cylinder
5. Hydraulic tank
6. Slow return valve
7. Hoist control valve
8. Demand valve
9. L.H. steering cylinder
10. Steering valve
10-85-1 HD325-6
7
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM (Steering and hoist)
1. Hydraulic tank 9. Hoist valve

2. Hydraulic pump (SAR(3)-063+050) 9A. Spool
3. Check valve 9B. Relief valve
4. Demand valve 10. Slow return valve
4A. Demand spool 11. Hoist cylinder
4B. Check valve 12. Oil filter
4C. Relief valve 12A. Bypass valve
5. Steering valve 13. Breather
7. Steering cylinder
8. Emergency steering circuit
8A. Emergency steering pump (SAL(1)-014)
8B. Check valve
10-86 HD325-6
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT SCHEMATICS
HYDRAULIC CIRCUIT SCHEMATICS

(Engine at “LOW” idle, hoist lever in “HOLD”, steering wheel in “NEUTRAL”.)
HD325-6 10-87
STRUCTURE AND FUNCTION DUMP BODY CONTROL
DUMP BODY CONTROL

HD325-6 : Serial No. 5680 – 6000
HD325-6W : Serial No. 5706 – 6000
HD405-6 : Serial No. 1055 – 2000
1. Rod OUTLINE
2. Cable (for hoist control) The hoist control lever and hoist control valve are
3. Hoist control lever connected by a mechanical control system con-
4. Hoist valve sisting of a push-pull cable.
5. Body positioner This control system is equipped with a body
6. Cable (for body positioner) positioner, so when the body is rising, the
7. Hoist cylinder positioner is automatically actuated when the
body reaches the position set for the positioner.
10-88 HD325-6
7
STRUCTURE AND FUNCTION DUMP BODY CONTROL
DUMP BODY CONTROL

1. Rod OUTLINE
2. Cable (for hoist control) The hoist control lever and hoist control valve are
3. Hoist control lever connected by a mechanical control system con-
4. Hoist valve sisting of a push-pull cable.
5. Body positioner This control system is equipped with a body
6. Cable (for body positioner) positioner, so when the body is rising, the
7. Hoist cylinder positioner is automatically actuated when the
body reaches the position set for the positioner.
HD325-6 10-88-1
7
STRUCTURE AND FUNCTION HYDRAULIC TANK, FILTER
HYDRAULIC TANK, FILTER

HD325-6 : Serial No. 5680 – 6000
HD325-6W : Serial No. 5706 – 6000
HD405-6 : Serial No. 1055 – 2000
1. Filter element
2. Bypass valve
3. Breather
4. Oil filler cap
5. Hydraulic filter
6. Transmission filter
7. Transmission filter
8. Sight gauge
9. Drain plug
HD325-6 10-89
7
STRUCTURE AND FUNCTION HYDRAULIC TANK, FILTER

1. Filter element
2. Bypass valve
3. Breather
4. Oil filler cap
5. Hydraulic filter
6. Sight gauge
7. Drain plug
10-89-1 HD325-6
7
STRUCTURE AND FUNCTION DEMAND VALVE
DEMAND VALVE
1. Spool return spring 7. Main relief valve spring a: From hydraulic pump (P2 port)
2. Demand spool 8. Pilot poppet b: From steering pump (P1 port)
3. Check valve 9. Pilot poppet spring c: To hoist control valve (PH port)
4. Check valve spring 10. Lock nut d: From emergency steering pump
5. Valve body 11. Adjustment screw (PE port)
6. Main relief valve e: To tank (PT port)
f: To steering control valve (PST port)
10-90 HD325-6
STRUCTURE AND FUNCTION DEMAND VALVE
FUNCTION
l The flow of oil from the steering pump and
hydraulic pump differs according to the en-
gine speed (pump delivery volume). The flow
control valve acts to divide the oil and send it
to the steering circuit and hoist circuit.
OPERATION To steering
control valve
1. Engine running at low speed
l The oil from the steering pump enters port
A. The oil from the hydraulic pump en-
ters port B, but demand spool (2) is closed,
so it pushes open check valve (3) and
flows to port A. Here it joins with the flow
of oil from the steering pump.
At the same time, oil passing through ori-
fice a of demand spool (2) enters port C.
As a result, the oil from the steering pump
and hydraulic pump all flows to the steer-
ing control valve.
t?I SWH00793
To steering
2. Engine running at mid-range speed
control valve
l The oil from the steering pump enters port
A. The oil from the hydraulic pump en-
ters port B, pushes open check valve (3)
and enters port A. Here it joins with the
flow of oil from the steering pump.
As the oil pressure to the steering circuit
rises, the pressure of the oil passing
through orifice a of demand spool (2) and
entering port C also rises.
When the pressure at port C becomes
greater than the force of spring (I), de-
mand spool (2) is pushed to the left in the
direction of the allow (*I, and port B and
port D are opened.
As a result, part of the oil from the hy-
draulic pump flows from port D directly
to the hoist circuit.
All the oil from the steering pump and the
t?l SWH00794
remainder of the oil from the hydraulic
pump flows to the steering circuit.
HD325-6 1o-91
STRUCTURE AND FUNCTION DEMAND VAVLE
3. Engine running at high speed To steering

control valve
l More oil from the steering pump and hy-
draulic pump flows to port A and port B.
Because of this, the pressure at port C
rises higher, and demand spool (2) is
moved further to the left in the direction
of the arrow (-1.
As a result, all the oil from the hydraulic
pump and part of the oil from the steer-
ing pump flows to the hoist circuit.
1 O-92 HD325-6
STRUCTURE AND FUNCTION DEMAND VAVLE
STEERING RELIEF VALVE
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring 56OBFO69
5. Adjustment screw
FUNCTION
l The steering relief valve is inside the demand
valve.
When the steering cylinder reaches the end
of its stroke or when abnormal pressure gen-
erated, the oil sent from the pump is relieved
through this valve.
This prevents damage to the pump and other
parts. (It sets the maximum pressure of the
circuit.)
56OEFO70
3
OPERATION
. Port A is connected to the pump circuit, and
port C is connected to the tank drain circuit.
The oil passes through the orifice of main
valve (I) and fills port B.
Pilot poppet (3) is seated in valve seat (2).
When the pressure at port A and B reaches
the force set by the poppet spring (set pres-
sure), pilot poppet (3) opens. The pressure at
port B escapes from port D to port C, and the 56OBFO71
pressure at port B drops.
l When the pressure at port B drops, a pres-

sure difference is formed between port A and
B due to the orifice of main valve (I). Main
valve (I) is pushed open by the pressure at
port A, and relives the oil at port A.
56OBFO72
HD325-6 1o-93
STRUCTURE AND FUNCTION STEERING CONTROL VALVE
STEERING CONTROL VALVE
6
2
10
11
b’
5
12
6
7 13
14
A-A
569F05045-K
1. Input shaft 8. Ball a: From demand valve (P port)

2. Upper cover 9. Torsion bar b: To tank (R port)
3. Valve spool 10. Link c: To steering cylinder (RT port)
4. Housing 11. Sleeve d: To hoist valve (AUX port)
5. Ball 12. Rotor e: To steering cylinder (LT port)
6. Stator 13. Manifold
7. Lower cover 14. Commutator
1o-94 HD325-6
OPERATION
1. When steering is at neutral
. The oil from the pump passes through the de-

mand valve and enters port A of the steering
valve.
When this happens, the steering is at neutral,
so valve spool (3) does not move. As a result,
all ports to the steering cylinders are closed,
and no oil flows to the cylinders.
Ports H and J, and port I are open, so the oil
from the pump all flows to the hoist control
valve.
HD3256 1o-95
2. Steering to right
(When steering wheel is turned to the right)
valve
Demand
valve
SWH00797
l When the machine is steered to the right cylinders. As a result, the two steering cylin-
(when the steering wheel is turned to the ders are actuated, and the wheels turn to the
right), valve spool (3) moves down. right.
When this happens, the oil from the pump l The return oil from the steering cylinder flows
flows from port A through port B and enters from port C through port D and port E, and
the metering positions (6, 12). Here the flow return to the tank.
of oil to the steering cylinders is measured, l The oil remaining in the steering circuit en-
and it then passes through the steering valve. ters port I from port J and flows to the hoist
From here it flows from hole a of valve spool control valve.
(3) through port G and goes to the steering
1 O-96 HD325-6
3. Steering to left
(When the steering wheel is turned to the left.)
l When the machine is steered to the left (when port C and flows to the steering cylinder.
the steering wheel is turned to the left), valve As a result, the two steering cylinders are ac-
spool (3) moves up. tuated, and the wheels turned to the left.
When this happens, the oil from the pump l The return oil from the steering cylinderflows
flows from port H through hole a, passes from port G through port F and port E, and
through the steering valve and enters the return to the tank.
metering portions. . The oil remaining in the steering circuit en-
Here the flow of oil to the steering cylinder is ters port I from port H and flows to the hoist
measured, and it then flows from port B to control valve.
HD325-6 1o-97
STRUCTURE AND FUNCTION CROSS-OVER RELIEF VALVE
CROSS-OVER RELIEF VALVE
F56903188A
1. Valve body a: To steering cylinder

2. Valve seat b: To steering cylinder
3. Relief valve c: To steering cylinder
4. Valve spring d: To steering cylinder
5. Sleeve e: To steering control valve
6. Adjustment screw f: To steering control valve
7. Lock nut
1 O-98 HD325-6
STRUCTURE AND FUNCTION HOIST VALVE
HOIST VALVE
I 2 3
566FO6039
1. Main relief valve A: To hoist cylinder
2. Lever B: To hoist cylinder
3. Spool P: From demand valve
4. Valve body T: To tank
5. Check valve
6. Detent
HD325-6 1o-99
STRUCTURE AND FUNCTION DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB

HD325-6
HD325-6W
HD405-6
* For details of this page, see Section 90. (l/3 - 3/3)
10-100 HD325-6
0
STRUCTURE AND FUNCTION DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB
DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB

HD325-6
HD325-6W
HD405-6
* For details of this page, see Section 90. (l/2 - 2/2)
::
10-101
0
STRUCTURE AND FUNCTION FRONT BRAKE CUT-OFF VALVE
FRONT BRAKE CUT-OFF VALVE
4 8
5 9
6 10
Wiring diagram
SVH0067tl
1. Coil cover A: Inlet port FUNCTION

2. Plunger B: Outlet port . This valve is installed in the pilot circuit be-
3. Coil assembly C: Exhaust port tween the brake valve and relay valve. It is
4. Core used to cancel the actuation of the front brake
5. Rod according to the travel conditions.
6. Body When the front brake OFF switch in the
7. Connector operator’s compartment is pressed, current
8. Valve body flows in the coil of the solenoid valve, and
9. Valve the solenoid valve is actuated. When this
IO. Spring happens, the circuit from the brake valve to
the front brake relay valve is shut off, and the
front brake is released.
10-102 HD325-6
STRUCTURE AND FUNCTION OVERRUN PREVENTION VALVE, EXHAUST BRAKE VALVE
OVERRUN PREVENTION VALVE

EXHAUST BRAKE VALVE
r~--fT%Y%
Structure of circuit
SVH00679
1. Core A: Input port FUNCTION

2. Coil assembly B: Output port . The input port and output port are connected
3. Spring C: Exhaust port by passing electricity through the coil of the
4. Plunger solenoid valve.
5. Valve seat In this way, the overrun prevention solenoid
6. Rod or exhaust brake are actuated.
7. Valve
8. Spring
9. Body
10. Connector
HD325-6 10-103
STRUCTURE AND FUNCTION HORN VALVE, WIPER SWITCH
HORN VALVE
HD325-6 : Serial No. 5680 – 6000
HD325-6W : Serial No. 5706 – 6000
HD405-6 : Serial No. 1055 – 2000
FUNCTION
When the horn button on the steering wheel is
pressed, the electric circuit is closed and electric-
ity flows to the coil to form an electromagnet that
raises the piston.
Compressed air then flows to sound the horn.
1. Coil assembly
2. Core
3. Plunger
4. Filter
5. Terminal
WIPER SWITCH
1. Ball FUNCTION
2. Spring • This switch is used to actuate the wiper and
3. Terminal base washer.
4. Ball Turn the knob to actuate the wiper, and press
5. Rotor the knob to actuate the washer.
7. Shaft
8. Knob
10-104 HD325-6
7
STRUCTURE AND FUNCTION WIPER RELAY
WIPER RELAY
---
-___-__-
________-_____-------~~~~--~- Wiper relay
1 2
n I
m
A-J 0
r-------? p
_-_-- 5H2
&II
L_
r’ Circuii diagram
Washer motor
b b
24V
SWH00806
1. Case FUNCTION
2. Bracket . This relay is used to give intermittent opera-
3. Terminal tion of the wiper and interconnected opera-
tion of the washer.
OPERATION
Intermittent operation:
When the wiper switch is turned ON, the wiper
is actuated to give the following movement.
Out-back-pause 5:: sec.
Interconnected operation of washer:

When the washer switch is turned ON, the
wiper is actuated to after a delay of 0.5 * 0.3
seconds, and when the washer switch is
turned OFF, the wiper is operated a further 3
+_ 1 times, and then stops.
HD325-6 10-105
STRUCTURE AND FUNCTION AIR CONDITIONER
AIR CONDITIONER
PIPING DIAGRAM
HD325-6
HD325-6W
HD405-6
4
SVH00436
1. Hot water take-off port HEATING

2. Vent . Heating is carried out using the cooling wa-
3. Air conditioner unit ter from the engine.
4. Compressor High-temperature cooling water from the hot
5. Pressure switch water take-off port flows to the air conditioner
6. Receiver dryer unit, and hot air is blown out by a fan.
7. Condenser When the temperature of the cooling water
8. Hot water return port drops, it is returned to the hot water return
port and flows as cooling water for the en-
gine.
FUNCTION
. The air conditioner makes a pleasant operat- COOLING
ing environment for the operator and acts to l The refrigerant gas compressed and pressur-
reduce fatigue. ized by the air conditioner compressor enters
the air conditioner condenser where it is
cooled by dissipating the heat. It then enters
the air conditioner unit and cold air is blown
out by the fan. When the temperature of the
refrigerant gas rises, it is retuned to the com-
pressor.
lo-106 HD3256
0
AIR CONDITIONER
ELECTRICAL CIRCUIT DIAGRAM
HD325-6
HD325-6W
HD405-6
Pressure switch
ET3
1__1
-Main harness inside cab
CN JO2
I
Compressor N :
ff
INSIDE CAB
-;
- 7
- 6
-9
L--R==
GNO
Servomotor
Servomot--
I Airconditioner controller panel

I
SVH00681
lo-108 HD325-6
0
ay
Blower relay
(Hi)
Blower r clay
(Ml
ComPressor clutch relay
Blower
motor
resistor
servo motor
Airconditioner unit
L______________
SVH00682
HD3256 10-109
REFRIGERANT CIRCUIT DIAGRAM
:
-
I
r
I-. -7
I-
Condenser
-
I-
:
/.I
ComPressor
I
-
5 t
I
Enaine
/,
Receiver dryer
SVH00683
10-110 HD325-6
UNIT
HD325-6
HD325-6W
HD405-6
1. Evaporator
2. Core
3. Blower motor
A. Hot water take-off port

B. Hot water return port
C. Refrigerant gas inlet port
D. Refrigerant gas outlet port
E. Dehumidifier water drain port
2
B
3 -1
3
SVH00438
RECEIVER DRYER
1. Body
2. Sight glass
3. Dryer
4. Dryer
423F633
HD325-6 10-l11
0
CONDENSER
1. Fin
2. Tube 561 FO3103
A. Refrigerant gas inlet port

B. Refrigerant gas outlet port
COMPRESSOR
9 ?
R \ /
1. Clutch
2. Case
A. Suction service valve

B. Discharge service valve
SPECIFICATION
561FO3104
Type: Piston type, 2-cylinder
10-112 HD325-6
STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM
ENGINE CONTROL SYSTEM

HD325-6 : Serial No. 5680 – 6000
HD325-6W : Serial No. 5706 – 6000
HD405-6 : Serial No. 1055 – 2000
1. Rod
2. Fuel injection pump
3. Rod
4. Engine stop motor
5. Accelerator sensor
6. Accelerator pedal
HD325-6 10-113
7
STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM

1. Accelerator sensor
2. Supply pump
3. Engine controller
4. Speed sensor
5. Engine harness
6. Accelerator pedal
10-113-1 HD325-6
7
STRUCTURE AND FUNCTION EXHAUST BRAKE
EXHAUST BRAKE
SYSTEM DIAGRAM
1. Exhaust brake 9. Exhaust brake OUTLINE

switch switch The exhaust brake shuts off the exhaust pipe at
2. Toque converter 10. Brake valve the exhaust brake cylinder and makes the engine
lockup valve 11. Accelerator sensor exhaust stroke act as an air compressor to in-
3. Brake switch 12. Pilot lamp crease the effect of the braking force of the en-
4. Retarder switch 13. Retarder control lever gine. The exhaust brake is also is also used as a
5. Exhaust brake 14. Exhaust brake retarder when traveling downhill. The exhaust
solenoid valve cylinder brake is actuated by a signal from the transmis-
6. Transmission 15. Battery relay sion controller, and acts as follows when the ex-
controller 16. Battery haust brake switch in the operator's compartment
7. Relay is turned ON or OFF.
8. Engine controller
ON position : Actuated when the accelerator
pedal is released (but only when
the torque converter is in the
lockup condition)
OFF position : Actuated when the foot brake or
retarder brake are operated (but
only when the torque converter is
10-114 HD325-6
SYSTEM DIAGRAM
HD325-6
HD325-6W
HD405-6
ACCELERITOR
SERSDR RHEOSTAT TORQUE
Y
;
0 - II I TRANSMISSION CONTROLLER ]
- ELECTRIC
EXHAUST ~~~;;"I" AIR TANK - AIR

BRAKE
CYLINDER SWHOO809
HD325-6
OPERATION
. Operating condition of exhaust brake
The exhaust brake is driven according to the
signal from the transmission controller, and
it operates as follows when the exhaust brake
switch in the operator’s cab is turned ON and
OFF.
ON position : The exhaust brake operates

when the accelerator pedal is
released (while the torque con-
verter is locked up, however)
OFF position : The exhaust brake operates
when the foot brake or retarder
brake is operated (while the
torque converter is locked up,
however)
. Exhaust brake ON
If the drive current flows from the transmis-
sion controller to the solenoid valve, the lat-
ter operates.
If the solenoid valve operates, the port to be
exhaust brake cylinder opens, then the com-
pressed air flows from the air tank.
The exhaust brake cylinder is operated by the
compressed airto close the exhaust pipe, and
the exhaust brake operates.
V
Air tank
To exhaust
Pipe SEH00343
. Exhaust brake OFF

If the drive current flows from the transmis-
sion controller to the solenoid valve is turned
off, the solenoid valve closes the port to the
exhaust brake cylinder, and opens the port
from the exhaust brake cylinder to the exhaust
pipe.
The compressed air in the exhaust brake cyl-
inder is discharged into the atmosphere, and
the exhaust brake cylinder is returned to the turbocharger
original position by the spring in it, then the
exhaust brake is released.
V Air tank
To exhaust
pipe SEH00344
lo-116 HD325-6
STRUCTURE AND FUNCTION AUTOMATIC RETARD SPEED CONTROL SYSTEM
AUTOMATIC RETARD SPEED CONTROL SYSTEM

SYSTEM DRAWING
HD325-6
HD325-6W I 2
HD405-6
\ /
SVH00440
1. Pressure switching valve OUTLINE

2. Pressure control valve ARSC stands for Automatic Retard Speed Con-
3. System switch trol. It has the following features.
4. ARSC set switch . With this system, when traveling downhill, the
5. Set travel speed display retarder is automatically actuated to maintain
6. READY lamp the travel speed previously set by the opera-
7. ARSC caution lamp tor.
8. Automatic retard speed controller . In this way, the operator can travel downhill
safely without operating the retarder lever,
and this reduces the operating load on the op-
erator.
HD325-6 10-117
0
AASC CAUTION LAMP
RETARDER LEVER
Front brake switch input

.
Rear brake switch inwt

Brake coolins oil
CONTROLLER READY LAMP
Digital input
Digital input
ARS brake input
. I
RETARD OIL
SHIFT LEVER Analog input
POSITION . TEXP SENSO
E/G SPEED
Speed pulse sional Exhaust brake switch input- Brake collino
oi I.
*
SETTING SPEED
EXHAUST SOLENOID i--- ----’
+2,V RESISTOR
I---------
& n---J-b------

HD325-6
HD325-6W
HD405-6
Ir For details of this page, see section 90.
HD325-6
AIR CIRCUIT DIAGRAM
_-__-__-
:
, RETARDER PILOT '
,
-__ J
__JL____&-_____
I -7
/ ----
CAB
SWHOO831
10-120 HD325-6
AUTOMATIC RETARD SPEED CONTROL

1. Basic operations
listed above, the ARSC controller receives
Setting of downhill travel speed by operator,
various types of signal inputs, processes
display
them inside the CPU, and outputs various
Judgement of machine condition (empty/
types of signals.
loaded)
2) System switch
Control of set speed travel at near set travel
This is used to turn the ARSC system ON/
speed
OFF.
Detection of overheating of retarder oil, de-
3) ARSC set switch
celeration control
This switch is used to set or change the
Self-diagnostic function and recording of er-
downhill travel speed.
ror codes in memory
When this switch is turned ON, the travel
(1) Setting of downhill travel speed by opera- speed at that moment is set as the set
tor, display
speed. By tapping up, the speed is in-
It is possible for the operator to set the
creased by 1 km/h; by tapping down, the
downhill speed in units of 1 km/h within a
speed is decreased by 1 km/h; and by can-
range of 10 km/h - 55 km/h.
celing, the system is set so that there is
The set travel speed is displayed on the
no set travel speed.
set travel speed display.
4) Set speed display
(2) Judgement of machine condition This displays the set travel speed. The
(empty/loaded)
display goes out when the system switch
It detects the suspension pressure (front
is turned OFF.
or rear, left and right) and judges if the
5) ARSC caution lamp
machine is empty or loaded. It carries out
This flashes if there is any abnormality in
retarder control according to the machine
the ARSC system when the system switch
condition.
is ON.
(3) Control of set speed travel (Special caution lamp for ARSC)
If the downhill travel speed exceeds or is
6) READY lamp
about to exceed the set travel speed, the
This lamps shows that the travel speed is
retarder is automatically actuated to con-
set and that operation of the ARSC is pos-
trol to a constant travel speed near the set
sible.
travel speed.
7) Pressure switching valve
(41 Detection of overheating, deceleration
This valve supplies air to the pressure con-
control in
trol valve. If there is any abnormality
If the retarder oil is about to overheat, a
the system, it cuts the supply of air to the
caution is issued and the set travel speed
pressure control valve.
is automatically reduced by 1 km/h at a
(It is actuated by a command from the con-
time.
troller.)
(5) Self-diagnostic function
8) Pressure control valve
The system is observed by a controller,
This valve is actuated by a command from
and if abnormality occurs in the system,
the controller, and controls the retarder.
it lights up a lamp and sounds the buzzer
to warn the operator. It displays an error
code and saves it to memory, and finishes
the system.
2. Structure of system
. The basic system for the ARSC consists of the
controller, switches, relays, lamps, displays,
and other electrical components, and the pres-
sure control valve and pressure switching
valve.
I) ARSC controller
In order to provide the basic functions
HD325-6 10-121
AUTOMATIC RETARD SPEED CONTROLLER
SVH00446
1. Self-diagnostic display window FUNCTION

2. Printboard To maintain the set speed obtained from the data
3. Connector from the ARSC set switch, it sends a signal to the
4. Connector pressure control valve and actuates the retarder.
5. Connector
6. Case
10-122 HD325-6
STRUCTURE AND FUNCTION AUTOMATIC SHIFT CONTROLE SYSTEM
AUTOMATIC SHIFT CONTROL SYSTEM

(Transmission control system with all electronic modulation)
HD325-6
HD325-6W
HD405-6 Machine monitor Panel
SYSTEM DIAGRAM
Network
sional
I
&Mode selection dimlay
I.Swsd diwlar
2.Encine soeed disrlar
3.9hlft limit dlr,Ibr
4.Shift position dltolar
6.Smed range dlr,lar
6.Lock-up diwlu
7.Automtic #ear shlftlwchatronictt I4.Caution/PiIot law outvut
abnormalitr dsaplar
detection sionalfH.L.1.2.3.4.R.)
Transmission
modulatino valve
a- C
Act
Stating
ewi tch
Transmission Transmission
shift controller
&57
rl
Self-diannostic
display ILock-up
solenoid control
Diff. lock sianal (OPT

- Heater relay signal c
* Inclination s’onal c t--- Sensorsffor Panel display)
/ \
Rodv SinnaL 1. Air Pressure
NoPer) 2. Coolant temperature
(for electronic sovernor only)
3.Toroue converter oil temoerature
:: ;$rder oi I temperature
6.Steerina oil temperature

l.Transmission oil filter sensor
&Brake chamber stroke
9.Radiator coolino water level
IO. Engine oi I Pressure
(for electronic sovernor only)
SVH00690
HD325-6 lo-123
OUTLINE
The automatic shift control system receives the
shift lever position signal, accelerator pedal ac-
celeration signal, transmission speed signal, and
signals from other switches and sensors are re-
ceived, and the shift controller acts to automati-
cally control the shift of the transmission to the
optimum speed range. The shift controller also
drives and controls the torque converter lockup
solenoid and overrun prevention solenoid valve
in addition to the shift control. Each clutch in the
transmission is equipped with an electronically
controlled modulation valve, and each clutch is
independently controlled.
In this way, the initial pressure for each clutch,
build-up ratio, and torque-off time are controlled
. to match the condition of the machine (the hy-
draulic wave pattern for each clutch, each accel-
eration angle, each shift up, and each shift down
are changed). As a result, it contributes to the
reduction of shock when shifting gears, preven-
tion of shift hunting, and improvement in the du-
rability of the clutches.
The transmission controller also receives the sig-
nals from the switches and sensors in order to
drive the displays, cautions, and pilot lamps on
the machine monitor panel, and sends these data
to the network.
lo-124 HD325-6

* For details of this page, see section 90.
- .A
HD325-6
TRANSMISSION CONTROLLER
HD325-6
HD325-6W
HD405-6
1. Self-diagnostic display window 4. Printboard

2. Connector 5. Model selection switch (rotary switch 1)
3. Case 6. Network connection switch (rotary switch 2)
OUTLINE
• This transmission controller is designed to 4. Speed sensors are located at three points
control the system, so it has a built-in com- (transmission input shaft, intermediate shaft,
puter. and output shaft) to make it possible to de-
It has the following features and functions. tect any slipping of the transmission clutches.
1. It has a high-power mode and economy mode It also acts to protect the transmission when
and it changes the shift pattern. (Machines there is any abnormality in the hydraulic sys-
not equipped with an electronic governor tem.
have only the high-power mode.) 5. It is connected to the network and makes vari-
2. The braking mode is the mode when the brake ous data common with other controllers.
is used. The gear shifting point is raised and 6. It receives the input of model selection data
the brake cooling pump speed is also in- (what machine the controller is mounted on)
creased to improve the cooling effect for the and network data (what controller is con-
retarder. At the same time it also enables the nected to the network), and contacts the other
braking force of the engine to be used effec- controllers through the network. (For details
tively. of the method of setting, see TESTING, AD-
3. It drives and controls the torque converter JUSTING, AND TROUBLESHOOTING.)
lock-up solenoid valve, overrun prevention so- 7. It has finely divided self-diagnostic functions
lenoid valve, exhaust brake solenoid valve, for both the input and output systems.
and BCV solenoid valve. 8. The content of the self-diagnostic display is
shown with 2-digit numbers.
10-126 HD325-6
C
9. When any failure is detected, it sends details

to the network, and displays this on the other
display panels.
10. The content of the self-diagnosis is recorded
in memory, so even when the main switch is
turned off it is possible to check details of fail-
ures.
11. It sends the trouble data to the network, and
displays this on the other display panels.
12. The location of any existing failure is dis-
played on the monitor panel.
13. It has an emergency travel function for use if
there is any failure in the electrical system.
14. It is located separately from the gearshift le-
ver.
HD325-6 lo-127
CONNECTOR SIGNALS
HD325-6
HD325-6W
HD405-6
ATCI ATC3A ATC4 ATC5A
41 -
5 1Throttle correction 6 Transmission filter clogging

7 I -
10 Emergency escape switch

11 I Steerinq oil temperature
191 -
20 I -
ATC2 ATC3A ATC5B
11 Accelerator angle
12 1Enqine oil pressure
1131 - I
15 I Coolina water
I
levell
16 1Mode switch
20 1 -
21 I GND
lo-128 HD325-6
0
SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES

HD325-6
HD325-6W
HD405-6
The automatic gear shifting ranges for each posi- Mode Setting conditions
tion of the gearf shift lever are as shown in the
table below. When either of the following
conditions are satisfied.
Braking 1. Rear brake signal ON
Speed range mode (foot brake, retarder, or emer-
gency brake applied)
2. Accelerator pedal released.
When the following three condi-

tions are satisfied.
1. Rear brake signal OFF
High-power
(foot brake, retarder, or emer-
mode
qency brake not applied)
2. Acceierator pedal depressed.
3. Economy mode switch off
When the following three condi-

Economy mode tions are satisfied.
(only machine 1. Rear brake signal OFF
equipped with (foot brake, retarder, or emer-
electronic gency brake not applied)
governor) 2. Accelerator pedal depressed.
3. Economy mode switch off
Braking mode:
The shift-down point and shift-up point are both
raised, and the engine speed is kept higher to
ensure the amount of oil for retarder cooling, and
to increase the effect of using the engine as a
brake.
High-power mode:
The mode is aimed at providing maximum pro-
duction by using the machines power to its ut-
most limit. However, when the machine load is
Characteristics of gear shifting light (high acceleration), such as when the ma-
The shifting up or down of the transmission is chine is traveling empty, the machine accelera-
carried out according to the shift map stored in tion is detected and the gear is shifted up early to
the memory of the controller. improve the acceleration. It uses an acceleration
There are three types of shift map according to sensing shift point to improve fuel consumption,
the condition of the input signals (for machines noise, and shock when shifting gear.
mounting an engine with mechanical governor,
there are two types, excluding economy mode). Economy mode:(only machine equipped with
The settings for each mode are as shown in the electronic governor)
following table. When the machine is being used under light load,
such as when traveling empty or when traveling
on flat ground, the shift-up point and shift-down
point are made lower to keep the engine speed
low, thereby improving fuel consumption, noise,
and shock when shifting gear. In this mode, the
engine output is kept to 85% of the maximum en-
gine output.
HD325-6 lo-129
0
AUTOMATIC GEAR SHIFTING LINE

GRAPH
Automatic shifting method
HD325-6
(1) Shift lever at D posjtion
HD325-6W
When shifting up (in high power mode)
HD405-6
i) If the shift lever is set to the D position,
. the transmission enters the F2 torque con-
The shift up/shift down points, torque con-
verter range.
verter lock-up ON/OFF points, and automatic
ii) When the accelerator pedal is depressed,
brake ON/OFF points in each mode are asseen
the engine speed rises and the machine
in the chart below.
Auto Auto accelerates. If the transmission input shaft
brake Shift brake
Shift down OFF up ON speed reaches 1500 rpm, the lock-up
clutch is engaged and the torque con-
verter is directly connected to give direct
Braking
mode
travel.
iii) If the speed increases further, and the en-
gine speed reaches 2,100 rpm, the trans-
mission shifts up to F3.
At the shift-up point, the lock-up clutch is
automatically disengaged momentarilyto
reduce the transmission shock.
iv) Immediately after shifting up, the engine
speed will drop, but as the machine ac-
celerates, it will rise again. In the same
way as in Step iii) above, the transmis-
sion will shift up to F4 - F7 in turn.
Transmission input shaft speed (rpm) When shifting down (in high power mode)
4 When the load increases and the engine
speed drops below 1400 rpm, the speed
Note: range is reduced by one level.
1. In high power mode, the shift down point from (For example, when traveling in F6, the
F2 to Fl is 1325 rpm. transmission is shifted down to F5.)
2. Lock-up ii) If the machine decelerates further, the
The lock-up is not actuated when travel-
l
speed range will be shifted down in turn
ing in reverse. to F2. If the engine speed goes down to
When reducing speed naturally (releasing
l
1100 rpm in F2, the torque converter lock-
the accelerator pedal but not applying the up clutch is disengaged and the transmis-
brake), the lock-up remains ON up to F4, sion shifts to torque converter drive.
but at F3 or below, the lock-up remains
OFF. t The set speeds and actuation conditions
When the accelerator
l pedal is released in the above explanation may differ ac-
and the machine starts to travel downhill, cording to the travel conditions. For de-
the lock-up is not engaged until the accel- tails, see the Automatic gearshifting chart.
erator pedal is depressed or the brake is
applied.
10-130 HD325-6
0
(2) Shift lever at 5, 4, 3, or L position Safety functions

These positions give an automatic shift range 1) Down-shift inhibitor function
from Fl to F5 (F4, F3, or F2). The method for When the gear shift lever is operated during
automatic shifting is the same as when the travel from D to 5 - L, from 5 to 3 - L, from
shift lever is at the D position. 4 to L, or from 3 to L:
(3) Shift lever at R position For example, when traveling at position D (F7),
This is the position for traveling in reverse. and the shift lever is moved to position 5, the
The lockup is not actuated. transmission is not shifted directly from F7 to
The safety functions when traveling in reverse F5. It is shifted down F7 to F6 to F5 in turn
are the FORWARD/REVERSE inhibit and RE- according to the engine speed.
VERSE safety, and if the operation is not cor- (The engine overrun prevention circuit pre-
rect, the transmission is held in neutral vents the transmission from shifting down
(4) Shift lever at N position two gears at a time when the operator shifts
This is the neutral position. None of the down too far by mistake.)
clutches in the transmission are actuated. 2) Neutral safety function
If the shift lever is in any position other than
N, this circuit prevents the engine from start-
Gearshifting time lag ing even when the key switch is turned to the
In the automatic shift range, to prevent any START position.
misoperation caused by excessive change in the (The safety circuit prevents the machine from
rotating speed when shifting gear, there is a moving off by mistake when the engine is
gearshifting time lag, and the transmission will sta rted . )
not shift during this time. 3) FORWARD/REVERSE inhibitor function
The length of the gearshifting time lag is con- When the machine is traveling forward at
trolled by the individual electronically controlled more than 4 km/h, the transmission will not
modulation system, which controls each enter in the R position by mistake.
gearshifting pattern in fine detail. (This improves durability and reliability by
The following table gives an outline of the preventing any excess load on the power
gearshifting pattern and the gearshifting time lag. train.)
4) Rear brake function to prevent overrun of
power train
If the engine speed goes above 2,500 rpm, the
Geashifiting Example geashifiting central warning lamp flashes and the alarm
Geashifiting Tme lag
pattern (m :geashifiting time lag) buzzer sounds.
I (see) I If the engine speed goes above 2,600 rpm, the
rear brake is automatically applied.
(This is to prevent overrun of the engine,
torque converter, and transmission, and to
improve the durability and reliability.)
5) REVERSE safety
The machine will not travel in reverse if the
dump lever is not at FLOAT. (Roll-over pre-
vention function)
6) Speed range limit with dump body raised
If the dump body is not seated properly, such
as when it has not been fully lowered after
dumping the load, the shift-up function is re-
stricted: when the shift lever is at D, the ma-
chine will start in F2; when the shift lever is at
5,4,3, or L, the machine will start in Fl. The
transmission will not shift up until the dump
body is properly seated.
HD325-6 10-131
SHIFT LEVER SWITCH

HD325-6
HD325-6W
HD405-6
r ----
A-A 561FO3119
1. Lever FUNCTION
2. Detent When the operator moves the lever to select the
3. Lock button travel conditions, such as FORWARD or REVERSE,
4. Screening plate electric signal is sent to the shift controller. The
5. Photo interruptor lever position is displayed on the indicator (with
night lighting) to the left of the shift lever.
The shift position is also displayed on the moni-
tor panel.
In addition, to prevent mistaken operation, the
gear shift lever is fitted with a lock button.
10-132 HD325-6
0
FILL SWITCH
7h-
SVH00695
1. Terminal FUNCTION
2. Case This switch is installed to the side face at the flow
3. Nut sensor valve end of the ECMV. When the clutch
4. Connector is engaged, the end face of the spool contacts the
terminal of the switch and turns the switch ON.
The fill completed signal is then sent to the shift
controller.
ACCELERATOR SENSOR
: (VI
2 I
:
> 4.4
Q%P
w a
3
Z
2- 0.4 1‘-----,
Lou idling Ful Ie
Output characteristics
SWH00812
1. Connector FUNCTION
2. Lever The accelerator sensor is installed at the bottom
3. Body of the operator’s cab, and the accelerator pedal
4. Potentiometer and sensor are connected by a link. When the
5. Coupling accelerator pedal is depressed, the movement is
6. Shaft transmitted through the link to rotate the shaft of
7. Stopper the potentiometer inside the accelerator sensor,
and the resistance value changes. A certain volt-
age is impressed between pins (I) and (3) of the
potentiometer, and a voltage signal correspond-
ing to the amount the accelerator pedal is de-
pressed is sent to the controller from No. 2 pin.
10-134 HD325-6
MODE SELECTOR SWITCH

HD325-6
HD325-6W
HD405-6
Layout of terminals
s ‘5
f The shift limiter switch and mode selector

switch differ only in the color of the actuaion display lamp.
Shift limiter switch:Red
Mode selection switch:Green
1. Knob 4. Connector ,
2. Body 5. Spring SVHOO699
3. Spring 6. Spring
OUTLINE
Mode selector switch Shift limit switch (Reference only)
. This switch is installed on the top surface of . This switch is installed at the rear of the shift
the console, and it is used to change the out- lever switch. When the shift lever is in the D
put characteristics of the engine and the gear or L range, it controls the speed ranges that
shifting map of the transmission to match the are covered by automatic gear shifting.
setting of the course and the conditions of the This switch is very effective if used when go-
jobsite. ing downhill or when working in jobsites
where there are speed limits.
SELF-DIAGNOSTIC FUNCTION
HD325-6
HD325-6W
HD405-6
The controller carries out self-diagnosis of the plays the user code on the monitor panel.
system and displays and records any abnormal- In some cases, the mechatronics abnormality dis-
ity. The abnormality display shows a 2-digit code play, the warning lamp, and alarm buzzer are also
with LEDs. If it detects an abnormality, it trans- actuated.
mits the abnormality data to the networkand dis-
HD325-6 10-135
0
STRUCTURE AND FUNCTION AUTOMATIC EMERGENCY STEERING SYSTEM
AUTOMATIC EMERGENCY STEERING SYSTEM

SYSTEM DIAGRAM
HD3256
HD325-6W
HD4056
SVH00449
1. Emergency steering pump OUTLINE

2. Hydraulic tank If the engine should stop when the machine is
3. Demand valve traveling, or there is any abnormality in the hy-
4. Check valve draulic pump and the specified amount of oil does
5. Steering pump not flow to the steering circuit, the emergency sys-
6. Flow switch tem automatically actuates an electric pump to
7. Emergency steering switch ensure the hydraulic pressure for the steering,
8. Timer thereby making it possible to use the steering.
9. Emergency relay switch This system can also be operated manually.
IO. Battery * Same machines have only manual operation.
lo-136 HD325-6
0

HD325-6
HD325-6W
HD4 .05-6
-FROM HYORAULIC TANK
0 DEMAND VALVE
TSIDE OF CA --7
_-__-__
INSIDE OF C
PILOT LAMP
SWITCH
EMERGENCY RELAY TIMER

STEERING SWITCH
HD3256
FLOW SWITCH
Lead switch
ll
structure of
circuit
A-A
SVH00701
1. Wire cable OUTLINE

2. Housing The flow switch is a switch forthe auto emergency
3. Magnet steering and is installed in the piping of the steer-
4. Pivot pin ing hydraulic circuit. If the flow of oil inside the
5. Disc hydraulic piping drops below the specified level
6. Spring or stops, the flow switch detects this and actu-
7. Lead switch ates the lead switch.
lo-138 HD325-6
OPERATION
l When oil flow is above specified level
Plate (5) is pushed in the direction of the oil
flow a by the oil in the piping. When this push-
ing force overcomes spring (61, magnet (3) is
moved to the right (pivot pin (4) is taken as
the center of rotation).
When this happens, the contact with the lead
switch is opened and the circuit is switched
OFF.
‘,,,,,,,,,,,,,,,,,,,,
a: Flow of oil WHO0702
l When oil flow is below specified level or

stops.
The force of the oil in the piping pushing plate
(5) is weaker than spring (61, so magnet (3)
returns to the left.
When this happens, the contact with the lead
switch is closed and the circuit is switched ON.
///,,,/,/,,,,,,
561 F03126
HD325-6 10-139
RELAY TIMER
-- NO NO
i____i
Wirino for Dins
SVH00703
1. Dial OUTLINE
2. Lock The relay timer is a delay timer to prevent the
3. Pin emergency steering system from being actuated
Set time: 1 seconds when the flow switch is acuated mistakenly by
the pulse of the oil ro fluttering of the flow switch.
With this relay timer, the relay points are switched
after electric current is passed through the coil
for the time set by the timer.
10-140 HD3256
STRUCTURE AND FUNCTION AUTOMATIC SUSPENSION SYSTEM
AUTOMATIC SUSPENSION SYSTEM

HD325-6
HD325-6W
HD405-6
SVH00451
1. Air cylinder OUTLINE

2. Suspension cylinder The front suspension mode (damper force) is au-
3. Pressure sensor tomatically switched according to the travel con-
4. Solenoid valve dition and load condition to give a more comfort-
5. Suspension controller able ride to the operator and to improve the travel
6. Limit switch (Float switch) stability.
7. Steering angle sensor -k For details of the internal mechanism of the
suspension, see SUSPENSION.
HD325-6 10-141
0
STRUCTURE OF SYSTEM
HD325-6
HD325-6W
HD405-6
Q, 0
Network date r\
ti Transmission
shift
controller
Suspension
a?
control Ier 0
Self-diaenostic
disDlav
SVH00704
NETWORK DATA
1. From suspension controller to monitor Actuation table for suspension control cylinder air circuit
panel r):IN x:OUT
l Suspension mode Suspension mode 1 PortA 1 PortB 1 PortC 1
l Troubleshooting data Hard or 6 X X
medium , soft 0
(user code, suspension (mechatronics) I
Medium 0 Hard 0 x 0
abnormality display)
2. From monitor panel to suspension controller
. Travel speed compensation data
3. From transmission shift controller to
suspension controller
. Model selection data
lo-142 HD325-6
0
SYSTEM CIRCUIT DIAGRAM

HD325-6
HD325-6W
HD405-6
* For details of this page, see section 90. (l/2 - 2/2) F!

?“I i
HD3256 10-143
0
AUTOMATIC SUSPENSION MODE SELECTION CONTROL

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 patterns and functions of the modes (damping force) are as shown in the table
below.
s: soft
M:Medium
H: Hard
Control pattern Function Content of control F S

Empty
M
Set mode
T
S
Loaded
M H
-
Distinguishing To set damping force Internal pressure of front suspen-
empty/loaded according to load on sion cylinder is measured and 0 0
machine compared with standard valve
-
c-\
Anti-roll To prevent the chas- This detects the travel speed 0 :._: -0
sisfrom rolling when and steering angle, and
(When
turning at high switches the mode according :urning)
speed to certain conditions.
(Not controlled when traveling
empty)
W(reb/s)
" Travel speed

SVH00707
;-‘
Anti-dive
To prevent nose-
The damping force is made
stronger when the brakes are
‘-:
.J
-
.O d -0
Brake Brake Brah (Brake
diving when braking applied. OFF) ON) OFF ON)
--\
Anti-lift
To prevent the front
The damping force is made
stronger when the dump body
(‘7 _
._I -0 :,_:
Float) Other Floa
‘ram lifting up when control lever is at any position
than
dumping except FLOAT. -loat)
*-\
High speed
stability To improve stability
Detects travel speed and se-
lects damping force. (No con-
0 :._:
rvhen traveling at trol when traveling empty)
.iigh speed
Mode
f
HI----v
I I
CV (km/h)
0 55 60
SVH00708
10-144 HD325-6
SUSPENSION CONTROLLER
HD325-6
HD325-6W
HD405-6 Ii I
SVH00454
1. Self-diagnostic display window FUNCTION

2. Print card . The suspension controller detects the signals
3. Connector from the sensors and switches mounted on
4. Connector the machine, and sends a signal to the damp-
5. Connector ing selector solenoid valve to switch the sus-
6. Case pension mode.
. When an abnormality is detected, the self-di-
agnostic function gives the user code and
mechatronics abnormality displaythrough the
network between the controllers, and also
actuates the warning lamp and alarm buzzer.
. The controller itself also has a self-diagnostic
display window, and the service code is dis-
played by 2-digit LEDs.
HD325-6 10-145
0
SENSORS, SWITCHES
STEERING ANGLE SENSOR
Sensor
-
Lw5r<
-7-4
SVH00709
1. Body FUNCTION
2. Tube A round disc with teeth like a comb is installed to
3. Connector the steering column, and as this passes through
the slit in the sensor, the sensor outputs a pulse
signal. The suspension controller can obtain the
steering speed from the number of pulses per unit
of time.
PRESSURE SENSOR
HD325-6
HD325-6W
HD405-6
2 3
SVH00710
1. Sensor FUNCTION
2. Tube This sensor is installed to the suspension cylin-
3. Connector der, and when the input pressure from the pres-
sure induction portion is impressed on the dia-
phragm of the pressure detector, the diaphragm
bends. A bridge is formed by a strain gauge on
the other side of this diaphragm, and when the
shape of the diaphragm changes, the resistance
value of the strain gauge changes.
A certain voltage in impressed on the strain
gauge, and the change in the resistance value of
the strain gauge is sent to the amp as a change in
voltage. At the amp, this change in voltage is
amplified and output to the controller.
10-146 HD325-6
0
The controller carries out self-diagnosis of the system and displays any abnormality.
1) Self-diagnostic display
The abnormality display shows a 2-digit service code with LEDs. When the condition is normal, it
displays 00. . ... it uses the networkto light up the user code on the monitor panel and the mechatronics
abnormality display, and actuates the warning lamp and alarm buzzer.
No. 2-digit LED display Defect in electrical system
1 1 E-0 1 or all OFF 1 Electrical system defective
2 E-/l Defective Pressure sensor (riaht)sustem
3 E.-W Defective Pressure sensor (IeftIsustem
Defective travel speed sensor system
Defective steering sensor system
Defective model selection data
Defective solenoid 1 svstenm
‘0
I
I i-c I
I
Disconnection in network
‘1 IE.43 Defective travel speed compensation data
SVH00711
2) Saving self-diagnostic display

Once an abnormality is detected, even if the abnormality is removed, the results of the self-diagnosis
are saved to the controller memory, and can be displayed later on the monitor panel as trouble data.
(For details, see MONITOR PANEL.)
HD3256 10-147
STRUCTURE AND FUNCTION PAYLOAD METER (Printer type)
PAYLOAD METER (Printer type)

STRUCTURE OF SYSTEM
561 F03136
1. Transmission shift lever OUTLINE

2. Body float detection switch . The dump truck is supported by four suspen-
3. Clinometer sion cylinders. By measuring the total for the
4. Pressure sensor (front left) loads bearing on each cylinder, it is possible
5. Pressure sensor (front right) to know the load on the springs of the ma-
6. Pressure sensor (rear left) chine.
7. Pressure sensor (rear right) The payload can be calculated by subtracting
8. Suspension cylinder the unladen machine weight from the laden
9. Payload meter machine weight.
10. Lamp drive relay The payload meter displays the payload cal-
11. External display lamps culated above on the panel, and at the same
12. Battery time, its display lamps. In addition, the re-
13. Fuse (for external display lamps) corded data can be printed out together with
14. Fuse (for controller) the loading time and number of cycles.
Furthermore, it can also estimate what the
total load will be if one more bucketful is
loaded. The estimate display function makes
the appropriate lamp flash to prevent over-
loading.
lo-148 HD325-6
STRUCTURE AND FUNCTION PAYLOAD METER (Printer tvoel

HD325-6
HD325-6W
HD405-6
PAYLOAD METER BLOCK DIAGRAM
Front
PreeeUre
riaht
seneor
: + (Prc luct)
Payload
T
Front left
~reeeure eeneor f
Rear right
/l (Product) 1/
I-
oreeeure eeneor L
Rear left -z
Preeeure eeneor z
0
a”
Clinometer
of
Gain adjustment
trimmer
SVH00713
HD325-6 10-149
0
PRINCIPLE OF CALCULATION
HD325-6
HD325-6W
HD405-6
1. Outline
The dump truck is supported by four suspen-
sion cylinders. By measuring the total for the
loads bearing on each cylinder, it is possible
to know the load on the springs of the ma- 561FO3139
chine.
The payload can be calculated by subtracting
the unladen machine weight from the laden
machine weight.
The load on each cylinder can be calculated
from the cross-sectional area and internal
pressure of suspension cylinder.
[Load bearing on suspension cylinder]
W = P6 SB - PT (SE - ST)
Where
W= Load bearing on suspension
cylinder
PB= Bottom pressure
PT = Top pressure
SE= Cross-sectional area of cylinder

$T= Cross-sectional area of rod
Because of the structure of the suspension

cylinder,
Pg=PT
Therefore, the load can be calculated as fol-
lows.
W = P&T
SVH00457
10-150 HD3256
0
2. Calculation of unladen weight (calibration)

The unladen weight is measured by calculat-
ing the average load when the dump truck
travels unloaded for approx. 30 seconds on
flat level ground at a speed of approx. 10 km/h.
Time
The measurement is carried out while travel-
ing because when the machine is traveling it
is possible to cancel the sliding resistance of
the suspension cylinder by extending and re-
tracting the cylinder give an average over a
period of time. WHO0714
The measured unladen weight is stored in the

memory inside the controller as calibration
data.
3. Measuring payload
The weight when the load is loaded is mea-
sured. Loading is carried out with the shift
lever at N, the body control lever at FLOAT,
and the machine at a front-to-rear angle of
within + 5”.
4. Compensating on slopes
When loading is carried out on slopes, the
weight of the load is different from the value
measured on flat ground, so the front-to-rear
angle of the machine is detected and com-
pensation is carried out according to the
angle. (Angle colmensation within f 5”) 561FO3142
HD325-6 10-151
FEATURES OF EQUIPMENT
1. Pay load meter 8 9 10
The payload meter inputs signals form the
pressure sensors, clinometer, body float de-
tection, and shift lever, calculates the payload
1
using its built-in microcomputer, and displays
the value on the panel. In addition, it also
2
displays the load level using the external dis-
play lamps.
It is also possible to print out the recorded
data together with the loading time and num-
561FO3143
ber of cycles by pressing the print out switch.
I) Basic functions of payload meter
The payload meter has the following ba- 1. Calibration
sic functions. 2. Night-time dimmer switch
i) Power reset 3. Time set, adjustment switch
When the power is switched ON , all 4. Time adjustment, shift switch
functions are checked. 5. Time adjustment, display increase switch
ii) Measurement of unladen weight (cali- 6. Memory data clear switch
bration) 7. Printer feed switch
iii) Display of load measurements 8. Display switch
The input signal for the payload meter 9. Print switch
is used to display the following 10. Print switch
Actual load display:
When the body control lever is at
FLOAT (body float signal at 20V or
more) and the shift lever is at N
(shift lever signal at 20V or more). HD325-6 '
Load display 0 ton:
From lOtons-less
l When the payload is less than 5% than Illtons
of the rated payload. From 14tons-less
V
l When the body control lever is at
a position other than FLOAT (body lzzP
float signal GND).
@&k?Y\A 1 than 38tons
Time display: I
When the body control lever is at 1 I 36tons and above I
FLOAT, and the shift lever is at a SWH00816
position other than N.
iv) External display lamp drive (estimate
display)
When the actual load is displayed, the
lamps light up as shown in the dia-
gram on the right. (The actual load
display is given only when the shift
lever is at N and the body control le-
ver is at FLOAT. At other times, all
From 40tons-less I
lamp go out. Note that for IO seconds
after the power is switched ON all 42tons and above I
lamps light up.)
@ :Liaht UP SWHOO817
10-152 HD325-6
The estimate display estimates what

the total load will be if one more buck-
etful is loaded, and makes the appro-
priate lamp flash to prevent over load-
ing.
VI Storing load data The Previous time.did the load

become less than l/5 of the rated
a) According to the relationship be- load 5 seconds after the dump
tween the load and the body float control lever was moved from a
Position other than FLOAT to
switch, the load data is stored in FLOAT (lever returned from
LOWER to FLOAT after dumping AND
RAM. the load)?
Load data
. The data stored in the memory is k- recorded
This time.was the load more than1 in msmorv
not deleted even when the start- l/2 of the rated load when the
dump control lever was moved
ing switch is turned OFF. from FLOAT to a position other
. A maximum of 200 items of data than FLOAT. (Lever moved from
:;;;:lto RAISE when dumpins
can be stored in the memory. If / \
this quantity is exceeded, FULL is recording
load data in memory
displayed on the panel. I SVH00716
. The load data is stored in memory
when the load data storage con-
ditions are satisfied. (See diagram
on right)
** PAY-LORD**
b) Printing our data in memory ‘88-18-17
When the print switch is pressed, **OPERATOR**
the data is printed out on the *HACHINE NO.*
printer paper.
*TOTAL C’fCLE*
c) Deleting data in memory 7 (crcle)
When the clear switch is pressed, *TOTFIL UEIGHT
all data in RAM is cleared. 535(ton)
** PAY-LOAD**
vi) Time ‘88-18-17
-0+--_-_-+__-__ NO DATA
If the body control lever is at FLOAT,
NO: TINE: ton
and the shift lever is at a position other --_+---_-_-+--__-_
than N, the time is displayed on the 1:11:42: 71
2:11:43: 78
panel.
vii) Dimming display at night
The level of lighting can be adjusted
to ten stages by using the night-time cCondition when
there is data 3
Condition when
data is cleared
from RAM 3
dimmer switch.
HD3256 1o-1 53
* Condition of dump truck and display on payload meter and external display lamps.
No
-
T Condition of dump truck Payload meter External display lamps
HD325-6
HD405-6 SWHOOSIS
0 Loading
561FO3154
SVH00459
561FO3146 Load caluculate with shift Lamps light up according to

lever at N payload
Traveling
0 (loaded)
561FO3151-1 561FO3155
Time display (display is

561FO3147 held during travel) Lamps out
-
0 Dumping
561FO3152-1
561FO3155
When dumping, display

value is 0 ton. At the same
time, the value immedi-
561FO3148 ately before dumping is Lamps out
stored in memory.
Traveling
(empty)
561FO3153-1 561FO3155
Time display Lamps out

561FO3149
10-154 HD3256
2. Pressure sensor
The pressure sensor is installed at the bot-
tom end of the suspension cylinder, and acts
to measure the pressure at the cylinder bot-
tom.
561FO3158
When replacing the pressure sensor (I), first

loosen the nipple (21, and remove it from the
valve (3). (The pressure sensor is removed
while still installed to the nipple (21.1 Next,
remove the pressure sensor (1) from the
nipple (2) and install a new pressure sensor
to the nipple (2).
After this, turn the nipple (2) to install it to the
valve (3). When removing or installing the
nipple (21, be careful that the vavle does not
rotate.
When the nipple (2) is removed, the valve core
(4) acts to prevent the suspension pressure SVH00717
from decreasing.
The out put characteristics of the sensor are as

shown in the diagram on the right.
’ When pin number 17 of the connector ’
(21-pin) of the payload meter controller is
GND, the output (12, 13, 14, 15) voltage 96
of each sensor is read in the voltage range
shown in the diagram on the right.
99
MPa
t k;vqomO;
Pressure sensor Pressure 16
561 F03391
HD325-6 10-155
Clinometer
This measures the front-to-rear angle of the
machine to carry out compensation on slopes.
561FO3161
The out put characteristics of the clinometer

are as shown in the diagram on the right.
Voltage between clinometer connector pin
1 (GND) and pin 2 (output) I
WDhill arade iS PIUS.
SVH00720
4. Lamp drive relay

This drives the external display lamps accord-
ing to the signal from the payload meter.
561FO3164
lo-156 HD3256
The controller always observes the condition of the sensors and outputs, and if any abnormality occurs,
it displays an error message.
ERROR MESSAGE DISPLAY
Detection
Content
time
1
Internal CPU stopped
““V 8
(Controller power source etc. normal, but CPU is reset)
Abnormal sensor power source (18V)

E-31 0.1 set
(Sensor power source line in contact with chassis, or output is less than IOV)
Short circuit in relay Less than

2 E-32 0.1 set
(Short circuit in coil inside relay, relay coil line in contact with 24V)
Drop in back-up battery voltage

E-33 5 set
(Internal battery (lithium battery) discharged, defective contact)
Rear right wheel Pressure sensor output is less than 4 mA

(pressure less than 0 MPa {O kg/cm?))
Rear left wheel l Disconnection in pressure sensor signal wire
l Signal wire in contact with chassis 5 set
Front right wheel l Defect inside sensor
E-04 Front left wheel
E-II Rear right wheel Pressure sensor output is more than 20 mA

(pressure more than 19.6 MPa I200 kg/cmz})
E-12 Rear left wheel l Pressure sensor signal wire in contact with power source
4 line 5 minutes
E-13 Front right wheel l More than 19.6 MPa (200 kg/cm*) continues
Clinometer output is more than IO”

E-41 or signal wire in contact with chassis)
(Disconnection in clinometer signal wire
5 5 minutes
Clinometer output is less than - IO’
E-42
(Signal wire in contact with electric line)
6 1 pAPE 1 Printer REDY signal is not given (paper jam) 10 set
7 1 FULL 1 Data saved in memory has reached 200 (overflow) -
Calibration needed (Content of data is abnorma!,,or model data stored in

8 CAL -
memory is different from wrnng of machine)
I
When sensor check is carried out, difference between pressure
when empty and pressure when carrying out calibration is more
1 E-24 1 Front leftwheel I
. No. 4 and 5 may be displayed during normal operation, so the detection time is made longer.
. Once an error is displayed, the error continues to be displayed until the CAL switch is pressed.
HD3256 10-157
STRUCTURE AND FUNCTION PAYLOAD METER II (Card type)
PAYLOAD METER II (Card type)

STRUCTURE OF SYSTEM
. From the following serial numbers, the engine oil pressure detection switch (* mark) has been dis-
continued.
HD325-6
HD325-6W
HD405-6
1. Shift lever neutral detection switch (relay) OUTLINE

2. Body FLOAT detection switch l 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 load
5. Pressure sensor (for front right) on the springs of the machine.
6. Pressure sensor (for rear left) The measurement of the payload is obtained
7. Pressure sensor (for rear right) by calculating the difference between the load
8. Suspension cylinder when empty and the load when full.
9. Payload meter Payload meter II displays the load calculated
10. Lamp drive relay above on the monitor screen and displays the
11. External display lamp load level on the external display lamps.
12. Battery The payload, distance, time, time engine was
13. Fuse (for external display lamp) turned ON/OFF, time of occurrence/cancella-
14. Fuse (for controller) tion of abnormalities or warnings, and other
15. Memory card data are automatically saved in memory.
16. Travel signal sensor These data can be later transmitted to a PC or
17. RS232C output (PC cable communication) written to a memory card.
socket It also has an estimation display function:
18. Battery charge signal (alternator terminal R) when loading the next load, the newtotal load
19. Engine oil pressure detection switch (%) is estimated and the appropriate lamp flashes.
This prevents overloading.
lo-158 HD325-6
0
STRUCTURE AND FUNCTION PAYLOAD METER II (Card tYpe)
PAYLOAD METER II (Card type) ELECTRICAL CIRCUIT DIAGRAM

HD325-6
HD325-6W
HD405-6
PAYLOAD METER BLOCK DIAGRAM
Front risht luct)

pressure sensor * e Payload
L
Front left
Pressure sensor
Rear rioht
oressure sensor
Rear left
Presure sensor
SVH00713
HD325-6 10-159
0
STRUCTURE AND FUNCTION PAYLOAD METER II (Card tvoe)
PRINCIPLE OF MEASUREMENT
1. Outline
2. Measurement of unloaded weight

(calibration)
3. Measurement of loaded weight
4. Compensation for slope
. For details of the above items, see PAYLOAD

METER (PRINTER TYPE).
5. Detection of distance, travel speed
HD325-6
HD325-6W
HD405-6
The distance and travel speed are detected

from the machine travel signal sensors.
* Travel signal sensor:
Transmission output shaft speed sensor
lo-160 HD325-6
0
STRUCTURE AND FUNCTION PAYLOAD METER II (Card tvtsel
FEATURES OF EACH DEVICE

1. Payload meter II
Payload meter II uses the signals from the
pressure sensors, clinometer, body FLOAT de-
tection, shift iever (on payload meter II, this is
the neutral detection switch) as input, calcu-
lates the payload using the built-in microcom-
puter, displays this on the panel screen, and
also displays the load level on the external
display lamps.
1) General locations of payload II

1. Display
2. Communication “receiving” lamp
(Rx busy)
3. Communication “transmitting” lamp I\
(TX busy)
4. Memory card access lamp
(CARD busy)
5. Mode switch IMOBBI
6. Calibration/clear switch
izq
7. Total/shift switch
8. Light/increment switch ES SVH00461
9. Memory card (opt) I%?

10. Cover
* Communication “transmitting” lamp
(3) lights up even when the commu-
nication cable is not connected to a
PC or when there is defective connec-
tion.
* When not inserting or removing

memory card (97, always keep cover
(IO) closed.
HD325-6 10-161
LEFT FACE
Remove this cover
O
0
R 7 6 5
dll
1 @
0 loI loI loI loI lOllSllOl

0
SVH00722
. Details of switches on left face
JO. Name Type Remarks
-20% - +20%
1. Payload compensation trimmer Rotary volume (Counterclockwise) (Clockwise)
2. Speed compensation trimmer 0 -F rotary selector switch 0:107%-7:107%-F:92%
3. Distance compensation trimmer 0 -F rotary selector switch 0: 107%-7: 107%-F:92%
4. Model selector switch 0 -F rotary selector switch According to model selector code table
5. Memory card use switch 2-stage selector switch Up : Not used Down : Used
6. Clinometer use switch 2-stage selector switch Up : Not used Down : Used
7. Weight unit setting switch 2-stage selector switch Up : Metric ton Down : Short ton
6. Switch forcible prohibition Up : Permitted Down : Prohibited

2-stage selector switch According to Permitted/prohibited setting table for switchf
setting switch
Turn CLOCKWISE to DECREASE volume
B. Buzzer volume adjustment Rotatory volume Turn COUNTERCLOCKWISE to INCREASE volum
-k 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.
lo-162 HD325-6
0
STRUCTURE AND FUNCTION PAYLOAD METER II (Card tvpe)
. Table of model selector code
. Permitted/prohibited setting table for switches

Left side switch No. 8
Top (prohibited) Bottom (permitted

I
Top (1) (2)
Left (memory card not used) I
side 1
switch
No. 5 Bottom
(3) (4)
(memory card used)
I I I
(I) Left side switch NO. 5 (top), NO. 8 (top)

Calibration, data all clear, time, date setting operations only are possible.
(2) Left side switch No. 5 (top), No. 8 (bottom)
All switches can be operated.
(3) Left side switch No. 5 (bottom), No. 8 (top)
Calibration, data all clear, card dump, time, date setting operations only are possible.
(4) Left side switch No. 5 (bottom), No. 8 (bottom)
All switches can be operated.
HD325-6 lo-163
Payload meter II has the following basic functions.

i) Power ON (reset)
When the power is turned ON, all functions are checked and displayed.
Power ON
External display
Display portion 8.8.:8.8.
1
lamps all ON
Communication “receiving” lamp (27 set)
All ON (3 set)
Communication “transmitting” lamp
Memory card access lamp
J
Buzzer sounds (3 set)
.L
Machine model selector code display (3 set) CO : XX (xx+ 0 - F-according to setting of switch on left face)
.L
Cd : - -+ Card not used According to
Memory card use switch setting display (3 set) setting of switch
Cd : oo + Card used on left face
I
CL : - - + Clinometer not used According to

Clinometer used switch setting display (3 set) setting of switch
CL : oo +Clinometer used on left face
1
US : - -+ Metric tons According to
Weight unit setting switch condition display (3 set) setting of switch
US : oo + Short tons (US tons) on left face
I
SU : - -+ Switchforcible prohibition ~~~~~~ggof

Switch forcible prohibition switch setting display (3 set)
SU : oo + Switch receptionpermitted ~ew,i’t”,h,,“n
I
Machine ID code setting detail display (3 set) d.xxx (xxx + 0 - 200... shows code for set input)
I
Opened ID code setting detail display (3 set) o.xxx (xxx + 0 - 200... shows code for set input)
J#
Limit speed setting detail display (3 set) SP : XX (XX . . . shows code for set input (km/h))
.L
Option code setting detail display (3 set) OP : xx (XX ... shows code for set input)
ITo Normal operation display I
f 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 iii) Normal operation display.
lo-164 HD325-6
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)
SWH00816
The chart on the right shows the payload dis-
play level for the external display lamps dur-
ing the normal operation display.
The estimated display shows the estimation
of the total payload when one more load is
added. The applicable lamp flashes to pre-
vent overload.
@ :Lioht UD SWH00817
Normal operation display
Payload drsplay and
(*I) When load is less than 50% of correct payload, display shows 0 ton.
(*2) For details of conditions taken as dumping, see v) Content of memory (1).
(“3) The aggregate payload display is shown in units of 100 ton. (Rounded to the nearest 100)
HD325-6 lo-165
VI Content of memory (for details, see Opera- On the Previous occasion. when ‘the
dump lever was moved from a
tion and Maintenance Manual) position other than FLOAT to FLOAT YES
(after dunnins. lever was returned
@ Cycle data from LOWER to FLOAT),
was load after 5 seconds less
* The period between one dumping opera- than l/5 of rated?
tion and the next dumping operation is
On the Previous occasion when the
taken as one cycle and the data are re- dump lever was moved from a
position other than FLOAT to FLOAT,
corded. did it stay at FLOAT for 5 seconds?
Ir The cycle data are recorded when the
dumping conditions are fulfilled (see This time. when the dump lever
was moved from a position other
right). than FLOAT to FLOAT
(after dumpins, lever uas returned
+ The maximum limit for cycle data in from LOWER to FLOAT).
was load more than l/2 of rated? SVH00723
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 O-23 Displays value and set value at time
Time Minute Minute o-59 of dumping
Machine ID Integer O-200
Open ID Integer O-200
Payload MT OR ST O-6553.5
Empty travel time MIN O-6553.5
Empty travel distance km O-25.5
Empty max. travel speed km/h o-99
Empty average travel speed km/h o-99
Empty stopped time MIN O-6553.5
Loading stopped time MIN O-6553.5
Loaded travel time MIN O-6553.5
Loaded travel distance km O-25.5
Loaded max. travel speed km/h o-99
Loadedaverage travel speed km/h o-99
Loaded stopped time MIN O-6553.5
Dumping time MIN O-25.5
Limit speed km/h o-99 Displays set value at time of dumping
Warning items/cycle
~n~~~spar~i----------------_---__________-------------------
MAX electric potential V O-4.0

MIN electric potential V O-4.0
1 Average electric potential v O-4.0
Analog spare 2
MAX electric potential V O-4.0 Data processing on PC
MIN electric potential v O-4.0 > Data inside cycle are handled
separately as spare signal input data.
I Average electric potential V O-4.0
Digital spare 1
Lo frequency Times O-255
Digital spare 2
Lo frequency Times O-255 ,
(MT: Metric ton, ST: Short ton)
10-166 HD325-6
@ Engine ON/OFF data

* Each time the engine was stopped and started is recorded.
* The maximum limit in memory for engine ON/OFF data is 115 ON/OFF sets.
Item Unit Range
Engine operation number Integer l-65535 Consecutive number for operation of engine
Year (last 2 digits) Year o-99
Month Month 1-12
Day Day 1-31 Shows when engine was switched ORI
Time Hour Hour Displayed as O-23
Time Minute -Minute 1
_Q-59________________-------------
Vear-(IZ 2 di$tsr - - - - G- - - - - - - o-99
Month Month 1-12
g$ws when engine was switched
Day Day 1-31
Time Minute
Aggrega~tepa;,oad_ Minute
- - - -MTORST - - - _ o_ggggooo
o-59 - - - - - -1 - - - - - - - - - - - - - -.- - - - - _ -
Total value between engme ON and
Total number of cycles Times o-9999 engine OFF
@ Abnormality, warning data

* Each time a payload meter II abnormality or warning is generated or cancelled is recorded.
* The maximum limit in memory for abnormality or warning data is 230 generated/cancelled sets.
Item Unit Range

Engineoperation numberwhen According to q
error code was generated integer 1-65535
Frequency of generation
after engine is switched ON Times l-255
Month Month 1-12
1-31 Shows when error code was
Day Day generated
Time Hour Hour (0 - 23) Displayed as O-23
Time _Mi_nuJe _Miflu_te_ _ _ _ _ _ Q-59 - - - - - - -
Engze opera~o~k%%
when cancelled Integer O-65535
Month Month 1-12
1-31 Shows when error code was
Day Day cancelled
Time Hour Hour (0 - 23) Displayed as O-23
Time Minute Minute o-59
HD325-6 lo-167
@ Data for aggregate payload, total number of cycles

* It is possible to calculate and record again from any desired time the aggregate payload and total
number of cycles for each time that the dumping conditions are fulfilled.
* The calculation is started again for both values when the data for aggregate payload and total
number of cycles are cleared.
* The maximum limit in memory for aggregate payload and total number of cycles is 999900.0
metric tons or short tons and 9999 cycles respectively.
Item Unit Range

Shows aggregate from time when data
Aggregate payload MT OR ST O-999900.0
were cleared
Total number of cycles Times o-9999
Month Month 1-12
Day Day 1-31 Shows date and time when data were
cleared
(MT: Metric ton, ST: Short ton)
G3 Other data
Content Item Unit Range
Operator check
I Machine ID Integer O-200
Imode set data Open ID Integer O-200 Operator check mode set in input
Limit speed km/h o-99 operation
Option code Integer O-11
Calibration Year (last 2 digits) Year o-99

performance Month Month 1-12
Date and time when calibration was
data Day Day 1-31
performed
Time Minute Minute O-59
User write data Data 1 20 Characters Comments that can be written freely
20 Characters into payload meter.
Data 2
Note:lnput and settings are possible
Data 3 20 Characters only from PC through cable
Data 4 20 Characters communications.
(For details, see software manual.)
L
10468 HD325-6
STRUCTURE AND FUNCTION PAYLOAD METER II (Card twe)
@ Calibration data
Jr These are saved in RAM each time calibration is performed.
* The maximum limit in memory for calibration data is 15 sets.
Item Unit Range
Year Year (last 2 digits) 00-99

Month Month 1-12
Day Day 1-31 Shows values and settings when
Time Hour Hour O-23 calibration was performed
Model selection code Intege_r______ _E______ I
____________________
su~,en~,-p,s~r~if~o~~l~~i - kg/cm* O-6553.5
Suspension pressure (front right) kg/cm2 O-6553.5
Suspension pressure (rear left) kg/cm* O-6553.5 Shows values before compensa-
Suspension pressure (rear right) kg/cm* O-6553.5 tion factor was calculated
Suspension load (front) MT O-6553.5
Suspension load (rear) MT O-6553.5 1
Tiltangle---__-----__-deg___---___9~99_+9.99_ ---------- ----------
Front wheel tilt compensation factor Integer o-9.99999

Rear wheel tilt compensation factor Integer o-9.99999
Front wheel link factor Integer o-9.99999
Rear wheel link factor Integer o-9.99999
Load on springs (empty) MT O-6553.5
HD325-6 10-169
STRUCTURE AND FUNCTION PAYLOAD METER II (Card tvr>e)
@ Payload calculation data (analog data)

* These are saved in RAM when the payload calculation data are required.
Sr The maximum limit in memory for payload calculation data is 180 sets.
Item Unit Range
Year Year (last 2 digits) 00-99

Month Month 1-12
Day Day 1-31
Time Hour Hour O-23
Suspension pressure (front left) kg/cm2 O-6553.5
Suspension pressure (front right) kg/cm2 O-6553.5
Suspension pressure (rear left) kg/cm2 O-6553.5
Suspension pressure (rear right) kg/cm* O-6553.5
Suspension load (front) MT O-6553.5
Suspension load (rear) MT O-6553.5
Tilt angle deg -9.99 - +9.99
Front wheel tilt compensation factor Integer o-9.99999
Rear wheel tilt compensation factor Integer o-9.99999
Front wheel link factor Integer o-9.99999
Rear wheel link factor Integer o-9.99999
Load on springs (empty) MT O-6553.5
(Calibration value)
Trimmer gain value Integer 0.7500 - 1.2500
Payload MT O-6553.5
Backup battery voltage V O-25.5
(MT: Metric ton)
1 The above data items @ - 0 are retained even when the power is switched OFF. 1
10-170 HD325-6
vi) Forced display of aggregate payload, total number of cycles

Forced display of existing abnormalities and warnings
TOTAL
By operating the switch of payload meter II, it is possible to carry out forcible display of
these items. SFT
EI
For details, see the Operation and Maintenance Manual.
vii) Operator check mode

By operating the switch of payload meter II, it is possible to carry out the following items.
For details, see the Operation and Maintenance Manual.
Memory card dump
Data all clear
Abnormality, warning exists/cancelled, input signal condition display
Machine ID setting
Open ID setting
Limit speed setting
Option code setting
Time, date correction
viii) Dimming of display portion

It is possible to adjust the brightness of the payload meter II display portion to 10 levels with the
switch.
ix) Downloading saved data

It is possible to download any data recorded in payload meter II to a PC through a cable (ANSVEIA
RS-232C).
For details, see the PC software manual provided by Komatsu.
HD325-6 m-171
x) Service check mode

By operating the switches of payload meter II, it is possible to forcibly carry out display, setting, and
correction of the following items.
Detailed calibration data display

The display shows the date, suspension pressure, etc. when the latest calibration was carried
out.
Detailed payload calculation data display (analog data)

The display shows the suspension pressure and machine angle used when calculating the present
payload.
Memory card dump (service area)

This writes all the data displayed for Items 6-6 and 6-7 to the memory card inserted in the ma-
chine.
This function is available only when the No. 5 switch on the left side of the controller (memory
card use switches) is set for “Use”.
Data all clear (service area)

This forcibly deletes all the calibration data and analog data, exceptforthe latest calibration data.
Before clearing the data, always download the data to a PC or carry out @ Card dump.
Input signal condition display

This displays some of the signal conditions for the sensors input to payload meter II and the
present recognition condition of the payload meter.
Forced initialization
This forcibly deletes all the data in payload meter II.
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 necessary.
Extra payload setting when loading

The extra load can be forcibly input or corrected to set the payload when loading.
Available range for setting: -9 - +9 (%)
lo-172 HD325-6
STRUCTURE AND FUNCTION PAYLOAD METER II(Card type)
(FJ Payload fixed display and cycle data recording, payload value setting
I) Payload fixed display
When displaying the payload in the range shown in the table below, it is possible to input
and correct to set the display for the payload when loading is completed (when loading at
least 50% of set payload and traveling 160 m and starting to dump), not the real-time pay-
load.
Setting Range Payload fixed display
The time that machine is Payloadwhen stopped in pre-

stopped when loading at vious cycle
TALKS not set
(option codes 0 - 3, 10, 11 set) least 50% of set payload and
traveling 160 m and startina
1 to dump .. I I
The time that machine is Payload last displayed in pre-
When there is per- stopped from permission to vious cycle
mission to start move off to starting to dump LL\;ll radio transmission
TALKS set
option codes
4-9set ~ohne~fd[~~~nf~~~ The time that machine is Payload last displayed in pre-
stopped from disconnection vious cycle
payload meter is
of line to starting to dump
requested
2) Switching payload fixed display in cycle data recording

If the payload fixed display in Item I) above is applicable, it is possible to input and correct
the data to set the payload inside the cycle data in Item 6-l to the fixed display payload value.
Possible set range: 00, 01, 10
Possible set value table
Display Payload fixed display Recorded payload value
00 Yes Payload fixed display value
01 Yes Value when dumping load
10 No Value when dumping load
@ Loading completion recognition travel distance setting

This is used to input and correct the values to set the travel distance recognized as completion of
loading by payload meter II.
Possible set range: 0 - 255 (ml
Q) Loading start recognition payload setting

This is used to input and correct the values to set the payload recognized as the start of loading
by payload meter II.
Possible set range:
HD325-6
HD325-6W 480 -1,480 1x100 ton]
H D405-6
H D465-5
690 -1,690 [xl00 ton]
HD605-5
H D785-5
1,000 -2,000 [x100 ton]
HD985-3
HD325-6 10-173
0
Zero ton display range setting

This is used to input and correct the values to set the range of the zero display on the payload
display.
Possible set range: 5 - 10 [%: ratio of correct payload]
External display lamp display range setting

This is used to input and correct the values to set the lamp display payload range when display-
ing the payload.
Possible set range:
C:Green
; Y:Yel low
R:Red
Lamp 5 (red) 1 E:D-255 SVH00724
The set value is displayed as a proportion

(%) of the correct payload.
n Of the service check mode functions, the following functions can be downloaded to a PC using
the PC downloading software provided by Komatsu.
. Calibration data
. Payload calculation data (analog data)
For details, see the software manual.
(I) Method of operation
ALways actuate the service check mode
Note, @ and @ are actuated on the HD1200-1 when the parking brake is ON or when the brake
lock is ON, and on machines other than the HDI 200-1 when the shift lever is at the N position and
when the dump lever is at FLOAT.
0 is actuated only when the power is ON.
* When the service mode is working, on the HD1200-1, setthe parking brake to ON or the brake
lock to ON, and on machines otherthan 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.
1o-1 74 HD325-6
i SVH00463
- Indicates flashing I I
t
Goto@
Operatron for
Flashing always setting extra pay-
load when
~::fa~?::,% loading
ON, 1 second OFF
Press switches
I
@ and @at the
same time for at Goto@
least 3 seconds. Operation for
When switch @ is setting payload
pressed, it returns to fixed display and
the normal display. cycle data record
I J value
I I Go tomoperation
I
for setting loading
completion
recognition travel
distance
I
Go to@Operation
Goto@ Goto@ Goto@ Goto@ Goto@ Go tab for settrng loading
Operation Operation Operation for Operation for Operation for Operation start recognition
for calibr- for payload memory card data all clear input signal for perfor- payload
ation data calculation dump (service (service area) condition ming forced
display data display factory) display initialization I
I
Goto@
I
Operation for set-
ing 0 ton display
range
I
Go to @Operation
for setting display
range of external
display lamps
\
I
/
CHEC
I
HD3256 10-175
STRUCTURE AND FUNCTION PAYLOAD METER II (Card tvr>e)
@ Operation for calibration data display
I
I SVH00464
q Set to CHEC display, then press

-I I From CAL0 flashing
CAL Last 2 digits of year for date

switch @ for at least 2 seconds. 0 when CAL was carried out
t IiE
Display: CAL0 Month and day for date
0 when CALwas carried out
Hour and minute for date
0 when CAL was carried out
•I Every time the gk switch Q) is pressed, Modelselectionswitch (decimal
0 value)when CALwascarried out
t
the display changes in the order @ kg/cm? P'FL (Front left)
--I Suspension
shown on the right. @ kg/cm2 P'FR (Front right) pressure less than
100 kg/cm? Xx.X
0 kg/cm* P'RL (Rear left) I More than 100 kg/
R If (MODE1 switch @ is pressed at any time cm*: XxX.X
@ 1 kg/cm2 1P’RR (Rear right)
during the display in Steps q or q, the dis-
Weight on front axle
play will return to CHEC. (End)
Less than 100 tons:
(=z D: (P'FLcP'RL))
xx.x
@,Iton 1Weight on rear axle More than 100 tons:

xxx.x
I I (=4 0: (P'RL+P'RR))
Appears when value
1s n gatrve
deg Angle of tilt when
@ deg
CAL was carried out f
(-)X.XX
x.xxx
@I I Rear axle link coefficient1 ]

Spring-up weight calculated Same number of
63 ton according to calibration
I I (I digits as @and @
All displayed values are rounded to

the value given.
lo-176 HD325-6
@I Operation for payload calculation data (analog data) display
PAYLOAD METER
I SVH00465
Set to CHEC display, then press From ALL0 flashing or

, l
A.FUL flashing
LIGHT
switch 0 for at least 2 seconds. 0 Hour, minute
t -iW-
@ kg/cm* P’FL (Front left)
Display: ALL0 (when data in memory is Suspension
@ kg/cm2 P’FR (Front right) pressure less than
less than 170 cycles)
100 kg/cm% Xx.X
A.FUL (when data in memory is
@ kg/cm* P’RL (Rear left) More than 100 kg/
more than 170 cycles) cm? XxX.X
A.FUL (when data in memory is @ kg/cm* P’RR (Rear right) I
more than 180 cycles) @ ton Weight on front axle

Less than 100 tons:
(= $ DE (P’FL+P’RL))
xx.x
Every time the ‘;FC? switch @ is pressed, 0 ton Weight on rear axle More than 100 tons:
t xxx.x
the display changes in the order (= a Di (P’RL+P’RR))
~
Appears when value
shown on the right. Angle of tilt when CAL IS n gabve
8 deg was carried out 1
I (-)X.XX
0 Front axle tilt coefficient 1

If 1-1 switch @ is pressed at any time
during the display in Steps q or q, the dis- _I} x.xxx
play will return to CHEC. (End)
All displayed values are rounded to

the value given.
HD325-6 10-177
@ Operation for input signal condition display
I SVH00466
ljj Set to CHEC display, then press

TOTAL
switch @
t -ST-
Display: Cd : dP
switch @ again.
The main display will go out and memory card access lamp @ will light up.
When the memory card dump operation is completed, it will return automatically to the CHEC display.
(End)
If it is desired to stop the memory card dump operation when the display is Cd : dP, press [MODE]
switch 0, and the display will return to CHEC without performing the memory card dump operation.
The memory card dump function can be used only when the No. 5 switch (memory card use switch) on
the left side of the controller is set to “Use”.
lo-178 HD325-6
STRUCTURE AND FUNCTION PAYLOAD METER II (Card tvpe)
@I Operation for data all clear (service area)
) q ojj @
0
/$$ I I
I-!
--- 0
2
/ I
I SVH00467
q Set to CHEC display, then press

LIGHT
t Xk-
switch @ and 0.
CAL
t -Gk--
Display: A : CLE
q Press gk switch 0.
t
The display will become A.CLE (lighted up), and when the data all clear operation is completed, it will
return automatically to the CHEC display. (End)
If it is desired to stop the data all clear operation when the display is A : CLE, press -1 switch (3),
and the display will return to CHEC without performing the data all clear operation.
Ir Before clearing the data, download the necessan/ data to a PC or carry out the card dump operation
in Item 0.
HD325-6 10-179
@ Operation for memory card dump (service area)
I’ 2 SVH00468
q Set to CHEC display, then press (a-a) Parking brake, brake lock switch signal
condition [HD1200-1 I
Display: C1:XX (lights up for 3 seconds)
switches @ and @ at the same time
CAL for at least 2 seconds. Either one ON: CL : oo
t i%i- Both OFF: CL:--
Display: S : CHE I
(a-a’) Shift lever position signal condition [except
HDI 200-I I
q Every time itk switch @ is pressed, Display: Cl : XX (lights up for 3 seconds)
t
the display changes in the order shown on
“N”: CL:00
the right. Except “N”: CL : - -
1
q If II switch @ is pressed at any time (2-b) Dump lever position signal condition
during the display in Steps q or q, the dis-
play will return to CHEC. (End) F. FLOAT c2 : 00
Except FLOAT: C2 : - -
L
(2-c) Engine oil pressure signal condition
Engine running: C3 : oo
Engine stopped: C3 : - -
I
Go to next page
lo-180 HD325-6
From previous page

1 1
(O-d) Battery charge signal condition (O-k) Payload meter present recognition display
Display: C4:XX (lights up for 3 seconds) Counter display
Engine running: C4 : oo
clcl*clcl
Engine stopped: C4 : - - lime CoXn
1 counter counter
(n-e) Analog spare input 1 signal condition
Display: C5:XX (lights up for 3 seconds) Emtty stopped . . . . .. . 03.01
x.x . . . . Input signal (V) Empty traveling . .. . .. 01.02
1 Loading . . . . . . . . .. .. .. . . . . . 06.03
(a-f) Analog spare input 2 signal condition Loaded traveling . . . . 02.04
Display: C6:XX (lights up for 3 seconds) Loaded stopped .. . . . . 04.05
X.X .. .. Same as C5 Dumping . .. . . . . .. . .._... 05.06
1
00
(m-g) Digital spare input 1 signal condition
tnvari- May change
Display: C7:XX (lights up for 3 seconds) able according to
N signal when
dumping
Hi: C7: oo
Lo: c7 :--
1 @l-l) Machine condition time display shown be-
(O-h) Digital spare input 2 signal condition low
Display: C8 : XX (lights up for 3 seconds)
X.X . . .. Same as C7 Every time switch Q) is pressed,
1
(m-i) Travel speed display the display advances one place in order from @
Display: C9 : XX to 0.
X.X . . .. Travel speed (km/h)
1 @ Empty traveling Sl :cllJ
(B-j) Travel distance display
@ Empty stopped s2:oo
Travel distance with machine in present @ Loaded traveling s3:lIlcl
I condition (empty or loaded) for that cycle I @ Loaded stopped s4:oEl
@ Dumping s5:oo
XXXX . . .. (m)
0 Loading S6:s
% If the value goes above 9999m, the display Unit: 0.1 minute
(When it
starts again from 0. exceeds 9.9
minutes, display
changes to -4
The value for the

present machine
recognition condi-
tion increases in
minutes in real
time.
HD325-6 lo-181
STRUCTURE AND FUNCTION PAYLOAD METER II (Card tYpeI
@ Operation for performing forced initialization
PAYLOAD METER
SVH00469
Ijl Set to CHEC display, then press

CAL
t mi-
switches (iJo, and @ at the same time for at least 2 seconds.
Display: 0 0 : 00
LI Press .!?& switch @ for at least 2 seconds.

EII
The display becomes 170 : 00 (lighted up) (2 seconds),

and when all the data is completely cleared, it automatically displays F.CAL. (End)
After that, it carries out the process from 10-m.
If it is desired to stop the forced initialization operation when the display isI70 : 00,
press 1-1 switch (41, and the display will return to CHEC without performing the forced
initialization operation.
lo-182 HD325-6
@ Operation for setting extra payload when loading
PAYLOAD METER
3 I 2 SVH00470
bl Set to CHEC display, then press

TOTAL
t -SF switch @ and @ at the same time for at least 2 seconds.
Display: S.5EL
q Press -& switch 0.

t
1
Display UP : j(lJ for+ :A
present set value: for _
:_X
LIGHT
If it is necessary to correct the setting, press switch @ and correct.
t XiC7
q When the correction operation from Step q is completed, pressll switch @I at any time to re-
turn to the CHEC display. (End)
HD325-6 lo-183
@ Operation for setting payload fixed display and cycle data record value
4 2 SVH00471
q Set to UP : Xx display, then press

CAL
switch @
t UK
Display: PL : Xx (present set value)
LIGHT
t -iKk-
When the correction operation is completed, press m switch @ at any time to return
to the CHEC display. (End)
lo-184 HD325-6
0 Operation for setting loading completion recognition travel distance
;
0 Ii
@
0
PYY I 1
I-!
--- 0
4 3 2 SVH00472
q Set to PL : Xx display, then press

CAL
switch @
t CM-
Display: O.SEL
q Press ‘igL switch 0.

t
Display: XXX
LIGHT
If it is necessary to correct the setting for the units, press switch @ and correct.
t 7Kic-
q Press :tk switch 0.

t
Display: X&X
LIGHT
If it is necessary to correct the setting for the tens, press switch @ and correct.
t ItiC-
CAL
q Press
Tic switch @again.
t
Display: XXX
LIGHT
If it is necessary to correct the setting for the hundreds, press switch @ and cor-
t -Itic-
rect.
q If Ek switch @ is pressed again, the display will return to XXX_ so it is possible to correct
t
the units again.
q When the correction operation from Step q is completed, press VI switch (I) at any time to re-
turn to the CHEC display after displaying 0.XxX (input value). (End)
If it is impossible to set the input values even when v] switch @ is pressed, it displays 0.XxX
(input value) and returns to Step IZi.
HD3256 lo-185
(j) Operation for setting loading start recognition payload
PAYLOAD METER
4 3 2 SVH00472
q Set to OSEL display, then press

CAL
--- switch @
t CLR
Display: PSEL
TOTAL
Press switch 0.
t SF4
Display: XXXX
LIGHT
If it is necessary to correct the setting for the tens, press switch @ and correct.
t WC?
CAL
Press switch 0.
t EiR
Display: XXXX
LIGHT
If it is necessary to correct the setting for the hundreds, press switch @ and cor-
t Xk-
rect.
CAL
Press switch @again.
t ?XR
Display: XXXX
LIGHT
If it is necessary to correct the setting for the thousands, press switch @ and cor-
t WE-
rect.
If ipk switch @ is pressed again, the display will return to Step q, so it is possible to correct
t
again.
When the correction operation from Step Ijl is completed, press 19 switch @I at any time to
return to the CHEC display. (End)
If it is impossible to set the input values even when m switch @ is pressed, it returns to Step q.
lo-186 HD3256
@ Operation for setting 0 ton display range
i 3 2 SVH00472
q Set to PSEL display, then press

CAL
switch @
F -tiff
Display: H.SEL
q Press ‘igL switch 0.

t
Display: --XX (present value)

LIGHT
t -itiC-
q When the correction operation from Step bl is completed, press [MoDEI switch 0 at any time to
HD325-6 lo-187
(IJ Operation for setting display range of external display lamps
PAYLOAD METER
4
I II
3 2 SVH0047'2
Display: A.= (present value of lamp 1)

LIGHT
If it is necessary to correct the display range for lamp 1, press switch @ and correct.
t MC-
Display: b.m (present value of lamp 2)

LIGHT
If it is necessary to correct the display range for lamp 2, press switch @and correct.
F -itiC-
q Press gk switch @again.

t
Display: C.m (present value of lamp 3)
LIGHT
If it is necessary to correct the display range for lamp 3, press switch @and correct.
t 7tiC-
q Press $ switch @ again.

t
Display: d.m (present value of lamp 4)
LIGHT
F ItiC-
switch @again.
Display: E.XXX (present value of lamp 5)

LIGHT
F MC-
IJ When the correction operation from Step q is completed, press )MODEI switch 0 at any time to
If it is impossible to set the input values even when vl switch @ is pressed, it displays d.FAL
(input value) and returns to Step a.
10-188 HD325-6
2. Pressure sensor
The pressure sensor is installed at the bot-
tom end of the suspension cylinder and acts
to measure the pressure at the cylinder bot-
tom.
561 F03158
When replacing pressure sensor (I 1, leave the

valve installed to the suspension and remove
only pressure sensor (1).
When removing or installing pressure sensor
(I), be careful not to let valve (2) rotate.
When removing pressure sensor (I), the ac-
tion of valve core (3) prevents the suspension
pressure from going down.
SVH00476
The output characteristics of the sensor are

as shown in the diagram on the right.
[Voltage between pin (I) (GND) and pin

(3) (output) of each pressure sensor con-
nector or voltage of output (pins (4), (51,
(61, (7)) of each sensor when pin (3) of
payload meter II controller connector
(PM61 is grounded]
(50) (1001 (1501

Pressure SVH00725
Pressure sensor
SVH00710
1. Sensor
2. Tube
3. Connector
HD325-6 lo-189
3. Clinometer
To carry out compensation on slopes, the cli-
nometer measures the tilt angle of the chas-
sis in the front-to-rear direction.
561FO3161
The output characteristics of the clinometer

are as shown in the diagram on the right.
r 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 (PH6
pin) is grounded
WDhill grade is PIUS.

SVH00720
4. Lamp drive relay

The external display lamps are driven by a
signal from the payload meter.
561FO3164
10490 HD3256
STRUCTURE AND FUNCTION PAYLOAD METER II (Card tvoe)
5. Self-diagnostic function
The controller always observes the condition of the sensors and outputs, and if any abnormality
occurs, it displays an error message.
Error message display
Irder
of Content Judgement
-r Error code displ f
isplay standard Controller xternal lamr Zancellatior Trming for display
riority display display of display
1 Dump lever at position - b-FL ON All flash When for HD1200-II
other than FLOAT (ex- removed Nhen parking brake
cept when dumping) )r brake lock is ON
b-FL ON - When for HD1200-11

removed Nhen parking brake
)r brake lock is OFF
2 Memory card - Cd flashes - When qemoval detection

removed removed ,nly for card dump
3 Drop in backup battery Defective contact F-09 flashes When Except during
voltage or voltage below removed oading
2.7 v
4 C$p data memory See (*I) See (*I) - See (*l) Ixcept during
oading
Engine ON/OFF data

memory FULL
Abnormality, warning
data memory FULL
Aggregate payload,
number of cycles data
memory FULL
Disconnection in Output below 2 V F-18 flashes All flash When Nhen engine is
terminal R when engine is removed punning
running
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
Short circuit with Suspension pres- F-21 flashes All flash When Any time
ground, disconnection sure sensor input removed
in front left suspen- signal is 0 kg/cm2
sion pressure sensor or below
system
Short circuit with F-22 flashes

ground, disconnection
in front right suspen-
sion pressure sensor
system
Short circuit with F-23 flashes

in rear left suspension
pressure sensor sys-
tem
10 Short circuit with F-24 flashes

in rear right suspen-
sion pressure sensor
system
lo-192 HD325-6
Saving abnormality,
warning data (PCsoft- Remarks
ware display code)
- Display timing for other
than HD1200-1: Shift le-
ver position N
- Display timing for other
than HD1200-1: Shift le-
ver 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

is abnormality
(000-022)
(000-023)
(000-024)
HD325-6 10-793
3rder Error code display

isplay standard Controller External lamp Cancellation Timing for display
riority 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 19.6 MPa
sure sensor system {200 kg/cm? or
more
power source in front
right suspension pres-
sure sensor system

power source in rear
left suspension pres-
sure 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+100 removed
in clinometer system
16 Short circuit with Clinometer input F-32 flashes

power source in signal above-100
clinometer system EG
17 Calibration not per- Calibration data F* CAL All flash When Any time
;r$n&or abnormality in memory dam- flashes removed
aged
18 Short circuit in exter- When coil is con- F-41 flashes See Remarks When Except when load-
nal display lamp No. 1 ducting electricity, column removed ing (for external
relay relay coil short cir- display lamps, see
cuits with power Remarks column)
19 Short circuit in exter- source F-42 flashes
nal display lamp No. 2
relay
20 Short circuit in exter- F-43 flashes

relay

relay

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 -2 km/h occurs
limit
10-194 HD325-6
-
Saving abnormality,
warning data (PC soft- Remarks
ware display code)
-
is abnormality
-
(000-026)
-
(000-027)
-
(000-028)
Re.cords Applicable only when

(000-031) clinometer “use” switch
is at “use”
- Calibration cannot be
is abnormality
-
Records Payload calculation
(000-019) stopped while problem
occurs
-
Records External display lamps
(000-041) actuated as follows
- Applicable lamp
(000-042) Machine stopped:
Always ON
Machine traveling: OFF
-
Other lamps during
loading:
Specified actuation
- Other than loading
(000-044) Machine stopped:
Flashes
Machine traveling: OFF
-
(000-045)
-
-
-
-
HD3256 10-195
3rder Error code display

lisplay standard Controller External lamp Cancellation Timing for display
Nriority display display of display
25 Defective communica- F-71 - When -
tions or defective set- F-73 removed
ting 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
lo-196 HD3256
Saving abnormality,
warning data (PC soft- Remarks
ware display code)
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)
HD325-6 10-197
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEM

SYSTEM DRAWING
HD325-6
HD325-6W
HD405-6
Lamp inside
dashboard
Alternator
\ -33
terminal
Km/h, mph
R
Dimmer switch
Unit selector
S*i tcheg connector
I \
l.Lamp chech switch
2. Al55 switch
XExhaust brake switch
4.Mode chance switches (I), (21
Transmission
shift
controller
Engine I
controller
NETWORK DATA
1. From monitor panel to controllers
Travel speed compensation
l data
Service mode data requested
l
2. From controllers to monitor panel

Display data related to controllers
l
Service mode data requested

l
Troubleshooting
l data
3. From transmission shiftcontrollerto monitor
panel
. Model selection data
SVH00728
10-l 98 HD325-6
0
OUTLINE
l With the machine monitor system, the con-
trollers on the network transmit the data for
observation and control of the machine con-
dition performed by sensors installed to vari-
ous parts of the machine, and transmit this
as network data to the monitor panel. The
monitor panel then displays these data to in-
form the operator of the condition of the ma-
chine.
. The monitor panel display has a normal mode
and a service mode.
. Normally, the normal mode is displayed to
the operator. The main contents are as fol-
lows.
(1) Items always displayed:
Meters (speedometer, tachometer, service
meter, odometer)
Gauges (air pressure, engine water tem-
perature, torque converter oil tempera-
ture, retarder oil temperature, fuel level)
Pilot displays
(2) Items displayed if there is any abnormal-
ity:
Cautions, user code display
. To make troubleshooting by the controller (in-
cluding the monitor panel itself) on the net-
work simpler, the system is equipped with a
service mode function. The main items are
as follows.
(I) Machine data monitoring mode:
The input and output values recognized
by the controller on the network are dis-
played in real time.
(2) Service code, travel data display mode:
This displays the failure data stored in the
controllers on the network.
. The machine monitor system consists of the
monitor panel itself, the lamps inside the
dashboard, central warning lamp, alarm
buzzer, switches used for input to the moni-
tor panel, the network, the controllers on the
network, and the sensors related to the con-
troller.
HD325-6 10-199
MONITOR PANEL DIAGRAM

HD325-6
HD325-6W 5 2 1 12 10 9 II 14 36 17 18 I! 20 21 23 24
HD405-6
30 i i 3’ i 13 15 16 37 i2 i7 is is
I
3i 33 32 31 35 SVH00729
Air pressure gauge 19. Abnormality in shift OUTLINE

Coolant temperature control system . The monitor panel consists of the L.H. mod-
gauge (mechatronics) ule, center module, R.H. module, service
Torque converter oil 20. Abnormality in other meter, odometer, plate, and other structural
temperature gauge control system
parts.
Retarder oil tempera- (mechatronics) . The center module has one microcomputer
ture gauge 21. Fuel level caution
mounted, and it processes and displays the
5. Air pressure caution 22. Fuel level gauge
23. Power mode high network and other signals.
6. Coolant temperature
caution power A liquid crystal display is used.
24. Power mode . The monitors and gauges inside the R.H. mod-
7. Torque converter oil
temperature caution economy ule and L.H. module are actuated by signals
8. Retarder oil tempera- 25. Suspension hard from the center module, and the odometer is
ture caution 26. Suspension medium also actuated by signals from the center mod-
9. Hi beam 27. Suspension soft ule.
10 Turn signal indicator 28. Service meter The service meter is actuated by a signal from
(left) 29. Service meter actua-
the alternator terminal R.
11
, ,. Turn signal indicator tion display lamp
(right) 30. Travel distance meter
12. Speedometer (odometer)
13. Tachometer 31. L.H. module
14. Shift limiter 32. Center module
15. Lock-up 33. R.H. module
16. Shift indicator 34. Service meter
17. Shift position 35. Odometer
18. Abnormality in en- 36. User code (for abnor-
gine control system mality only)
(mechatronics) 37. Travel speed compen-
sation rotary switch
10-200 HD325-6
0
MACHINE MONITOR NORMAL DISPLAY FUNCTIONS

HD325-6
HD325-6W
HD405-6
1. Monitor panel gauge and gauge caution display
Display
Symbol Display item category Display range, conditions Display method
Air pressure Gauge 7-level display

One place lights up to show level.
No. 1
Caution When below 0.51 MPa OFF when normal

{5.2 kg/cm2} When there is any abnormality,
lamp flashes, central warning
lamp lights up, and alarm buzzer
sounds.
Engine water Gauge 7-level display

temperature One place lights up to show level.
No. 2
SAP00527
Caution When above 102˚C OFF when normal

When there is any abnormality,
sounds.
Torque Gauge 7-level display
converter oil One place lights up to show level.
temperature
No. 3

sounds.
HD325-6 10-201
C
Display
Retarder oil Gauge 7-level display

temperature One place lights up to show level.
No. 4

sounds.
Fuel level Gauge 14-level display

All lamps for appropriate level
and below light up
No. 5
Caution When below low level OFF when normal

When it is below low level, lamp
flashes and central warning lamp
lights up.
10-202 HD325-6
C
2. Monitor panel mechatronics caution display
Display
No. 6 Engine control Caution When there is an abnormal- OFF when normal
system ity in engine control system When there is any abnormality,
(mechatronics) (mechatronics) lamp flashes, central warning
WHO0481 sounds.
No. 7
Shift control Caution When there is an abnormal- OFF when normal
system ity in shift control system When there is any abnormality,
(mechatronics) (mechatronics) lamp flashes, central warning
SVH00482 sounds.
No. 6
Other control Caution When there is an abnormal- OFF when normal
system ity in other control system When there is any abnormality,
[D
PP (mechatronics) (mechatronics) lamp flashes, central warning
SVH00483 sounds.
3. Monitor panel user code display
Display
User code User code When there is abnormality When normal, lamps are OFF
No. 9 or failure on machine When an abnormality or failure
occurs, “E-” and a 2-digit user
code are displayed in turn.
For details, see Monitor panel
user code display and service
WHO0484 mode function.
4. Monitor panel pilot display
Symbol Display item Display method
No. IO Hi beam ON
1 I
SVH00485
Turn signal When left or right is Left or right ON

indicator actuated
(right, left)
SVH00486 1 I I
No. 12 Lock-up Pilot When actuated ON
A0132430
No.13 Shift limiter Pilot When actuated ON

/
Q
AD132490
HD3256 1 O-203
Display
Shift lever Pilot When shift lever is at R ON
R
position R position
t
Shift lever Pilot When shift lever is at N ON
N
position N position
Shift lever Pilot When shift lever is at D ON

position D position
Shift lever Pilot When shift lever is at 5 ON

position 5 position
5
position 4 position I
4
position 3 position
3
Shift lever Pilot When shift lever is at L ON
position L position
L
No.14 High power Pilot When in high power mode ON when in high power mode.
P mode Flashes in high power mode
during delayed operation.
T
SVH00487
No.15 Pilot When in economy mode ON when in economy mode.

Flashes in economy mode
during delayed operation.
E TSVH00488
H Suspension
mode: Hard
Pilot When suspension mode is
at “Hard”
ON
ii3i
SVH00489
Su;p;;;ion Pilot When suspension mode is ON

at “Medium”
M Medium
SVH00490
Pilot When suspension mode is ON

at “Soft”
3 SVH00491
1 O-204
5. Monitor panel pilot display
Display
No. 16 Travel speed Meter 0-99km/horO-99mph Digital display.

When CNP15 is not connected:
Unit = km/h
B@AaC”
When CNP15 is connected:
Unit = mph
SVH00492
No. 17 Engine speed Meter 0 - 2,800 rpm 25 bar graph display.

When engine speed goes above
2500 rpm (23rd segment), central
warning lamp lights up and alarm
buzzer sounds.
No. 18 Shift Meter l-8 Digital display

indicator R, N. E “E” displayed when there is
abnormality in shift range.
SVH00494
No. 19 Service meter Meter 0 - 99999 h Advances when engine is

running.
Advances 1 for each 1 hour of
operation
SVH0049!
Service meter Pilot Flashes when service meter is

indicator advancing
(when engine is running).
No. 20 Odometer Meter 0 - 999999.9 km Operates when machine is

traveling
SVH00496
HD325-6 1O-205
6. Lamps inside dashboard (caution items)
Display
No.21 I?adiator water Caution When cooling water level OFF when normal.
level drop drops When there is any abnormality,
warning lamp flashes, central warning
lamp fights up, and alarm buzzer
SAP00519
sounds.
No.22 Engine oil Caution When engine oil pressure OFF when normal.
pressure drop drops When there is any abnormality,
SDH002310 sounds.
No.23 Warning of Caution When there is abnormality OFF when normal.
‘sbnormafity in in charging circuit When there is any abnormality,
charging lamp flashes, central warning
circuit lamp fights up, and alarm buzzer
SDH0023 1 sounds.
Transmission Caution When transmission filter is OFF when normal.
filter clogging clogged When there is any abnormality,
AK62878f ,_ sounds.
No.25 Rear brake Caution When brake chamber OFF when normal.
warning stroke is too large When there is any abnormality,
0! 9JMOO679 I
sounds.
No.26 Tilt warning Caution OFF when normal.
When dump body is raised
and there is excessive tilt to When there is any abnormality,
left or right lamp flashes, central warning
& lamp fights up, and alarm buzzer
AK62697C b sounds.
No.27 Maintenance Caution When there is a mainte- OFF when normal
q
warning nance related warning gen- ON when there is any abnormal-
erated ity
SVH00497I
No. 28 Steering oil Caution When steering oil tempera- OFF when normal
temperature ture rises When there is any abnormality,
rise warning lamp flashes, central warning
SVH00498 sounds.
I3ody actuated Caution When body dump fever is Lights up when fever is at posi-
at position other than tion other than FLOAT or body is
No. 29 FLOAT or when body is raised.
raised Goes OFF when fever is at FLOAT
and dump body is lowered.
When dump fever is at position
other than FLOAT and shift fever
AK626770 is at position other than N, cen-
tral warning lamp fights up and
alarm buzzer sounds.
Parking brake Caution When parking brake is ON

No.30 caution applied When parking brake is applied
and shift fever is at position other
than N, central warning lamp
fights up and alarm buzzer
SOH0023I I sounds.
1 O-206 HD3256
7. Lamps inside dashboard (pilot item)
Symbol Display item Display method
Lamp lights up and central

warning lamp also lights up.
Pilot When exhaust brake is ON

applied
Pilot When preheat switch is ON ON

pilot
Pilot When rear brake is applied ON
Pilot When differential lock is ON

actuated
8. Other actuation of central warning lamp and alarm buzzer
(I) When the shift lever is at a position other than N and the starting switch is turned ON, the shift
control system (mechatronics caution) flashes, the central warning lamp lights up, and the alarm
buzzer sounds. (Neutral safety function - service code b003)
(2) When the shift lever is at a position other than N and the starting switch is turned to the START
position, the central warning lamp lights up, and the alarm buzzer sounds.
HD3256 1 O-207
SELF-DIAGNOSTIC FUNCTION WHEN STARTING SWITCH IS OPERATED

HD325-6
HD325-6W
HD405-6
(I) When the starting switch is turned ON, self-diagnosis of the monitor itself is carried out and all
lamps light up for 3 seconds.
At the same time, the lamps inside the dashboard light up for 3 seconds, the central warning
lamp lights up for 3 seconds, and the alarm buzzer sounds for 1 second.
After this, all lamps return to the normal operation.
(2) If the starting switch is turned to the START position before 3 seconds have passed after turning
the starting switch ON, all lamps will return to normal operation at this point.
Note: When the lamps return to normal operation, the gauges will not display for 3 seconds after
the starting switch is turned ON.
TRAVEL SPEED COMPENSATION ROTARY SWITCH

HD325-6
HD325-6W
HD405-6
1. OUTLINE
Rotary switch (2) inside the grommet at the rear of the monitor panel center module is used to
compensate the travel speed if tires of a different size are used.
2. ROTARY SWITCH (2) AND TRAVEL SPEED COMPENSATION

As shown in the table below.
Setting of rotary switch (2) 0 1 2 3 4 5 6 7
Travel speed compensation (%) +7 +6 +5 +4 +3 +2 +I +0
Setting of rotary switch (2) 8 9 A B C D E F
Travel speed compensation (%) k0 -1 -2 -3 -4 -5 -6 -7
3. CAUTION
1) When turning rotary switch (21, use a fine crosshead screwdriver and turn the switch slowly.
2) Rotary switch (3) is not used for anything, but do not turn it.
3) There is no switch inside grommet (1).
1 O-208 HD325-6
0
ENGINE OIL PRESSURE

(Only for machines not equipped with electronic governor)
HD325-6
HD325-6W
HD405-6 4. 5
: 3.5
"
0
> 2.5
';
a
2
I. 5
0. 5
MPa
1kdcm'l
Pressure SVH00730
Structure of circuit SVH00731
1. Center FUNCTION
2. Connector . The engine oil pressure sensor is installed to
3. Wiring harness the block at the oil inlet and outlet port for the
4. Connector engine oil filter.
It measures the oil pressure and sends a volt-
age signal to the shift controller_
HD325-6 1O-209
0
ENGINE WATER TEMPERATURE SENSOR

(Only for machines not equipped with electronic governor)
RETARDER OIL TEMPERATURE SENSOR
TORQUE CONVERTER OIL TEMPERATURE SENSOR
HD325-6
HD325-6W
HD405-6
SVH00732
1. Connector FUNCTION
2. Plug l These sensors are installed to the engine cyl-
3. Thermistor inder block, at a mid-point of the retarder oil
piping, and to the transmission case. Any
change in the temperature is taken as a
change in the resistance of the thermistor, and
a signal is sent to the shift controller. The
signal is then sent from the shift controller
through the network to the machine monitor
panel to display the temperature. When the
monitor panel display reaches the specified po-
sition, the lamp flashes and the buzzer sounds
to warn the operator of an abnormality.
AIR PRESSURE SENSOR
1. Connector
2. Tube
3. Frame
FUNCTION
HD325-6
HD325-6W
HD405-6
. The air pressure sensor is installed to the air
1 piping behind the operator’s seat. It converts
2
8 any change in the air pressure inside the wet
tank to a change in the resistance, and sends
a signal to the shift controller.
3 The signal is sent from the shift controller
through the network to the machine monitor
panel, and the air pressure is displayed. If
the air pressure goes belowthe specified pres-
sure, the monitor panel lamp flashes and the
SVH00733
alarm buzzer sounds to warn the operator of
the abnormality.
10-210 HD325-6
0
FUEL LEVEL SENSOR
\._,’
4 5 Ei
k
E
F
Y
7 Structure of circuit
A-A SWHOOBZO
I. Connector FUNCTION
2. Float
HD325-6
3. Arm
HD325-6W
4. Body
HD405-6
5. Spring
6. Contact . The fuel level sensor is installed to the side
7. Spacer face of the fuel tank and a float moves up or
down in accordance with the change in the
fuel level. The movement of the float is
passed through the arm and actuates a vari-
able resistance, and a signal is sent to the shift
controller. The signal is sent from the shift
controller through the network to the machine
monitor system to display the fuel level.
When the display on the monitor panel
reaches a certain position, the warning lamp
flashes.
HD3256 10-211
0
TILT SWITCH
SVH00677
1. Magnet FUNCTION
2. Plate
HD325-6
3. Gasket
HD325-6W
4. Print card
HD405-6
5. Bracket
6. Plate . If the chassis tilts to the left or right, the disc
7. Plate magnet moves to the left or right. If the chas-
8. Plate sis tilts into the roll-over danger range, either
9. Connector the left or right switch is turned OFF. If the
dump lever is operated to the RAISE position
in this condition, the lamp lights up and the
buzzer sounds to warn of the danger.
1o-21 2 HD325-6
0
TRANSMISSION OIL FILTER SENSOR
SVH00734
1. Body FUNCTION
2. Tube . This sensor are installed to each filter, and
3. Connector when the filter becomes clogged, and the dif-
ference in pressure between the low-pressure
A: Low pressure pickup port side and high-pressure side reaches the speci-
B: High pressure pickup port fied pressure, the switch goes OFF. The main-
tenance monitor display then flashes to warn
of abnormality.
Actuating pressure:
Transmission oil filter sensor:
275 f 20 kPa I2.8 If: 0.2 kg/cm*}
Principle of switch: Pressure difference sliding

piston type
RADIATOR WATER LEVEL SENSOR
SVH00735
1. Float FUNCTION
2. Sensor . This sensor is installed to the top of the radia-
3. Connector tor, and when the cooling water level goes
below the specified level, the float goes down
and the switch goes OFF. The caution lamp
then flashes and the buzzer sounds to warn
of abnormality.
HD325-6 10-213
BODY SEATED SWITCH
HD325-6
HD325-6W
HD405-6
SVH00500
1. Roller FUNCTION
2. Lever . The body seated switch distinguishes if the
3. Housing dump body is fully lowered or not. If the dump
4. Cable body is not fully lowered, the caution lamp
5. Connector lights up.
10-214 HD325-6
0
STEERING OIL TEMPERATURE SENSOR

HD325-6
HD325-6W
HD405-6
1. Switch FUNCTION
2. Plug • The steering oil temperature sensor is in-
3. Wire stalled in the return piping of the steering and
4. Connector hoist circuit. The temperature is detected at
the switch portion and when the temperature
goes above the specified level, the switch is
turned ON, the caution lamp lights up, and
the alarm buzzer sounds to warn the operator
of the abnormality.
REAR BRAKE CHAMBER STROKE SENSOR

HD325-6
HD325-6W
HD405-6
1. Ball FUNCTION
2. Shaft • The brake stroke sensor is installed to the
3. Switch brake chamber. If the air piston in the brake
4. Wiring harness chamber goes beyond the specified stroke, the
5. Connector rod installed to the brake chamber pushes the
ball and shuts off the electric current. The
switch is turned OFF, the caution lamp lights
up, and the alarm buzzer sounds to warn the
operator of the abnormality.
HD325-6 10-215
7
STRUCTURE AND FUNCTION OIL FILTER CAUTION SYSTEM
OIL FILTER CAUTION SYSTEM (IF EQUIPPED)

SYSTEM DIAGRAM
OUTLINE
• The oil filter caution system monitors the ma-
chine condition with the sensors installed to
various parts of the machine and processes
the collected information quickly and displays
the result on the oil filter caution monitor to
notify the operator of the machine oil main-
tenance information (replacement periods of
various oils, filters, etc.)
• The oil filter caution system consists of the
oil filter caution monitor, various sensors, and
the power supply unit.
• The indicators are roughly classified into the
monitor unit (check before starting) which
turns on the alarm when the machine has
abnormality and the maintenance timer which
indicates the replacement periods of the oils
and filters.
10-216 HD325-6
C
MONITOR PANEL
1. Engine oil 12. Replacement OUTLINE

2. Transmission oil switch • Oil filter caution monitor consists of the main-
3. Hydraulic oil 13. Wrong operation tenance module, monitor module, plates, and
4. Final differential oil cancel switch other mechanism parts.
5. Full-flow filter 14. Replacement pe- • The maintenance module has 1 microcom-
(Clogging) riod check switch puter, which processes the signals from the
6. Fuel filter (Filter) sensors and calculates and indicates the us-
7. Corrosion resistor 15. Maintenance ing hours of various oils and filters. A liquid
8. Transmission oil filter module crystal display is used to indicate the using
(Clogging) (Tank side) 16. Monitor module hours.
9. Hydraulic oil filter 17. Switch A • The monitor module is operated with the sig-
(Clogging) 18. Switch II nals from the maintenance module.
10. Display of mainte 19. Switch B
nance time 20. Switch C
11. Replacement period 21. Switch I
check switch (Oil) 22. Switch D
HD325-6 10-216-1
C
CIRCUIT DIAGRAM OF OIL FILTER CAUTION MONITOR

fl For details of this page, see section 90.
10-216-2 HD325-6
C
ITEMS DISPLAYED BY MONITOR AND FUNCTIONS

Classifi-
cation of Displayed item Display range Method of display
display
Clogging of full-flow filter Above set differential pres-

sure Displayed when torque converter oil tem-
perature is above 50 °C while engine is run-
ning. Display lamp goes off when normal
Clogging of transmission oil Above set differential pres- and flashes when abnormal.
Check filter (Tank side) sure
Displayed when brake oil temperature is

Clogging of hydraulic oil fil- Above set differential pres- above 50 °C while engine is running. Dis-
ter sure play lamp goes off when normal and flashes
when abnormal.
Engine oil (*1) Display lamp goes off when displayed time
is 1 – 250 h and lights up when abnormal.
Display lamp goes off when displayed time

Engine oil (*2)
is 1 –- 500 h and lights up when abnormal.

Transmission oil
is 1 – 1,000 h and lights up when abnormal.

Hydraulic oil
Mainte- is 1 – 2,000 h and lights up when abnormal.
Below 0 h of displayed time
nance
Final differential oil Display lamp goes off when displayed time
Full-flow filter ( 1) Display lamp goes off when displayed time

Full-flow filter ( 2) Display lamp goes off when displayed time


Fuel filter
1. HD325-6 Serial No.: 5680 – 5999, HD325-6W Serial No.: 5706 – 5999, HD405-6 Serial No.: 1055 – 1999
2. HD325-6 Serial No.: 6001 and up, HD325-6W Serial No.: 6001 and up, HD405-6 Serial No.: 2001 and up
HD325-6 10-216-3
C
Classifi-
cation of Displayed item Display range Method of display
display

Corrosion resistor

Mainte- is 1 – 500 h (Both valve side and tank side)
nance Transmission oil filter Below 0 h of displayed time
and lights up when abnormal (filter on tank
side).

Hydraulic oil filter
Display of time
Mainte- 0 – 9999 h (Negative time is Time of item indicated by arrow ( , ) is
nance
timer indicated by flashing) displayed.
10-216-4 HD325-6
C
FUNCTIONS OF SWITCHES
Switch name Function
Each time this switch is pressed, the arrow ( ) moves to the following items
order and the indicated time also changes.
Replacement period check Engine oil ––––––––––––– Transmission oil ––––––––––––– Hydraulic oil
(Oil)
Final differential oil
Each time this switch is pressed, the arrow ( ) moves to the following items in
Replacement period check Full-flow filter ––––––––––––– Fuel filter ––––––––––––– Corrosion resistor
(Filter)
Hydraulic oil filter ––––––––––––– Transmission oil filter
When an oil or a filter is replaced, if the replaced oil or filter is selected with the
above switch and this switch is held for 2 seconds, the displayed item is set to the
Replacement initial set time (shown in the table at right).
This function is effective only while the engine is stopped. (The set time is entered
when the engine is started (when the alternator starts generation.)
If a wrong item is set by the above operation, it is returned to the original value by
Wrong operation cancel pressing this switch.
This function is effective only while the engine is stopped.
While this switch is pressed, the maintenance timer is set in the manual setting
mode. In this mode, the operator sets the time of the item selected with switch II
by using the following switches. Each time switch A, B, C, or D is pressed, the
figure of the place corresponding to the pressed switch changes in the order of
0 → 1 → 2 ..... → 9.
→
Switch I
 
Operate this switch only
when the maintenance 4th figure from right 3rd figure from right 2nd figure from right 1st figure from right
module is replaced. Switch A Switch B Switch C Switch D
Each time all the figures are set to 0, the "+" and "–" of the set time changes to each
other.
(Flashing of the number indicates "–".)
This function is effective only while the engine is stopped.
This switch is used to check the replacement period in the manual setting mode.
Each time this switch is pressed, the arrow ( , ) moves to the following items in
Engine oil Full-flow filter
Transmission oil Fuel filter

Switch II
Hydraulic oil Corrosion resistor
Transmission oil filter
Final differential oil Hydraulic oil filter
HD325-6 10-216-5
C
Initial set time of maintenance timer
Item Initial set time (H)

Engine oil ( 1) 250
Engine oil ( 2) 500
Transmission oil 1,000

Hydraulic oil 2,000
Final differential oil 2,000
Full-flow filter ( 1) 250
Full-flow filter ( 2) 500

Fuel filter 500
Corrosion resistor 1,000
Transmission oil filter

500
(Both valve side and tank side)
Hydraulic oil filter 1,000
1. HD325-6 Serial No.: 5680 – 5999

HD325-6W Serial No.: 5706 – 5999
HD405-6 Serial No.: 1055 – 1999
2. HD325-6 Serial No.: 6001 and up
HD325-6W Serial No.: 6001 and up
HD405-6 Serial No.: 2001 and up
10-216-6 HD325-6
C
HYDRAULIC OIL FILTER SENSOR

TORANSMISSION OIL FILTER SENSOR
1. Body FUNCTION
2. Tube • This sensor is installed to each filter. If the
3. Connector filter is clogged and the difference between
the low pressure and high pressure becomes
A. Low oil pressure pickup plug the set pressure, the switch is turned OFF and
B. High oil pressure pickup plug the lamp on the maintenance monitor flashes
to notify the operator of the abnormality.
Operating procedure
For hydraulic oil filter sensor:
98.1 ± 19.6 kPa {1.0 ± 0.2 kg/cm2}
For transmission oil filter sensor (Tank side):
98.1 ± 19.6 kPa {1.0 ± 0.2 kg/cm2}
Principle of switching:
Differential pressure sliding piston type
FULL-FLOW FILTER SENSOR
FUNCTION
• This sensor is installed to the full-flow filter.
If the filter is clogged and the difference be-
tween the low pressure and high pressure
1. Spring becomes the set pressure, the switch is turned
2. Spring OFF and the lamp on the maintenance moni-
3. Contact tor flashes to notify the operator of the ab-
4. Contact normality.
+39.2
A. High oil pressure pickup plug Operating procedure: 147.1 0 kPa
B. Low oil pressure pickup plug {1.5 +0.4 2
0 kg/cm }
HD325-6 10-216-7
C
STRUCTURE AND FUNCTION FRONT DRIVE SYSTEM
FRONT DRIVE SYSTEM

HD3256W
SYSTEM DIAGRAM
-_
F -4 I-wheel
controller
drive
I ~__
-__+-ff-v //j f
---
-----i 1
1I
L
In
,E
FUNCTION
. The front drive system receives the transmis-
sion speed range signal, front and rear wheel
speed signals, and the signals from the other
switches and sensors. The 4-wheel drive con-
troller automatically controls the drive force
for the front wheels to the optimum value.
. When there is any abnormality in the front
drive system, the central warning lamp lights
up and the alarm buzzer sound. In addition,
the 4-wheel drive switch lamps flash and the
error code is displayed on the top surface of
the controller. (For details of the error codes,
see TROUBLESHOOTING.)
HD325-6 10-217
0
STRUCTURE AND FUNCTION 4-WHEEL DRIVE CONTROLLER
4-WHEEL DRIVE CONTROLLER
566FO6253
1. Printboard FUNCTION
2. Self-diagnosis display window . The controller detects the signals from the
3. Case sensors and switches mounted on the ma-
4. Connector chine, truns the ECMV (clutch control valve)
5. Connector ON/OFF, and controls the front drive pump
6. Connector and motor.
lo-218 HD325-6
0
20 TESTING AND ADJUSTING
Standard value table for engine related Testing hydraulic pressure of torque
parts ............................................................ 20- 2 converter valve ......................................... 20- 36
Standard value table for chassis ................ 20-2-2 Testing ECMV oil pressure ......................... 20- 37
Standard value table for electrical parts...... 20-6-1 Testing torque converter stall speed ........ 20- 39
Table of tools for testing, adjusting, Testing brake pressure ............................... 20- 40
and troubleshooting .................................. 20-17 Bleeding air from brake circuit .................. 20- 41
Adjusting valve clearance ............................ 20-19 Testing and adjusting parking brake
Measuring compression pressure .............. 20-20 performance ............................................. 20- 42
Measuring blow-by ...................................... 20-21 Testing wear of front brake pad ................ 20- 43
Adjusting alternator belt tension ................ 20-22 Testing wear of front brake disc ................ 20- 43
Adjusting fan belt tension ........................ 20-22-1 Testing wear of rear brake disc ................. 20- 44
Measuring engine speed ............................. 20-23 Testing rear brake caution system ........... 20-44-1
Measuring engine oil pressure ................... 20-24 Testing and adjusting suspension
Measuring boost pressure ........................... 20-25 cylinder ..................................................... 20- 45
Measuring exhaust temperature ................. 20-26 Testing and adjusting set pressure of
Measuring exhaust gas color ...................... 20-27 air governor .............................................. 20- 51
Testing and adjusting fuel injection Adjusting hoist lever linkage ..................... 20- 52
timing .......................................................... 20-28 Adjusting body positioner ......................... 20- 53
Air bleeding from fuel system ..................... 20-32 Testing and adjusting hydraulic pressure
Checking for leakage in fuel system ........ 20-32-3 in steering, hoist circuit ........................... 20- 54
Measuring fuel pressure ........................... 20-32-4 Air bleeding from steering cylinder .......... 20- 56
Releasing remaining pressure in fuel Bleeding air from front drive hydraulic
system ...................................................... 20-32-4 circuit ........................................................ 20-56-1
Handling equipment in fuel circuit .......... 20-32-5 Adjusting electronic monitor ..................... 20- 57
Reduced cylinder mode operation ........... 20-32-6 Setting rotary switch .................................. 20- 58
Handling of engine controller high controller Method of deleting data from
high tension circuit .................................... 20-32-7 transmission controller memory ............ 20- 59
Adjusting engine stop motor cable ............ 20-33 Method for emergency escape when
Adjusting accelerator pedal ......................... 20-34 there is failure in electrical system ......... 20- 62
Adjusting engine speed sensor ................... 20-35 Pm clinic check sheet ................................. 20- 69
Adjusting transmission speed sensor ........ 20-35 Troubleshooting ......................................... 20-101
HD325-6 20-1
C
fl Note the following when making judgements using the standard value tables for testing, adjusting,
or troubleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the ma-
chine from the factory and is given for reference. It is used as a guideline for judging the progress of
wear after the machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on
the results of various tests. It is used for reference together with the state of repair and the history of
operation to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
¤ When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, inset
the safety pins, and use blocks to prevent the machine from moving.
¤ When carrying out work together with other workers, always use signals and do not let unautho-
rized people near the machine.
¤ When checking the water level, always wait for the water to cool down. If the radiator cap is
removed when the water is still hot, the water will spurt out and cause burns.
¤ Be careful not to get caught in the fan, fan belt or other rotating parts.
20-1-1 HD325-6
9
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS

HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
Model HD325-6, HD405-6
Engine SAA6D140E-2
Item Measurement conditions Unit Standard value Permissible

value
High idling rpm 2,450 ± 50 2,450 ± 50
Engine speed Low idling rpm 650 ± 50 650 ± 50
Rated speed rpm 2,000 ± 50 2,000 ± 50
Bosch
At sudden acceleration index Max. 6.0 —
Exhaust gas color
Bosch
At high idling index Max. 2.0 —
Intake valve mm 0.43 —

Valve clearance
(normal temperature)
Exhaust valve mm 0.80 —
Compression pressure MPa Min. 3.82 Min. 2.65

Oil temperature: 40 – 60˚C {kg/cm2} {Min. 39} {Min. 27}
(SAE30 oil) (Engine speed) (rpm) (160 – 200) (160 – 200)
Blowby pressure (Water temperature: Operating range) kPa Max. 20.0 Max. 40.0
(Reference value) At rated output {mmH2O} {Max. 150} {Max. 300}
(Water temperature: Operating range)

At high idling
(SAE30) MPa 0.343–0.490 {3.5–5.0} Min. 0.196 {2.0}
Oil pressure (SEA10W) {kg/cm2} 0.245–0.441 {2.5–4.5} Min. 0.177 {1.8}
At low idling
(SAE30) Min. 0.147 {1.5} Min. 0.069 {0.7}
(SEA10W) Min. 0.098 {1.0} Min. 0.069 {0.7}
Whole speed range

Oil temperature
(Inside oil pan) °C 80 – 110 Max. 120
Fuel injection timing Before top dead center deg. 20 ± 0.5 20 ± 0.5
Belt tension (Alternator) Deflection when pressed with fin- Max. 13

ger force of approx. 98.07 {10 kg} mm 13 – 16 Min. 16
Boost pressure (Water temperature: Operating range) kPa Min. 146.65 Min. 117.32
With torque converter stall {mmHg} {Min. 1,100} {Min. 880}

Exhaust gas temperature
Whole speed range °C Max. 700 Max. 700
20-2 HD325-6
8
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS

Model HD325-6, HD405-6
Engine SAA6D140E-3
Item Measurement conditions Unit Standard value Permissible

value
High idling rpm 2,400 + 050 2,400 + 050
Engine speed 0 0
Low idling rpm 725 – 50 725 – 50
Rated speed rpm 2,000 ± 50 2,000 ± 50
Bosch
At sudden acceleration index Max. 4.0 Max. 6.0
Exhaust gas color
Bosch
At high idling index Max. 1.0 Max. 2.0
Intake valve mm 0.35 —

Valve clearance
(normal temperature)
Exhaust valve mm 0.57 —
Compression pressure MPa Min. 4.12 Min. 2.84

Oil temperature: 40 – 60˚C {kg/cm2} {Min. 42} {Min. 29}
(SAE30 oil) (Engine speed) (rpm) (200 – 250) (200 – 250)
Blowby pressure (Water temperature: Operating range) kPa Max. 1.96 Max. 3.94
(Reference value) At rated output {mmH2O} {Max. 200} {Max. 400}

At high idling
(SAE30) MPa 0.34 – 0.54 {3.5 – 5.5} Min. 0.21 {2.1}
Oil pressure (SEA10W) {kg/cm2} 0.29 – 0.49 {3.0 – 5.0} Min. 0.18 {1.8}
At low idling
(SAE30) Min. 0.12 {1.2} Min. 0.07 {0.7}
(SEA10W) Min. 0.10 {1.0} Min. 0.07 {0.7}
Whole speed range

Oil temperature
(Inside oil pan) °C 90 – 110 Max. 120
Deflection when pressed with fin- 13 – 15 (New part) 13 – 15 (New part)

Belt tension (Alternator) mm 17 – 19 (Tension 17 – 19 (Tension
ger force of approx. 98.07 {10 kg} adjusted) adjusted)
Boost pressure (Water temperature: Operating range) kPa Min. 133.32 Min. 111.99
With torque converter stall {mmHg} {Min. 1,000} {Min. 840}

Exhaust gas temperature
Whole speed range °C Max. 650 Max. 700
HD325-6 20-2-1
8
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS

The figures in [ ] are the HD325-6W
Compo- Standard Permissible
nent Item Measurement conditions Unit value value
• Engine water temperature: 11.0 ± 5% 11.0 ± 5%

F1 [10.5 ± 5%] [10.5 ± 5%]
Within operating range
• Transmission oil temperature:
60 – 80˚C 15.5 ± 5% 15.5 ± 5%
F2 [14.7 ± 5%] [14.7 ± 5%]
• When empty
20.7 ± 5% 20.7 ± 5%
F3 [19.7 ± 5%] [19.7 ± 5%]
Performance
28.1 ± 5% 28.1 ± 5%
F4 [26.7 ± 5%] [26.7 ± 5%]
Travel speed km/h
37.8 ± 5% 37.8 ± 5%
F5 [35.9 ± 5%] [35.9 ± 5%]
51.3 ± 5% 51.3 ± 5%
F6 [48.7 ± 5%] [48.7 ± 5%]
70 ± 5% 70 ± 5%
F7 [66.0 ± 5%] [66.0 ± 5%]
11.9 ± 5% 11.9 ± 5%
R [11.3 ± 5%] [11.3 ± 5%]
Shift up • Engine water temperature: 2,100 ± 50 2,100 ± 50

60 – 80˚C 1,400 ± 35 1,400 ± 35
• Hydraulic oil temperature:
Shift down 45 – 55˚C
• “Braking mode” refers to when 1,325 ± 35 1,325 ± 35
✩ (F2→F1 only) (F2→F1 only)
the accelerator is OFF or the
rear brake is ON.
Shift up 2,400 ± 50 2,400 ± 50
Braking
mode
Shift down 1,550 ± 35 1,550 ± 35
Automatic shift control
Shift up 2,100 ± 50 2,100 ± 50

Engine speed
High
power rpm 1,400 ± 35 1,400 ± 35
mode
Shift down
1,325 ± 35 1,325 ± 35
(F2→F1 only) (F2→F1 only)
Shift up 2,000 ± 50 2,000 ± 50

✩✩
Economy
mode 1,300 ± 50 1,300 ± 50
Shift down
1,250 ± 50 1,250 ± 50
(F2→F1 only) (F2→F1 only)
Shift up 2,450 ± 50 2,450 ± 50

Braking
mode
Shift down 1,550 ± 50 1,550 ± 50
✩ HD325-6 Serial No.: 5680 – 6000 ✩✩ HD325-6 Serial No.: 6001 and up
HD325-6W Serial No.: 5706 – 6000 HD325-6W Serial No.: 6001 and up
HD405-6 Serial No.: 1055 – 2000 HD405-6 Serial No.: 2001 and up
20-2-2 HD325-6
8
The figures in [ ] are the HD325-6W

Compo- Standard Permissible
F1 • F2 • Engine water temperature: 1,500 ± 50 1,500 ± 50

Set Within operating range
F3 – F7 60 – 80˚C 1,250 ± 50 1,250 ± 50
45 – 55˚C
Auto lock-up
• “Braking mode” refers to when ✩ 1,100 ± 50 1,100 ± 50

the accelerator is OFF or the
F1 • F2 rear brake is ON.
✩✩ 1,200 ± 10 1,200 ± 10
Reset
✩ 1,100 ± 50 1,100 ± 50
F3 – F7
✩✩ 1,100 ± 10 1,100 ± 10
prevention
2,600 ± 10 2,600 ± 10
Overrun
Set
Engine speed
rpm 2,350 ± 10 2,350 ± 10

Reset
Same as shift
down for au-
Down-shift inhibitor tomatic shift
control given
above

85 – 110˚C ✩ 1,945 ± 75 1,945 ± 75
45 – 55˚C
• Engine water temperature:
converter
Torque

Economy High power
Engine speed at torque

converter stall 1,915 1,915 ± 100
±100
mode
✩✩
1,850 1,850 ± 100
mode
±100
• Operating effort at a point 150 ✩ Max.34.3 Max.34.3

Starting to {Max.3.5} {Max.3.5}
mm from pedal fulcrum
depress
17.7 ± 4.9 17.7 ± 4.9
✩✩ {1.8 ± 0.5} {1.8 ± 0.5}
Operating N
force {kg)
Accel- 34.3 ± 9.8
✩ {3.5 34.3 ± 9.8
erator ± 1.0} {3.5 ± 1.0}
pedal Fully +2.0 +2.0
42.1 –4.9 42.1 –4.9
✩✩
{4.3 +0.2
–0.5 } {4.3 +0.2
–0.5 }
• Travel at a point 150 mm from ✩ 32 ± 5 32 ± 5

Starting to
Travel depress pedal fulcrum mm
↔ fully
✩✩ 44 ± 5 44 ± 5
HD325-6 20-3
8
The figures in [ ] are the HD3256W

Compo Standard Permissible
l Oil temperature: 60 - 8O’C
Operating force l When machine stopped (empty) Max.29.4 Max.35.3
(Turning speed for (If it is impossible when the &) iMax.3.0) IMax.3.6)
steering wheel: 30 rpm) machine stopped, travel at low
speed with engine at low idling)
l Length at circumference of
Play steering wheel
Steering mm Max. 160 Max. 160
l Engine stopped, until tires start
wheel to move
No. of turns l Lock _j lock Turns 3.4 i 0.4 3.4 * 0.6
Left
+ right l Oil temperature: 60 - 80°C Max. 4 Max. 5
Turning time l Engine speed: Whole range sec.
Right Lock + lock Max. 4
l
Max. 5
+ left
l Oil temperature: 45 - 55’C

Steering . Engine: Full throttle MPa 19.61$.@ 19.61$:$
valve Relief pressure
l Demand valve relief valve {kg/cmz) (2102 ) (2102 )
Max.294 Max.294
Operating force l Tip of pedal
Brake &) (Max.30) (Max.30)
pedal
Travel mm 78+8 785 15
9.81 - 32.23 4.90 - 58.84

Retarder Operating force l At point 10 mm from tip of lever 11.o - 4.0)
& (0.5 - 6.0)
control
lever Travel deg O-84+3 O-84+6
Parking Max.19.6 Max. 29.4
brake lever Operating force l -Rip of lever IMax.2.0) (Max.3.0)
&)
Emergeno Max.19.6 Max.19.6
brake level Operating force l Tip of lever iMax.2.0) (Max.2.0)
&
0.814 + 0.029 0.814 i. 0.029
Cut-out pressure
Air MPa (8.3 + 0.3) (8.3 f 0.3)
govern0 (kg/cm*)
0.686 f 0.029 0.686 * 0.029
Cut-in pressure
17.0 + 0.3) t7.0 + 0.3)
Service 32 ton payload l Initial speed: 32 km/h Max. 22.3 Max. 22.3
brake l Distance from starting to lose
braking speed to stopping
distance Empty l Max. actuating air pressure: Max. 17.0 Max. 17.0
0.814 MPa (8.3 kg/cm*} m
Retarder 32 ton payload l Max. hydraulic pressure Max. 30.0 Max. 30.0
brake Rear: 3.92 MPa (40 kg/cm2}
braking Front: 16.18 MPa {I65 kg/cm*}
distance Empty l On flat, dry road surface Max. 25.0 Max. 25.0
. Max. actuating air pressure: Min.16.18 Min.16.18

Brakes Front
{Min. 165) {Min. ISS}
chamber 0.814 MPa (8.3 kg/cm2} -
LMin.3.92(MinAO}][Min.3.92{Min.40}]
l Engine: Stopped
Brake Rear chamber When first operated MPa
l
Min. 3.92 Min. 3.92
actuating (service) {kg/cm*) {Min. 40} {Min. 40}
pressure
Rear chamber Min. 3.92 Min. 3.92
(retarder) {Min. 40} {Min. 40}
Stopping distance when l Carrying 32 ton payload

emergency brake is l Initial speed: 32 km/h m Max. 52.1 Max. 52.1
applied l On flat, dry road surface
HD325-6 20-5
0
Compo. Standard Permissible

nent Item I Measurement conditions Unit value value
l With 25ton payload

Braking capacity (sin 8) l After adjusting clearance % Min. 25 Min. 25
between disc and pad
l F2
Starting test l Torque converter stall
HOLD l Center of control lever knob

+ RAISE
RAISE Must return Must return

+ HOLD smoothly smoothly
HOLD Max.58.8 Max.58.8

(Max.61 {Max.61
Operating
force
Max.58.8 Max.58.8
lMax.61 (Max.61
Hoist
lever
FLOAT
+ LOWER
I
mm 8.5 + 1 8.5 + 1
I 8.5 + 1 8.5 + 1
l Oil temperature: 45 - 55’C

Hoist l Engine: Full throttle MPa 20.59 f 0.49 20.59 * 0.49
Relief pressure Measure at end of stroke when
valve l @3n*l {210 f 51 1210 z!z5)
raising body
Lifting speed l Oil temperature: 45 - 55’C 10 i 1.5 IOf 1.5

l Engine: Full throttle sec. .
Lowering speed l Use FLOAT when lowering 115 1.5 11 * 1.5
Body
mm Max. 85 170
233 i 10 233+ 10
REAR
mm
Suspen- 191ilO 191+10

sion
cylinder
2.903 * 0.49 2.903 + 0.49
MPa (29.6 + 5) 129.6 I 5)
(g/cm21
I I 2.246 + 0.49 2.246 * 0.49
Rear
TVH00181 (22.9 +_5) (22.9 * 5)
20-6 HD325-6
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
Sys- Connector Inpsec- Measurement

Name of component tion Judgement table
tem No. method conditions
If the condition is within the range shown 1) Turn starting
Measurement of
in the table below, it is normal switch OFF.
2) Insert T-
Power supply CN4 Between (9), (20) – (1), (10) 20 – 30 V adapter.
3) Turn starting
voltage
switch ON.

Measurement of in the table below, it is normal switch OFF.
2) Insert T-
Power supply for Between (6), (14) – (5), (13) 20 – 30 V adapter.
CN7 3) Turn starting
power parts
voltage
switch ON.

Measurement of

2) Insert T-
Power supply for Between (4) – (11) 4.6 – 5.4 V adapter.
sensors
voltage
switch ON.
Engine controller (✩✩)

Measurement of

2) Insert T-
Controller
Power supply for CN2 Between (2) – (10) 4.6 – 5.4 V adapter.
sensors 3) Turn starting
voltage
switch ON.

Measurement of

2) Insert T-
Starting switch Between (7), (18) – (1), (10) 20 – 30 V adapter.
[ACC (ON)] signal
voltage
switch ON.

Measurement of

2) Insert T-
Starting switch Between (2) – (1), (10) 20 – 30 V adapter.
[C] signal
voltage
switch ON.
If the condition is within the range shown in 1) Turn starting

Measurement of
the table below, it is normal switch OFF.

2) Insert T-
Acceleration Power adapter.
CN1 Between (4) – (11) 4.6 – 5.4 V 3) Turn starting
signal supply
voltage
Acceleration switch ON.

Between (6) – (11) 0.3 – 4.5 V
signal
✩✩ HD325-6 Serial No.: 6001 and up

HD325-6 20-6-1
8

Measurement of
2) Insert T-
Idle validation CN4 When accelerator adapter.
signal 2 pedal is pressed Between Max. 1 V 3) Turn starting
voltage
(11) – (8), switch ON.
When accelerator (19)
pedal is not pressed 15 – 30 V

Measurement of

2) Insert T-
Acceleration When accelerator adapter.
CN4 pedal is pressed Between 15 – 30 V 3) Turn starting
validation signal 3
voltage
(12) – (8), switch ON.

When accelerator (19)
pedal is not pressed Max. 1 V

Measurement of

2) Insert T-
Between (5) – (12) 85 – 210 Ω adapter.
resistance
Ne rotation sensor CN1 (male) 3) Turn starting

switch ON.

Measurement of

2) Disconnect
Controller
1,400 – 3,500 Ω connector.

resistance
G rotation sensor CN2 (male) Between (1) – (9)

3) Connect T-
adapter.

Measurement of

Engine oil pressure 2) Disconnect
Engine oil pres- connector.
sure sensor (High CN4 Min. 0.17 MPa {1.7 kg/
cm2} (Engine speed: Between 18 – 30 V 3) Insert T-
voltage
pressure) Min. 1,300 rpm) (6) – adapter.

chassis
Turn starting switch
ON. Max. 1 V

Measurement of

Engine oil pressure 2) Insert T-
Engine oil pres- adapter.
sure sensor (Low CN4 Min. 0.07 MPa {0.7 kg/
cm2} (Engine speed: Between 18 – 30 V 3) Turn starting
voltage
pressure) (5) – switch ON.

Low idling) chassis
Turn starting switch Max. 1 V
ON.
If the condition is within the range shown in 1) Turn starting

Measurement of
the table below, it is normal switch OFF.

2) Insert T-
Common rail fuel CN1 Power Between adapter.
supply CN2 (2) – (10) 4.6 – 5.4 V 3) Turn starting
pressure sensor CN2
voltage
switch ON.
Sensor Between
signal CN1 (1) – CN2 (10) 0.3 – 4.7 V

20-6-2 HD325-6
8

Measurement
2) Insert T-
of voltage
Boost pressure CN1 Power Between adapter.
supply CN2 (2) – (10) 4.6 – 5.4 V
sensor CN2 3) Turn starting
Sensor Between switch ON.
signal CN1 (3) – CN2 (10) 0.3 – 4.7 V
Measurement
of resistance
Engine water 2) Disconnect
temperature CN2 10˚C Approx. 90 kΩ connector.
sensor (High (female) Between 3) Connect T-
temperature) (4) – (10) adapter.
100˚C Approx. 3.5 kΩ

Measurement
in the table below, it is normal

of resistance
switch OFF.
Engine water 2) Disconnect
temperature CN2 10˚C Approx. 9 kΩ connector.
sensor (Low (female) Between 3) Connect T-
temperature) (3) – (10) adapter.

Measurement
of resistance

2) Disconnect
Fuel temperature CN2 10˚C Approx. 90 kΩ connector.
sensor (female) Between 3) Insert T-
(11) – (10) adapter.
Controller

Measurement
of resistance

No. 1 fuel injector CN6 2) Disconnect
[A] (female) Between (7) – (8) 0.4 – 1.1 Ω connector.
3) Insert T-
adapter.

Measurement
of resistance

[B] (female) Between (4) – (10) 0.4 – 1.1 Ω connector.
3) Connect T-
adapter.

Measurement
of resistance

[C] (female) Between (3) – (9) 0.4 – 1.1 Ω connector.
3) Connect T-
adapter.

Measurement
of resistance

[F] (female) Between (3) – (9) 0.4 – 1.1 Ω connector.
3) Connect T-
adapter.

HD325-6 20-6-3
8

Measurement
of resistance
2) Disconnect
No. 5 fuel injector CN7
[B] (female) Between (1) – (7) 0.4 – 1.1 Ω connector.
3) Connect T-
adapter.
Measurement If the condition is within the range shown 1) Turn starting

of resistance in the table below, it is normal switch OFF.
[D] (female) Between (2) – (8) 0.4 – 1.1 Ω connector.
3) Connect T-
Controller
adapter.
Measurement

of resistance

Fuel supply pump CN7 2) Disconnect
PCV1 (female) Between (10) – (11) 2.3 – 5.3 Ω connector.
3) Connect T-
adapter.

Measurement
of resistance

Fuel supply pump CN7 2) Insert T-

PCV2 (female) Between (4) – (12) 2.3 – 5.3 Ω adapter.
3) Turn starting
switch ON.

Measurement
2) Insert T-
Power Between 4.6 – 5.4 V adapter.
of voltage
Acceleration signal WAS1 supply (3) – (1) 3) Turn starting

Accelera- All stroke 0.3 – 4.7 V switch ON.
tion High idling Between V
signal (2) – (1)
Low idling V
Measurement

of resistance

2) Insert T-
Ne rotation sensor NE (male) Between (1) – (2) 85 – 210 Ω adapter.
3) Turn starting
switch ON.
Measurement

of resistance

2) Disconnect
G rotation sensor G (male) Between (1) – (2) 1,400 – 3,500 Ω connector.
3) Connect T-
adapter.

Measurement
switch OFF.
of resistance

Engine oil pressure Min. 0.17 MPa {1.7 kg/ connector.
sensor (High pressure) PSH cm2} (Engine speed: Between Min. 1MΩ 3) Connect T-
Min. 1,300 rpm) (1) – adapter.
chassis
Turn starting switch
ON. Max. 1 Ω

20-6-4 HD325-6
8

Measurement of
Engine oil pressure connector.
resistance
PSL Min. 0.07 MPa {0.7 kg/
sensor (Low pressure) cm2} (Engine speed: Between Min. 1MΩ 3) Connect T-
(1) – adapter.
Low idling) chassis
Turn starting switch Max. 1 Ω
OFF.
Measurement of
2) Insert T-
Common rail fuel Between adapter.
PFUEL Power supply (3) – (1) 4.6 – 5.4 V 3) Turn starting
pressure sensor
voltage
switch ON.
Between
Sensor signal (2) – (1) 0.3 – 4.7 V

Measurement of

2) Insert T-
Between adapter.
Boost pressure sensor PIM Power supply (3) – (1) 4.6 – 5.4 V 3) Turn starting
voltage
switch ON.
Between
Sensor signal (2) – (1) 0.3 – 4.7 V

Measurement of

Engine water tempera- 2) Disconnect
connector.
resistance
ture sensor (High TWH (male) 10˚C Approx. 90 kΩ

temperature) Between 3) Connect T-
(1) – (2) adapter.

Measurement of

2) Disconnect
Engine water tempera- connector.
resistance
ture sensor (Low TWL (male) 10˚C Approx. 9 kΩ

Between 3) Connect T-
temperature) adapter.
(1) – (2)

Measurement of

2) Disconnect
Fuel temperature connector.
resistance
THL (male) 10˚C Approx. 90 kΩ

sensor Between 3) Insert T-
(1) – (2) adapter.

Measurement of

No. 1 2) Disconnect
injector Between (2) – (3) 0.4 – 1.1 Ω connector.
resistance
No. 1 fuel injector [A] 3) Connect T-

connector
CN1 adapter.

HD325-6 20-6-5
8

Measurement of
No. 5 2) Disconnect
resistance
No. 5 fuel injector [E] connector 3) Connect T-
CN5 adapter.

Measurement of

No. 3 2) Disconnect
resistance
No. 3 fuel injector [C] 3) Connect T-

connector
CN3 adapter.

Measurement of

No. 6 2) Disconnect
resistance
No. 6 fuel injector [F] connector 3) Connect T-

CN6 adapter.

Measurement of

No. 2 2) Disconnect
resistance
No. 2 fuel injector [B] connector 3) Connect T-

CN2 adapter.

Measurement of

No. 4 2) Disconnect
resistance
No. 4 fuel injector [D] connector 3) Connect T-

CN4 adapter.

Measurement of

2) Disconnect
Fuel supply pump PCV1 Between (1) – (2) 2.3 – 5.3 Ω connector.
resistance
PCV1 (female) 3) Connect T-

adapter.

Measurement of

2) Insert T-
Fuel supply pump PCV2 Between (1) – (2) 2.3 – 5.3 Ω adapter.
resistance
PCV2 (female) 3) Turn starting

switch ON.

20-6-6 HD325-6
8

If the condition is as shown in the table 1) Turn starting
below, it is normal switch ON.
2) Insert
Voltage value T-adapter.
When When not
Measure of voltage
selected selected
Between (3)–(2) R Min.1.0V Max.15.0V
Between (4)–(2) N Min.1.0V Max.15.0V
Shift lever SF (male)
Between (5)–(2) D Min.1.0V Max.15.0V
Between (6)–(2) 5 Min.1.0V Max.15.0V
Between (9)–(2) L Min.1.0V Max.15.0V
Between (1) – (2) 11.0 – 13.0V
HPS (male) Between (1) – (2) Approx. 5 – 25 Ω 1) Turn starting

switch OFF.
Measure of
LPS (male)
resistance
RPS (male) ª 13.85Ω (20˚C) ± 5% 2) Disconnect PS

Pressure control valve connector.
solenoid 1PS (male)
2PS (male)
3PS (male)
Transmission controller
4PS (male)
Between (1) – (2) 30 – 80 Ω 1) Turn starting

switch OFF.
Measure of
resistance
2) Disconnect
L/CT.
Lock-up solenoid L/CT(male)

switch OFF.
Measure of
resistance
2) Disconnect
Exhaust brake SL5.
solenoid SL5 (male)

switch OFF.
Measure of
resistance
Rear brake 2) Disconnect

(Overrun prevention) SL4 (male) SL4.
solenoid
Oil Measure 1) Turn starting

temperature resistance switch OFF.
Measure of
resistance
2) Disconnect
Transmission oil Normal tempera- C/VT.
C/VT (male) ture (25˚C) Between 37 – 50 kΩ
temperature sensor
(1) – (2)
100˚C 3.5 – 4.0 kΩ
HD325-6 20-7
8

Between (1) – (2) 100 – 500 Ω Check as

individual part
Measure of
Between (3) – (6) Max. 1 Ω
resistance
Relay
(Check as individual R01 – R29
(Except R09,11) Between (3) – (5) Min. 1 MΩ
part)
Between (5) – (6) 100 – 500 Ω Check as

individual part
Measure of
Between (3) – (4) Max. 1 MΩ

resistance
Relay
(Check as individual R09
R11 Between (1) – (2) Min. 1 MΩ
part)
1) Turn starting
HSW (male) Between (1) switch OFF.
Switch OFF Min. 1 MΩ
Measure of
LSW (male) – chassis 2) Disconnect

resistance
RSW (male) switch

Fill switch 1SW (male) connector.
2SW (male)
3SW (male)
4SW(male)
If the condition is within the range shown 1) Start engine.

in the table below, it is normal 2) Insert
Measure of
T-adapter.
resistance
Engine oil pressure 27 (male) Between (1) – (3) Approx. 0.45 – 4.5 V
sensor (✩)
When engine is running 1) Start engine.

(1/2 throttle or above) → 27.5 – 29.5 V
Measure of
resistance
Alternator ª If the battery is old, or after starting in

Alternator terminal cold areas, the voltage may not rise
R – chassis for some time.

Measure of
2) Disconnect
resistance
Approx.160 Ω
Air pressure or less, or SR5.
Air pressure sensor SR5 (male) 0.81MPa {8.3kg/cm2} Between approx. 320 Ω
(1) – (2) Approx.640 Ω
Air pressure or
0.51MPa {5.2kg/cm2} approx. 800 Ω

Engine water in the table below, it is normal switch OFF.
Measure of
resistance
temperature sensor (✩) 26 (male) 2) Disconnect 26,

Torque converter oil Normal tempera- Approx. TC.SE, and 64.
TC.SE(male) ture (25˚C) Between 37 – 50 kΩ
temperature sensor 64 (male)
Retarder oil (1) – (2) Approx.
temperature sensor 100˚C 3.5 – 4.0 kΩ
✩ HD325-6 Serial No.: 5680 – 6000

HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
20-8 HD325-6
8

Measure of
resistance
2) Disconnect 61.
Fuel level sensor 61 (male) Full (1) – Approx. 12 Ω or less
sensor
Empty flange Approx. 85 – 110 Ω

Transmission input in the table below, it is normal switch OFF.
shaft speed sensor Measure of
N1 (male) resistance 2) Disconnect
Transmission
intermediate shaft Between (1) – (2) 500 – 1,000 Ω N1 – N3.
N2 (male)
speed sensor
Transmission output N3 (male)
shaft speed sensor

Measure of
resistance
2) Disconnect E6.
Engine speed sensor B E6 (male) Between (1) – (2) 500 – 1,000 Ω

Measure of
resistance
2) Disconnect 21.
Steering oil tempera- 21 (male) Oil temperature 25˚C No
ture sensor (✩) Between (normal temperature) continuity
(1) –
chassis Oil temperature No
above 123˚C continuity
Measure of voltage

in the table below, it is normal switch ON.
2) Insert
WAS2 Accelerator at Approx. T-adapter.
Accelerator sensor (male) Max. position 1.0 – 1.4 V 3) Accelerator
Between
(1) – (2) pedal MIN
Accelerator at Approx. ↔ MAX
Min. position 3.6 – 4.0 V

Continuity
2) Disconnect
Differential DLB.
Differential lock switch DLB (male) pedal ON Continuity
Between
(3) – (4) Differential No
pedal OFF continuity

Continuity
2) Disconnect
Air pressure AS3.
Retarder switch AS3 (male) Min. 0.14 MPa Continuity
Between {1.4 kg/cm2}
(1) – (2) Air pressure No
Max. 0.06 MPa
{0.6 kg/cm2} continuity
✩ HD325-6 Serial No.: 5680 – 6000

HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
HD325-6 20-9
8
.r Zonnector Ipsec- Measurement

Vame of component tion Judgement table
n No. lethod conditions

2) Disconnect
AS5.
Service brake switch 4S5 (male)

2) Disconnect
imergency brake AS4.
iS4 (male)
switch

2) EIIcxnect
‘arking brake switch VS2 (male)

2) EIrnnect
Dump lever at No
Body FLOAT switch IH2 (male) FLOAT continuity
Between
(7) - (‘I Dumplever at position
other than FLOAT Continuity

2) E’;synnect
Body seated switch DBI (male1

2) lY$onnect
Tilt sensor SR3 (male1

2) iIis;onnect
Body RAISE switch RH2 (male;
20-10 HD325-6
0
Sv! lonnector npsec Measurement

ter No. letho conditions

1Filternormal Icontour]
2) Disconnect 52.
Transmission filter
52 (male) / ES~;;;
clogging sensor
Filter clogged Continuity

2) Disconnect
Rear brake chamber
ILSRfmale) BLSR and
stroke sensor
ILSL(male) BLSL.
[Brake stroke switch]

2) Disconnect
ASI.
Exhaust brake switch 4Sl (male)
Engine running + Min. 20V 1) Start engine.
telay
Emergency steering erminal78
timer relay - chassis

2) gzonnect
Shift limit switch SH (male)

2) Disconnect 03.
Radiator water level 03 (male)
switch

2) F$onnect
Power mode switch PW (male)
HD3256 20-11
0
. Zonnector npsec- Measurement

n No. iethoc conditions
If the condition is within the range shown 1) Remove sensor

RR suspension in the table below, it is normal from suspension
63 (male) cylinder.
pressure sensor
2) Insert T-adapter.
Between each Approx. 3) Checkthat there is
connector (3) -chassis 0.45 - 1.50 v no disconnection
or short circuit in
RL suspension wiring harness.
62 (male)
pressure sensor 4) Turn starting
switch ON.
If the condition is within the range shown I) Turn starting

2) Disconnect
Transmission output 1 Between (I) - (2) 1 506 - l.nCO Q 1 N3.
N3 (male)
shaftspeedsensor

2) Wrnnect
Air pressure No
Emergency brake Min. 0.48 MPa
AS4 (male)
switch i4.s kg/cm21 Between continuity
Air pressure (1) -(2)
Max. 0.36 MPa Continuity
13.7 kg/cm21

2) LIJFnnect
Service brake switch 4S5 (male)
If the condition is within the range shown I) Turn starting

SLI (male) switch OFF.
2) Disconnect SLl,
SL2, and SL3.
Suspension control
SL2 (male) 1 Between (I) - (2) 1 20-6OQ
3) Put black pole of
solenoid valve
tester in contact
with (I); put red
SL3 (male) pole in contact
with (21.

2) Disconnect
Body FLOAT switch 3H2 (male) RH2.
20-12 HD325-6
0

If the condition is within the range shown 1) Remove
FR suspension 39 (male) in the table below, it is normal sensor from
pressure sensor suspension
Between each Approx. cylinder.
connector (3) – chassis 0.45 – 1.50 V 2) Insert
Measure of voltage
T-adapter.
FL suspension 13 (male) 3) Check that
pressure sensor there is no dis-
connection or
short circuit in
wiring harness.
Payload meter
RR suspension 63 (male) 4) Turn starting

pressure sensor switch ON.
RL suspension 62 (male)
pressure sensor
Measure of voltage
If the condition is within the range shown 1) Stop chassis at

horizontal place.
in the table below, it is normal 2) Check that there
is no disconnec-
Between (1) – (2) Approx. 2.1 – 3.1 V tion or short cir-
Clinometer PM3 cuit in wiring har-
ness.
3) Insert T-adapter.
4) Turn starting
switch ON.
If the condition is within the range shown 1) Disconnect

in the table below, it is normal terminal.
Measure of
resistance
2) Start engine.
Engine oil pressure Min. 68.6 kPa
sensor (✩) 27 (male) Between
{0.7 kg/cm2} Max. 1 Ω
sensor
terminal Max. 29.4 kPa
– chassis {0.3 kg/cm2} Min. 1 MΩ

Measure of
resistance
2) Disconnect
Engine oil pressure Engine oil pressure
PSH Min. 0.17 MPa {1.7 kg/ Min.
connector.
sensor (High pressure) Between
sensor cm2} (Engine speed: Between 1MΩ 3) Connect T-
Chassis monitor
(✩✩) terminal – Min. 1,300 rpm) (1) – adapter.

chassis
chassis Turn starting switch Max.
OFF. 1Ω

Measure of
resistance

Engine oil pressure Min. 0.07 MPa {0.7kg/ connector.
sensor (Low pressure) PSL Between Min.
Between 1MΩ
sensor cm2} (Engine speed: 3) Connect T-
(✩✩) Low idling) (1) – adapter.
terminal – chassis
chassis Turn starting switch Max.
OFF. 1Ω
Measure of voltage
When engine is running 1) Start engine.

(1/2 throttle or above) → 27.5 – 29.5 V
Alternator ª If the battery is old, or after starting in
Alternator terminal R cold areas, the voltage may not rise
– chassis for some time.
HD325-6 20-13
8

Measure of
resistance
2) Disconnect
Max. approx.
Air pressure sensor Air pressure 3 Ω or SR5.
SR5 (male) 0.93MPa {9.5kg/cm2} Between approx. 160 Ω
Air pressure (1) – (2) Approx.640 Ω
or
0.51MPa {5.2kg/cm2} approx. 800 Ω

Engine water in the table below, it is normal switch OFF.
Measure of
resistance
temperature sensor (✩) 26 (male) 2) Disconnect 26,

Torque converter oil TC.SE(male) Normal tempera- Approx. TC.SE, and 64.
temperature sensor 64 (male) ture (25˚C) Between 37 – 50 kΩ
Retarder oil (1) – (2) Approx.
temperature sensor 100˚C
3.5 – 4.0 kΩ

Measure of
2) Disconnect
resistance
Engine water connector.

temperature sensor TWH (male) 10˚C Approx. 90 kΩ
Between 3) Connect T-
(High temperature) adapter.
(1) – (2)
(✩✩) 100˚C Approx. 3.5 kΩ

Chassis monitor

Measure of
2) Disconnect
resistance
Engine water connector.

10˚C Approx. 9 kΩ 3) Connect T-
temperature sensor TWL (male) Between
(Low temperature) (1) – (2) adapter.
(✩✩) 100˚C Approx. 0.3 kΩ

Measure of
resistance
2) Disconnect 61.
Fuel level sensor 61 (male) Full (1) – Approx. 12 Ω or less
sensor
Empty flange Approx. 85 – 110 Ω

Measure of
resistance
2) Disconnect
Transmission output N3 (male) Between (1) – (2) 500 – 1,000 Ω N3.
shaft speed sensor

Measure of
resistance
2) Disconnect E6.
Engine speed sensor B E6 (male) Between (1) – (2) 500 – 1,000 Ω
20-14 HD325-6
8

If the condition is within the range shown 1) Start engine.
in the table below, it is normal 2) Disconnect 52.
Continuity
Transmission filter Filter normal Continuity
52 (male) Between
clogging sensor
(1) – (2) No
Filter clogged continuity

Continuity 2) Disconnect
Caution pilot lamp Switch ON Continuity GK1.
GK1 (male) Between
bulb check switch
(1) – (2) No
Switch OFF continuity

Continuity
2) Disconnect
Exhaust brake switch Switch ON Continuity EXH.
EXH (male) Between
(2) – (4) No

Chassis monitor

Continuity
Between
switch Switch ON Between switch Continuity
Mode change switch 1 terminals terminals No
MS11 – Switch OFF MS11 – MS12 continuity
MS12

Continuity
Between
switch Switch ON Between switch Continuity
Mode change switch 2
terminals terminals
MS21 – No
Switch OFF MS21 – MS22 continuity
MS22

Continuity
2) Disconnect
Switch ON Continuity HAZ.
Hazard switch HAZ (male) Between
(2) – (4) No

Continuity
2) Disconnect FL.
Switch ON Continuity
Fog lamp switch FL (male) Between
(2) – (4) No
HD325-6 20-15
8

Continuity
2) Disconnect FB.
Switch ON Continuity
Front brake cut switch FB (male) Between
(2) – (4) No

Continuity
2) Disconnect
Lamp switch ON Continuity CM.
Between
No
Lamp switch OFF (5) – (7) continuity
If the condition is within the range shown

Continuity
Lamp switch ON Between Continuity

(5) – (6), No
Lamp switch OFF (6) – (7) continuity

Chassis monitor

Continuity
Turn signal lamp

Combination switch CM (male) at RIGHT Continuity
Between
Turn signal lamp (3) – (8) No
at N continuity

Continuity
Turn signal lamp

at LEFT Continuity
Between
Turn signal lamp (3) – (4) No
at N continuity

Continuity
Dimmer switch Between

at high beam (2) – (7) Continuity
Dimmer switch Between No
at low beam (1) – (7) continuity
20-16 HD325-6
8
TABLE OF TOOLS FOR TESTING, ADJUSTING,
TESTING AND ADJUSTING AND TROUBLESHOOTING
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND

TROUBLESHOOTING
Test, measurement item Symbol Part No. Part Name Remarks
L:60 – 2,000rpm
Engine speed A 799-203-8001 Multi-tachometer Digital display H:60 –19,999rpm
Water, exhaust, oil Digital temperature –99.9 – 1,299˚C

temperatures B 799-101-1502 gauge
Pressure gauge 2.4,5.9,39.2,58,8 MPa
799-101-5002 Hydraulic tester {25,60,400,600kg/cm2}
1
Oil pressure C 790-261-1203 Digital hydraulic tester Pressure gauge 49.0MPa{500 kg/cm2}
2 799-401-2320 Hydraulic gauge 1.0 MPa {10 kg/cm2}
1 795-502-1590 Gauge assembly

0.69 MPa {0 – 70 kg/cm2}
Kit Part No. 795-502-1205
2 795-502-1500 Adapter assembly
Compression pressure D
3 795-471-1310 Adapter assembly
4 6217-71-6110 Gasket
1 799-201-1511 Nozzle
2 799-201-1450 Adapter Kit Part No. 799-201-1504

Blow-by pressure E
3 799-201-1571 Tube
Measurement range:
5 799-201-1541 Gauge 0 – 4.903 kPa {0 – 500 mmH2O}
Commercially —
Valve clearance F available Feeler gauge
Air supply pressure R 799-201-2202 Boost gauge kit –760 – 1,500 mmHg
Adjusting fuel injection Dial gauge is commercially

timing X 795-471-1200 Gauge assembly available
799-201-9000 Handy smoke checker Discoloration 0 – 70%

(with standard color)
Exhaust color G (Discoloration % × 1/10
Commercially
available Smoke meter •
=• Bosch index)
79A-264-0091 Push-pull scale 0 – 490 N {0 – 50 kg}

Operating effort H
79A-264-0021 Push-pull scale 0 – 294 N {0 – 30 kg}
Commercially —
Stroke, hydraulic drift I available Scale
Commercially —
Work equipment speed J available Stopwatch
Measuring brake disc For brake

wear K 567-98-41301 Disc gauge
Measuring voltage,
resistance value L 79A-264-0211 Tester
HD325-6 20-17
9
1 799-601-8000 T-adapter assembly
2 799-601-7360 Adapter For relay 5P
3 799-601-7400 T-adapter assembly
AMP070 connector For AMP07010

799-601-7500 adapter assembly
• 799-601-7510 For AMP07012
• 799-601-7520 For AMP07014

4
• 799-601-7530 Adapter For AMP07018
• 799-601-7540 For AMP07020
• 799-601-7550
• 799-601-9320 T-adapter
5
Troubleshooting for • 799-601-9310 Plate for T-adapter
sensors and wiring M
harnesses • 799-601-9200 DT Series connector For DT2
adapter assembly
• 799-601-9020 For DT3
• 799-601-9030 For DT4
• 799-601-9040 For DT6

6 Adapter
• 799-601-9050 For DTM2
• 799-601-9010 For DT8B
• 799-601-9070 For DT12B
• 799-601-9120
• 799-601-9410 For G sensor

Socket
7 • 799-601-9430 For PVC
Adapter For fuel pressure and boost

• 799-601-9420 pressure sensors
• Measurement of
transmission clutch
pressure N 799-607-2000 Checker assembly
• Measurement of torque
converter stall speed
20-17-1 HD325-6
9
1 792-610-1130 Pump assembly
2 792-610-1110 Hose
Pump, joint assembly
3 792-610-1120 Joint [Kit Part No.:792-610-1100]
4 07020-21730 Fitting
Adjusting suspension 5 792-610-1140 Joint

cylinder
P
 Kit Part No.  6 792-610-1250 Valve assembly
 792-610-1,000 
 
7 792-610-1260 Nipple
8 792-610-1480 Stem
Gas charge tool assembly
9 792-610-1640 Joint [Kit Part No.:792-610-1200]
10 792-610-1400 Regulator assembly
10 Gauge
(a) 792-610-1430 24.5 MPa {250 kg/cm2}
10 Gauge
(b) 792-610-1440 9.8 MPa {100 kg/cm2}
792-415-1110 Cover
Spacer
792-415-1120 (for 1st, 2nd, R clutch)
Spacer
792-415-1130 (for 3rd, H clutch) Assembly Part No.:
1 792-415-1200
Spacer
792-415-1140 (for 4th, L clutch)
Measuring transmission
clutch pressure Q
175-15-15540 Valve
238-15-12930 Spring
792-415-1150 Wrench
Assembly Part No.:
2 792-415-1100
792-415-1160 Adapter
HD325-6 20-17-2
9
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE

HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
fl When adjusting the valve clearance, adjust as fol-
lows to bring the clearance between the valve and
rocker arm to the standard value.
1) Remove the cylinder head cover.
fl For the No. 3 cylinder, remove intake con-
nector (1).
fl For the No. 4 cylinder, remove brake cyl-
inder (2).
2) Rotate the crankshaft in the normal direction
to align 1.6 TOP line on the crankshaft pulley
with pointer (3) when the No. 1 cylinder is at
compression top dead center. When rotating,
check the movement of the valves.
3) When the No. 1 cylinder is at compression
top dead center, adjust the valves marked b
in the valve arrangement chart. Then set so
that the No. 6 cylinder is at compression top
dead center and adjust the valve clearance of
the valves marked c.
fl Valve arrangement
Cylinder No. 1 2 3 4 5 6
Intake valve b c b c b c
Exhaust valve b b c b c c
4) To adjust the valve clearance, loosen locknut

(7) of adjustment screw (6), then insert tool F
between the top of crosshead (4) and rocker
arm (5), and turn adjustment screw (5) until
the clearance is a sliding fit. Then tighten
locknut (7) to hold the adjustment screw in
position.
3 Locknut :
58.3 ± 4.9 Nm {6.0 ± 0.5 kgm}
5) Next, rotate the crankshaft one turn in the nor-
mal direction and adjust the clearance of the
remaining valves marked c.
fl After adjusting No. 1 cylinder at compres-
sion top dead center, it is also possible to
turn the crankshaft 120˚ each time and
adjust the valve clearance of the intake
and exhaust valves of each cylinder ac-
cording to the firing order.
• The firing order is as follows: 1-5-3-6-2-4
fl After tightening the locknut, check the
valve clearance again.
HD325-6 20-19
8
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
HD325-6 Serial No.: 6001 and up 4. Tighten locknut (6) to hold adjustment screw
HD325-6W Serial No.: 6001 and up (5) in position.
3 Locknut :
53.0 – 64.7 Nm {5.4 – 6.6 kgm}
1. Remove cylinder head cover (1).
fl After tightening the locknut, check the
clearance again.
2. Rotate the crankshaft in the normal direction

to set No. 1 cylinder at compression top dead
center, and align pointer (2) with the [1.6] mark 5. Turn the crankshaft 120˚ each time in the nor-
a on the damper. mal direction and repeat the procedure in
fl Crank the crankshaft with the hexagonal Steps 2 to 4 to adjust the valves of each cylin-
portion at the tip of the water pump drive der according to the firing order.
shaft. fl Firing order : 1–5–3–6–2–4
fl At compression top dead center, the valve
rocker arm can be moved by hand by the 6. After completing the measurement, set to the
amount of the valve clearance. If the original condition.
rocker arm does not move, the crankshaft
3 Cylinder head cover mounting bolt:
is not at compression dead center, so ro-
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
tate it one more turn.
3. To adjust the valve clearance, insert the feeler

gauge into clearance b between rocker arm
(3) and crosshead (4), and adjust the valve
clearance with adjustment screw (5).
fl Insert the feeler gauge and turn adjust-
ment screw (5) until the clearance is a slid-
ing fit.
fl Valve clearance Intake valve: 0.35 mm
Exhaust valve: 0.57 mm
20-19-1 HD325-6
8
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION
PRESSURE
HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
¤ When measuring the compression pressure, be

careful not to touch the exhaust manifold or muf-
fler, or to get caught in rotating parts.
1. Adjust valve clearance.

fl For details, see ADJUSTING VALVE CLEAR-
ANCE.
2. Warm up the engine (oil temperature 40 to 60˚C).
3. Remove the nozzle holder assembly.

fl For details, see REMOVAL OF NOZZLE
HOLDER ASSEMBLY.
4. Install tool D2 in mount of nozzle holder assem-

bly and connect tool D1.
5. Disconnect engine stop motor wires.
6. Crank engine with the starting motor and mea-

sure compression pressure.
fl Measure the compression pressure at the
point where the pressure gauge indicator re-
mains steady.
fl When measuring the compression pressure,
measure the engine speed to confirm that it
is within the specified range.
fl Install the nozzle holder assembly after measur-

ing the compression pressure.
For details, see INSTALLATION OF NOZZLE
HOLDER ASSEMBLY.

fl See the Shop Manual for the engine.

For REMOVAL OF FUEL INJECTOR ASSEMBLY,
see REMOVAL OF FUEL INJECTOR ASSEMBLY in
DISASSEMBLY AND ASSEMBLY, however.
Before starting the above work, be sure to dis-
connect centralized engine intermediate connec-
tors J10 and J11.
20-20 HD325-6
8
TESTING AND ADJUSTING MEASURING BLOW-BY
MEASURING BLOW-BY
Procedure for measuring blow-by
Warm up the engine fully so that the water tem-
perature is in the operating range before mea-
suring the blow-by.
Stop the engine, install adapter E2 to tool El, then

install crankcase breather hose (I 1.
Install tube E3 to tool El, then connect to tool E5

{O - 500 mmHz0).
Run the engine at torque converter stall, and read

the measurement for the blow-by pressure.
* Carry out this operation carefully.
For details, see TESTING TORQUE CON-
VERTER STALL SPEED.
Carefully for measuring blow-by

* The blow-by should be measured with the engine
running at rated output.
l When measuring in the field, a similar value
can be obtained at torque converter stall
speed.
l If it is impossible to check at rated output or
torque converter stall speed, measure at high
idling.
In this case, the blow-by value will be about
80% of the value at rated output.
* Blow-by varies greatly according to the condition
of the engine. Therefore, if the blow-by value is
considered abnormal, check for problems con-
nected with defective blow-by, such as excessive
oil consumption, defective exhaust gas color, and
prematurely dirty or deteriorated oil.
HD325-6 20-21
0
TESTING AND ADJUSTING ADJUSTING ALTERNATOR BELT TENSION
ADJUSTING ALTERNATOR BELT

TENSION
* If the deflection of the belt when it is pressed with
a finger force of approx. 6 kg. at a point a midway
between alternator (1) and the fan pulley (2) is
not within the standard value, adjust the belt ten-
sion as follows.
1. Loosen the mounting bolts, lock bolts, and lock-
nuts (3) and (4) OF alternator (I 1.
2. Adjust the belt tension with locknuts (3) and (4).
f After adjusting, tighten the alternator mount-
ing bolts and lock bolts.
3. Check that the belt tension is within the standard
value. If it is within the standard value, tighten
locknuts (3) and (4).
HD325-6
20-22
0
TESTING AND ADJUSTING ADJUSTING FAN BELT TENSION
ADJUSTING FAN BELT TENSION

1. Inspection
Check that the deflection is normal when the belt
is pressed with a finger at a point midway be-
tween the fan pulley and crankshaft pulley.
fl Check each belt individually.
fl Pushing force: Approx.98 Nm {approx.10 kg}
fl Deflection: 13 – 15 mm (new part)
17 – 19 mm (tension adjusted)
2. Adjustment
fl If the deflection is not within the standard
value, adjust as follows.
1) Install 2 belts (1).
2) Adjust the deflection of the belt with adjust-
ment bolt (2).
fl Deflection: 13 – 15 mm (new part)
17 – 19 mm(tension adjusted)
HD325-6 20-22-1
8
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED

HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
¤ When removing or installing the measuring

equipment, be careful not to touch any of the
high temperature parts.
fl Measure the engine speed under the following
conditions.
1) Cooling water temperature:
2) Engine oil temperature: 70 – 90˚C
3) Hydraulic oil temperature: 45 – 55˚C
1. Remove cap (1) from the speed pickup port, and

install the adapter of tachometer A.
2. Connect tachometer A and the adapter with the

cable.
¤ When measuring the speed, be careful not
to touch any of the rotating parts or high tem-
perature parts.
3. Start the engine and measure the engine speed

at high idling and low idling.
fl For details of the method for measuring the
torque converter stall speed, see TESTING
TORQUE CONVERTER STALL SPEED.

1. Referring to USER MODE AND SERVICE MODE

FUNCTIONS OF MONITOR PANEL in TOUBLE-
SHOOTING, display the engine speed of the
monitored items.
2. Start the engine and measure its speed during

high idling and low idling.
fl For details of the method for measuring the
torque converter stall speed, see TESTING
TORQUE CONVERTER STALL SPEED.
HD325-6 20-23
8
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL

PRESSURE
HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
¤ Always stop the engine before removing or in-

stalling the tubes or oil pressure gauge.
fl Before measuring the oil pressure, remove all dirt
and mud from around the mount.
fl Warm up the engine thoroughly to raise the cool-
ant temperature to the operating range.
1. Remove plug (1).
2. Install the adapter of oil pressure gauge kit C1 and

oil pressure gauge C2 (0.981 MPa {10 kg/cm2}).
3. Start the engine and measure the oil pressure.

1. Remove engine oil low pressure switch (1) or en-

gine oil high pressure switch (2).
2. Install the adapter of oil pressure gauge kit C1 and

oil pressure gauge C2 (0.981 MPa {10 kg/cm2}).
3. Start the engine and measure the oil pressure.
20-24 HD325-6
8
TESTING AND ADJUSTING MEASURING BOOST PRESSURE
MEASURING BOOST PRESSURE

¤ Be careful not to touch any hot parts when re- HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
moving or installing the measuring tools. HD405-6 Serial No.: 1055 – 2000
1. Remove the boost pressure measurement plug,

then install coupler (1) inside oil pressure gauge
kit C.
2. Connect the oil pressure measurement hose to

the coupler and pressure gauge R {1,500 mmHg}.
¤ When measuring the pressure, be careful not
to touch the rotating parts or hot parts.
Note: Operate the engine speed at midrange or
above, and use the self-seal portion of the
gauge to bleed the oil inside the hose.
• Insert the gauge about half way, repeat the
action to open the self-seal portion, and bleed HD325-6 Serial No.: 6001 and up
the oil. HD405-6 Serial No.: 2001 and up
fl If there is oil inside the hose, the gauge will
no work, so always bleed the oil.
3. Run the engine at the rated speed and read the

gauge indicator.
HD325-6 20-25
8
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST
TEMPERATURE HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
¤ The temperature sensor must be installed to the HD405-6 Serial No.: 1055 – 2000
exhaust manifold, so if the machine has been
operated, wait for the manifold temperature to
go down before installing the sensor.
fl Raise the coolant temperature to the operating

range before measuring.
1. Remove the measuring exhaust temperature plug
from the exhaust manifold and install tempera-
ture sensor (1).
• Temperature sensor
: 6215-11-8180
(cable length 610 mm) or
: 6215-11-8170
(cable length 490 mm)
2. Connect to digital temperature gauge B with the HD325-6 Serial No.: 6001 and up
wiring harness. HD325-6W Serial No.: 6001 and up
MEASUREMENT PROCEDURE
1) Measuring by torque converter stall
fl If the exhaust temperature is measured only
under torque converter stall condition, the
torque converter will overheat before the sen-
sor core warms up and a stable value can be
obtained.
(1) Use the full stall condition (torque converter
stall + hydraulic relief) to raise the exhaust
temperature (approx. 650˚C: standard value).
(2) From the above condition, cancel the hydrau-
lic relief and continue only the torque con-
verter stall. (The temperature will start to go
down. If the temperature does not go down
but goes up instead, raise the set tempera-
ture for Step 1.)
(3) Record the stable temperature when the tem-
perature starts to go down.
2) Measuring maximum value for exhaust

temperature
Carry out actual work and measure the maximum
value during operation.
fl Use the PEAK mode (it can store the maxi-
mum value in memory) of the temperature
gauge function.
20-26 HD325-6
8
TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR
MEASURING EXHAUST GAS

COLOR
• For tests in the field where there is no air or elec-
tricity available, use handy smoke checker; for
tests in a repair shop, use smoke meter.
MEASURING WITH HANDY SMOKE

CHECKER
¤ When measuring the exhaust color, be careful
not to touch the exhaust pipe.
¤ Raise the body, then lock with safety pin.
fl Measure the exhaust color when the engine is
warm (oil temperature is 60˚C).
1) Fit the filter paper in tool G1.
2) Insert the exhaust gas suction port into the
exhaust pipe, accelerate the engine suddenly,
and operate the handle to catch the exhaust
gas on the filter paper.
3) Remove the filter paper and compare with the
scale provided to judge the condition.
MEASURING WITH SMOKE METER

¤ When measuring the exhaust color, be careful
not to touch the exhaust pipe.
¤ Raise the dump body and lock it with the safety
pin.
fl Measure the exhaust color when the engine is
warm (oil temperature is 60˚C).
1) Insert the probe in the outlet of exhaust pipe
and secure it to the exhaust pipe with a clip.
2) Connect the probe hose, accelerator switch
to plug and air hose to tool G2.
fl The pressure of the air supply should be
under (1.47 MPa {15 kg/cm2}).
3) Connect the power cord to a power source
socket.
fl Check that the power switch is OFF be-
fore connecting the cord.
4) Loosen the cap nut of the suction pump and
insert the filter paper.
fl Fit the filter paper securely so that the ex-
haust gas does not leak.
5) Turn the power switch ON.
6) Accelerate the engine suddenly. At the same
time, depress the accelerator pedal, operate
the relief valve and catch the exhaust gas color
on the filter paper.
7) Lay the filter paper used to catch the exhaust
gas color on top of unused filter papers (10
sheets or more) inside the filter paper holder,
and read the indicated value.
HD325-6 20-27
1
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING

FUEL INJECTION TIMING
HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
¤ Set the parking brake valve lever to PARKING.
1. Lock pin method

fl Normally, use this method.
(When removing or replacing only the fuel in-
jection pump: when the gear train and front cover
are not changed, and the relationship between
the positions of the injection timing lock pin and
fuel injection pump gear pin hole is maintained
in the same condition as when the engine was
shipped from the factory.)
1) Crank the engine and align pointer (2) with

the 1.6 TOP line (1) on the damper.
fl When doing this, check that the position
of key (4) of fuel injection pump shaft (3)
is more or less at the top.
[If it is at the bottom, rotate the crankshaft
a further 360˚. (The fuel injection pump
shaft will rotate 180˚.)]
2) Remove nut (7) and snap pin (6) of injection

timing lock pin (5).
3) Rotate the crankshaft approx. 45˚ in the re-

verse direction from the No. 1 TOP (top dead
center) position.
4) Loosen fuel injection pump coupling bolt (8)

and set coupling (9) free.
5) Push pin (10) into the engine end, rotate the

crankshaft in the normal direction, and insert
pin (10) into gear (11).
¤ In this condition, do not start the engine
or try to crank it by force. If this is done,
the tip of pin (10) will break and get
caught in the gear, and this will lead to
serious damage.
20-28 HD325-6
8
6) In the condition in Step 5), move coupling (9)

to align lines a and b, then tighten bolt (8).
3 Bolt : 88.3 ± 4.9 Nm {9.0 ± 0.5 kgm}
• Procedure for releasing lock pin

i) Pull out pin (10) and remove it from gear
(11).
fl Turn pin (10) while pulling it out makes
it easy to remove.
fl Pull out pin (10) until it does not move
any further.
ii) Tighten nut (7).
3 Nut :
30.5 ± 3.5 Nm {3.1 ± 0.36 kgm}
fl Put a flat-head screwdriver in the slit
of pin (10) to hold it in position, and
tighten securely.
iii) Insert snap pin (6) and lock with nut (7).
iv) Crank the engine and check that it rotates
smoothly.
2. Piston displacement method

(When the engine is overhauled: when the gear
train and front cover are changed, and the rela-
tionship between the positions of the injection
timing lock pin and fuel injection pump gear pin
hole is not maintained in the same condition as
when the engine was shipped from the factory.)
1) Remove No. 1 cylinder nozzle holder assem-
bly (13).
fl For details, see REMOVAL OF NOZZLE
HOLDER ASSEMBLY.
2) Remove the coupling cover of the fuel injec-
tion pump.
fl When doing this, check that the fuel in-
jection timing line on the fuel injection
pump is near the line on the fuel injection
pump body.
3) Set dial gauge AA to the nozzle holder hole
where the nozzle holder assembly has been
removed. (See the diagram.)
fl Set the magnet stand of dial gauge AA in
a stable position where installation is pos-
sible.
HD325-6 20-29
8
4) Set the scale on the dial gauge to "0" when

the piston is at top dead center.
fl Rotate the crankshaft in the normal direc-
tion and in the reverse direction in turn to
set to top dead center.
fl Note down the value shown by the short
hand on the dial gauge.
5) Rotate the crankshaft approx. 45˚ in the re-
verse direction from the No. 1 cylinder TOP
position.
6) Rotate the crankshaft again in the normal di-
rection until the dimension becomes the
specified dimension.
fl Specified dimension C : 6.49 +0.32
–0.31 mm
fl Always rotate the crankshaft in the nor-
mal direction to align the position.
fl Continue to rotate in the normal direc-
tion and check that the scale on the dial
gauge reads 0 ± 0.05 mm when the No. 1
cylinder is at the top dead center (the po-
sition where the indicator of the dial gauge
starts to move back in the opposite
direction). If it is not 0 ± 0.05 mm, carry out
the operation again for Steps 3) and 4).
7) Loosen bolt (8), and with the position of the
piston at set dimension C, move coupling (9)
to align lines a and b, then tighten the bolt.
3 Bolt : 88.3 ± 4 Nm {9.0 ± 0.5 kgm}

fl Since the match mark on the timing gear case is

matched to the key way of the supply pump drive
shaft, ADJUSTMENT OF FUEL INJECTION TIM-
ING is not necessary.
20-30 HD325-6
8
8) Remove nut (7) and snap pin (6) of injection

timing lock pin (5).
9) Remove the mounting bolts of injection tim-
ing lock pin (5) and set whole flange free.
10) With the piston position at set dimension C,
insert pin (10) into the hole in gear (11), then
tighten the mounting bolts of the injection tim-
ing lock pin to hold the flange in position.
¤ In this condition, do not start the engine
or try to crank it by force. If this is done,
the tip of the pin will break and get
caught in the gear, and this will lead to
serious damage.
11) Pull pin (10) out from gear (11).
For details, see RELEASING LOCK PIN in LOCK
PIN METHOD.
12) Install No. 1 cylinder nozzle holder assembly
(13).
For details, see INSTALLATION OF NOZZLE
HOLDER ASSEMBLY.
HD325-6 20-31
1
TESTING AND ADJUSTING AIR BLEEDING FROM FUEL SYSTEM
AIR BLEEDING FROM FUEL

SYSTEM
HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
1. Loosen air bleed plug (1) of fuel filter, then oper-

ate priming pump (2).
2. When no more bubbles in fuel flow out from air

bleed plug (1), tighten air bleeding plug (1).
3. Loosen joint bolt of inlet hose of injection pump,

operate priming pump to bleed air between filter
and fuel injection pump hose.
4. Operate priming pump further to bleed air from

fuel injection pump.
fl If bleed air from fuel injection pump, operat-
ing force of priming pump becomes heavier.
fl There is no air bleeding plug on fuel injection
pump.
When operate priming pump, open check ball
inside joint bolt on fuel injection pump outlet
hose, and bleed air to fuel tank.
20-32 HD325-6
8
HD325-6 Serial No.: 6001 and up fl If clean fuel is not available, do not remove
HD325-6W Serial No.: 6001 and up the filter. Operate the priming pump to fill
HD405-6 Serial No.: 2001 and up the inside of the filter with fuel.
fl Bleed the air as follows if the engine has run 2. Remove air bleed plug (2) of the fuel filter and
out of fuel or the fuel circuit equipment has operate priming pump (3).
been removed and installed. fl Continue operating the priming pump un-
fl With the type where the priming pump and til fuel flows out from the plug hole. When
fuel filter have a remote mount, operate the fuel comes out, install the plug.
remote control for the priming pump to bleed
the air. 3 Air bleed plug:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
1. Remove fuel filter (1), fill with fuel, then install
again. 3. Loosen air bleeder (4) of the fuel supply pump
fl When filling, use clean fuel and be careful and operate priming pump (3) 90 – 100 times.
not to let dirt get in. fl Operate the priming pump until fuel flows
out from the bleeder. When the fuel flows
out, tighten the bleeder, then operate the
priming pump several times until the
pump becomes stiff.
3 Air bleeder:
4.9 – 6.9 Nm {0.5 – 0.7 kgm}
HD325-6 20-32-1
9
4. Crank the engine with the starting motor and

start the engine.
fl When the high-pressure circuit is cranked
with the engine, the air is automatically
bled.
fl If the engine does not start, the air has
probably not properly bled from the low-
pressure circuit, so repeat the procedure
from Step 2.
20-32-2 HD325-6
9
TESTING AND ADJUSTING CHECK FOR LEAKAGE IN FUEL SYSTEM
CHECK FOR LEAKAGE IN FUEL SYSTEM

HD325-6 Serial No.: 6001 and up 8. Start the engine, run it at high idling, then ap-
HD325-6W Serial No.: 6001 and up ply load to the engine.
HD405-6 Serial No.: 2001 and up fl If this inspection is carried out with the
engine mounted on the machine, stall the
¤ With the fuel system, the high-pressure cir- torque converter or relieve the hydraulic
cuit is under extremely high pressure, so if pump.
fuel leaks when the engine is running, there
is danger of fire. 9. Check the fuel piping and equipment for fuel
Check for fuel leakage as follows when leakage.
checking the fuel circuit or when equipment fl Check the high-pressure circuit for fuel
has been removed and installed. leakage, particularly at the places sprayed
fl To make it easier to check for fuel leakage, with color checker.
wipe the engine itself and the surrounding fl If there is fuel leakage, carry out repairs,
area clean and remove all oil and grease be- then repeat the check from Step 2.
fore starting the inspection. fl If no fuel leakage is found, the check is
complete.
1. Spray the fuel supply pump, common rail, fuel
injector, and high-pressure piping connec-
tions with a color checker (developing solu-
tion).
2. Start the engine, run it at under 1000 rpm, and

when the speed stabilizes, stop the engine.
3. Check the fuel piping and equipment for fuel

leakage.
fl Check the high-pressure circuit for fuel
leakage, particularly at the places sprayed
with color checker.
fl If there is fuel leakage, carry out repairs,
then repeat the check from Step 2.
4. Start the engine and run it at low idling.

leakage.
with color checker.
6. Start the engine and run it at high idling.

leakage.
with color checker.
HD325-6 20-32-3
9
MEASURING FUEL PRESSURE,
TESTING AND ADJUSTING RELEASING REMAINING PRESSURE IN FUEL SYSTEM
MEASURING FUEL PRESSURE RELEASING REMAINING

HD325-6 Serial No.: 6001 and up PRESSURE IN FUEL SYSTEM
fl Measure the fuel pressure only for the low-
pressure circuit between the feed pump – fuel
fl When the engine is running, pressure is gen-
filter – fuel supply pump.
erated in both the low-pressure circuit and
¤ The high-pressure circuit between the fuel high-pressure circuit of the fuel line.
supply pump – common rail – fuel injector
Low-pressure circuit: Feed pump – fuel filter
is under extremely high pressure, so it can-
– fuel supply pump
not be measured.
High-pressure circuit: Fuel supply pump –
common rail – fuel in-
1. Remove fuel pressure measurement plug (1).
jector
fl For both the low-pressure circuit and high-
pressure circuit, the pressure automatically
goes down to a safe level 30 seconds after
the engine is stopped.
fl The remaining pressure in the fuel system
must be completely released before carrying
out inspection of the fuel system or removal
or installation of the equipment. Always fol-
low the following precautions when carrying
out the operation.
¤ When inspecting the fuel line or removing
or installing equipment, wait for at least 30
seconds after the engine is stopped to re-
2. Fit nipple 1 of pressure test kit A, then con- lease the remaining pressure in the fuel sys-
nect to the pressure test kit. tem before starting the operation. (There is
still pressure remaining in the circuit, so do
not start operations immediately after the
engine is stopped).
3. Start the engine and measure the fuel pres-

sure at high idling.
4. After completing the measurement, remove

the measurement equipment and set to the
original condition.
20-32-4 HD325-6
9
TESTING AND ADJUSTING HANDLING EQUIPMENT IN FUEL CIRCUIT
HANDLING EQUIPMENT IN
FUEL CIRCUIT
fl Precaution for inspection and maintenance of

fuel system
With the common rail type fuel injection sys-
tem, more precise equipment is used than
with the conventional fuel injection pump and
nozzle, so problems may occur if dirt or dust
get in.
When carrying out installation and mainte-
nance of the fuel system, pay more attention
than usual to prevent dirt or dust from get-
ting in. If there is any dirt stuck to any part,
use clean fuel to wash it off completely.
fl Precautions when replacing fuel filter car-
tridge.
Always use a genuine Komatsu part for the
fuel filter cartridge.
With the common rail type fuel injection sys-
tem, more precise equipment is used than
with the conventional fuel injection pump and
nozzle, so a special filter with high efficiency
filtering ability is used to prevent dirt or dust
from getting in.
For this reason, if any filter is used as a sub-
stitute for the genuine filter, there is danger
that problems will occur with the fuel system.
To prevent this, never use such filters.
HD325-6 20-32-5
9
TESTING AND ADJUSTING REDUCED CYLINDER MODE OPERATION
REDUCED CYLINDER MODE OPERATION

HD325-6 Serial No.: 6001 and up <Reference>
HD325-6W Serial No.: 6001 and up • When the fuel injector of cylinder No. 3
HD405-6 Serial No.: 2001 and up has a trouble and combustion in cylinder
No. 1 is abnormal (Judge from the engine
fl If irregular engine speed seems to be caused speeds before and after starting the re-
by a defective fuel injector, perform reduced duced cylinder mode operation):
cylinder mode operation to find out the de- 1) If the engine is started with cylinder No. 3
fective fuel injector according to the follow- disabled, the engine speed does not
ing procedure. change since combustion in only 1 cylin-
der is abnormal both before and after the
fl Perform the reduced cylinder mode operation engine is set in the reduced cylinder
with the [reduced cylinder mode] in the [ser- mode.
vice mode] on the monitor panel. 2) If the engine is started with a cylinder
For details of the functions of the monitor other than cylinder No. 3 disabled, the
panel (including the reduced cylinder mode), engine speed lowers since combustion in
see MONITOR PANEL USER CODES AND SER- only 1 cylinder is abnormal before the
VICE MODE FUNCTION in TROUBLESHOOT- engine is set in the reduced cylinder mode
ING. but combustion in 2 cylinders is abnor-
mal during the reduced cylinder mode
1. Before setting the engine in the reduced cyl- operation.
inder mode, start the engine and measure its
low idling speed and high idling speed. 6. After finishing the measurement, cancel the
reduced cylinder mode.
2. Set the engine in the reduced cylinder mode. fl The reduced cylinder mode can be can-
fl For the method for setting the reduced cyl- celled by turning off the starting switch,
inder mode, see 3.4.4) ITEMS DISPLAYED too.
IN REDUCED CYLINDER MODE AND
METHOD FOR SETTING REDUCED CYL-
INDER MODE in SERVICE MODE OF
MONITOR PANEL in the introduction to
TROUBLESHOOTING.
3. Select one or more cylinders to be reduced

(in which fuel will not be injected).
fl You can select only 1 or multiple cylinders
to be reduced.
4. Start the engine and measure the engine

speed in the reduced cylinder mode.
5. Cancel the reduced cylinder mode.

fl If multiple cylinders have been reduced,
cancel the reduced cylinder mode for all
of them.
fl Compare the engine speed to find out the
defective fuel injector.
fl Possible causes of troubles are as follows.
• Leakage through cylinder head gasket
• Defective injection by fuel injector
• Defective piston, piston ring, or cylin-
der liner
• Defective valve mechanism (moving
valve system)
• Trouble in electric system
20-32-6 HD325-6
9
HANDLING ELECTRONIC DEVICES IN FUEL INJECTION
TESTING AND ADJUSTING SYSTEM OF COMMON RAIL TYPE ENGINE
HANDLING OF ENGINE
CONTROLLER HIGH TENSION
CIRCUIT
¤ In the engine controller, a high tension cir-

cuit (110 to 130 V) is used to drive a fuel in-
jector. For this reason, on the harnesses and
connectors between the engine controller
and the fuel injector, a high tension circuit is
connected.
fl Usually, only during rotation of the engine,
high voltage is output from the engine con-
troller to the fuel injector. Stopping the en-
gine stops outputting high voltage.
¤ Direct touching the high tension circuit may
give you an electric shock. When you make
tests, be sure to follow the precautions be-
low.
1. Connectors including a high tension circuit are

as follows.
• Engine controller connector: CN6, CN7
• Relay connector: J10
• Injector connector:
CN1, CN2, CN3, CN4, CN5, CN6
• Terminal at the injector head (In the head
cover)
2. Before disconnecting and connecting a corre-

sponding connector, be sure to turn off the
starting switch.
3. When a T-adapter is inserted or connected to

the connector for a diagnosis, do not start the
engine.
fl You are allowed to move the starting
switch only to ON or OFF position.
Do not move it to the START position.
HD325-6 20-32-7
9
TESTING AND ADJUSTING ADJUSTING ENGINE STOP MOTOR CABLE
ADJUSTING ENGINE STOP

MOTOR CABLE
HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
1. Temporarily install the ball joints connecting the

fuel injection pump to the engine stop motor
cable.
2. Pull stop lever (1) of the fuel injection pump to

the engine stop position (NO INJECTION), then
install ball joint (2) to the stop lever and secure
cable (3) to bracket (4).
fl Stroke a of fuel injection pump stop lever:
30 mm
fl Travel of engine stop motor: 35 mm
fl The engine stop motor is delivered with the
cable in the pulled position.
fl Stop lever (1) is in the OPERATION position
when the lever is free.
3. Turn the engine starting switch ON/OFF repeat-

edly and check the adjustment condition.
If necessary, adjust with nut (5).
(Check that the engine stops.)
fl Check visually that there is 5 mm slack in the

engine stop motor cable and that the stop le-
ver returns fully to the OPERATION position
when the engine is running. The OPERATION
position is maintained by the action of the
spring built into the fuel injection pump.
fl Problems caused by improper adjustment of
the engine stop motor cable
• When engine stop motor • Engine does not stop

cable is pulled, clearance
between stop lever and
STOP stopper is too large
• When condition is free, • Engine output goes

clearance between stop down because of
lever and OPERATION drop in fuel injection
stopper is too large amount

• Engine stop solenoid is not installed.
HD325-6 20-33
8
TESTING AND ADJUSTING ADJUSTING ACCELERATOR PEDAL
ADJUSTING ACCELERATOR PEDAL

HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
1. Adjust dimension a of low idling stopper bolt (1),

and adjust clearance b at the low idling end.
Dimension a of stopper bolt: 19.0 mm
Clearance b: 2.5 ± 0.1 mm
2. Adjust dimension c of low idling stopper bolt (2),

and adjust clearance d at the low idling end.
Dimension c of stopper bolt: 25.0 mm
Clearance d: 0.8 ± 0.1 mm
3. After adjusting, measure the output voltage of the

accelerator sensor.
Sensor output voltage: See Standard Value Table
4. After adjusting the accelerator sensor, adjust the

amount that rod (3) is screwed in so that the fuel
injection pump control lever is at the LOW IDLING
position when the accelerator pedal is at the LOW
IDLING position.

• The accelerator pedal does not need to be ad-
justed.
20-34 HD325-6
8
ADJUSTING ENGINE SPEED SENSOR,
TESTING AND ADJUSTING ADJUSTING TRANSMISSION SPEED SENSOR
ADJUSTING ENGINE SPEED

SENSOR
fl The G rotation sensor and Ne rotation sensor for
the fuel injection system of common rail type can-
not be adjusted.
1. Screw in sensor (1) by hand until the tip of sensor

(1) contacts gear (2).
fl When putting the tip of the sensor in contact
with the gear, tighten lightly by hand, and
confirm that it is in contact. Never tighten with
a wrench or any other tool.
2. Turn back 1/2 – 2/3 turn from the point when sen-
sor (1) contacts gear (2).
3. Tighten locknut (3).

8 Threaded part of sensor:
Hydraulic sealant
3 Locknut : 69 – 74 Nm {7.0 – 7.5 kgm}
fl Be careful to arrange the sensor wiring so that
there is no excessive force brought to bear
on the wire.
fl Be careful not to damage the tip of the sensor
or get iron particles stick to it.
fl Standard clearance: 0.75 – 1.0 mm
ADJUSTING TRANSMISSION
SPEED SENSOR
1. Screw in by hand until the tip of sensor (1) con-
tacts gear (2).
fl When bringing the tip of the sensor into con-
tact with the gear, tighten lightly by hand and
check that there is contact. Never use a
wrench to tighten.
2. When sensor (1) contacts gear (2), turn back 1/2 -
1 turn.
3. Tighten locknut (3).
3 Locknut : 58.8 ± 9.8 Nm {6 ± 1 kgm}
fl Be particularly careful when handling the sen-
sor wiring to ensure that no excessive force
is brought to bear on the wiring.
fl Be careful not to let the tip of the sensor be
scratched or to let any iron particles stick to
the sensor tip.
fl Standard clearance: 1.5 mm
HD325-6 20-35
8
TESTING AND ADJUSTING TESTING HYDRAULIC PRESSURE OF TORQUE CONVERTER VALVE
TESTING HYDRAULIC
PRESSURE OF TORQUE
CONVERTER VALVE
¤ Raise the dump body and lock it with the safety
pin.
¤ The oil is at high temperature, so be careful not
to get burned.
¤ Always remove and install the plugs and hydrau-
lic pressure gauge with the engine stopped.
1. Testing main relief pressure (P4)

1) Raise the transmission oil temperature.
fl Oil temperature when measuring:
60 – 80˚C
2) Remove plug (1), then install tool C {60 kg/
cm2}.
3) Start the engine, place the gearshift lever at
N, and measure the hydraulic pressure at low
idling and high idling.
2. Testing hydraulic pressure at torque converter in-

let port (relief) (P1)
1) Check that there is no abnormality.
For details, see Testing main relief pressure.
2) Remove plug (2), then install tool C 2.45 MPa
{25 kg/cm2}.
3) Start the engine, and measure the hydraulic
pressure at high idling.
3. Testing hydraulic pressure at torque converter

output port
For details, see Testing main relief pressure.
2) Remove plug (3), then install tool C 2.45 MPa
{25 kg/cm2}.
3) Start the engine, and measure the hydraulic
pressure at high idling.
20-36 HD325-6
8
TESTING AND ADJUSTING TESTING ECMV OIL PRESSURE
TESTING ECMV OIL PRESSURE

(Testing oil pressure using fixed
valve)
A Raise the dump body and lock it with the safety
pin.
A The oil is at high temperature, so be careful not
to get burned.
Always remove and install the plugs, hydraulic
pressure gauge, and fixed valve with the engine
stopped.
Block the wheels, apply the brake, and place the
shift lever at the N position.
When measuring the oil pressure using a fixed
valve, never measure 2 places at the same time.
Ir Before replacing the fixed valve assembly, clean

the area around the ECMV, and remove all mud
and dirt.
1. Measuring transmission modulating pressure

(Clutch circuit pressure)
1) Raise the transmission oil temperature.
Ir Oil temperature when measuring:
60 - 8O’C
For details, see TESTING TORQUE CON-
VERTER MAIN RELIEF PRESSURE.
3) Remove plug (I) - (7) from the pressure mea-
suring points, and install tool C 5.88 MPa {60
kg/cm?.
Circuit Circuit
Puug No. measured Puug No. measured
4) Disconnect connectors (8) and (9).

* Connector No.: CNTM3, TM4
5) Disconnect connectors (IO) and (II) of the
proportional solenoid forthe clutch where the
oil pressure is being tested.
6) Using tool Q2, remove proportional solenoid
(12) for the clutch where the oil pressure is
tested.
HD325-6 20-37
0
TESTING AND ADJUSTING TESTING ECMV OIL PRESSURE
7) Assembly of fixed valve assembly (tool Ql)

U Assemble spring (14) to cover (13).
ii) Refer to the table below and select neces- ______Ol-__-____.-
sary spacer (15) for the clutch where the r----
oil pressure is being measured.
Ir There are three types of spacer: each
spacer has a stamped mark showing
the number of the clutch for which it
is used.
1 Clutch measure- 1 Spacer used when 1

ment location measuring
0
WHO0333
H clutch
;;;ned
3rd clutch H,3
R clutch
1
1st clutch
2nd clutch E;;ped 8 I r
.I3
L clutch
4th clutch
iii) Assemble valve (16).

iv) Assemble the O-ring at the matching sur-
face of the ECMV and proportional sole-
noid to the fixed valve cover. 14
BVH00334
8) Using tool 02, install fixed valve assembly
(17) to the ECMV.
w Mounting bolt of fixed valve assembly:

13.24 f 1.47 Nm Il.35 f 0.15 kgm1
9) Start the engine and measure the hydraulic

pressure with tool Cl.
* Note that the pressure measured using
the fixed valve is different from the set
pressure for the hydraulic pressure when
installed on the machine.
* See STANDARD VALUE TABLE FOR
CHASSIS.
IO) After measuring, remove the fixed valve as-
sembly, then install the proportional solenoid
valve.
* Always be sure to install the O-ring used
with the fixed valve to the proportional
solenoid valve.
w Mounting bolt of fixed valve

assembly:
13.24 f 1.47 Nm Il.35 + 0.15 kgm}
20-38 HD325-6
0
TESTING AND ADJUSTING TESTING TORQUE CONVERTER STALL SPEED
TESTING TORQUE CONVERTER

STALL SPEED
a Stop the machine on level ground and put blocks
under the tires.
1. Remove cap (I) from the speed pickup port, then

install tool A (adapter).
2. Warm the engine water temperature up to the op-
erating range.
3. Use tool A (tachometer) to measure the engine
high idling and low idling speeds.
j, If the speed is too low, see TROUBLESHOOT-
ING OF ENGINE. WHO0711
4. Raise the hydraulic and transmission oil tempera-
ture.
* Oil temperature when measuring:
Hydraulic oil 45 - 55’C
Transmission 60 - 80°C
5. Apply the parking brake, depress the brake pedal
fully, then operate the gearshift lever and set to
n.
6. Gradually depress the accelerator pedal and run
the engine at full throttle to stall the torque con-
verter. When the oil temperature exceeds 90°C
(green range A on the torque converter oil tem-
perature gauge lights up), lowerthe engine speed
to low idling and return the gear shift lever N.
7. Keep the gear shift lever at the N, run the engine
at a midrange speed, and lower the oil tempera-
ture until green range 6 on the torque converter
oil temperature gauge lights up.
8. Lower the engine speed to low idling, repeat the
procedure in Steps 4 - 6, make the oil tempera-
ture in the torque converter and transmission the
same, then measure the stall speed when the oil
temperature is approx. 80°C (green range 6 on
the torque converter oil temperature gauge lights
up).
* Measure the stall speed 2 or 3 times.
A Do not operate the gear shift lever when the

TVH00185
accelerator pedal is depressed.
This will cause a big shock and will also re-
duce the life of the machine.
The stall speed varies according to the following
conditions, so always measure the stall speed
when the machine is delivered.
1) Variations according to engine serial number
2) Variations in engine output according to at-
mosphere pressure and ambient temperature
3) Variation in torque consumed by auxiliary
equipment
4) Variations according to characteristics of
torque converter
5) Variations according to the method of mea-
suring stall
HD325-6 20-39
0
TESTING AND ADJUSTING TESTING BRAKE PRESSURE
TESTING BRAKE PRESSURE

A Stop the machine on level ground, apply the
parking.brake, and put blocks under the tires.
1. Rear brake actuating pressure

1) Raise the air pressure to the specified pres-
sure.
2) Remove air bleed plug (I), and install tool Cl
(hydraulic pressure gauge: 5.88 MPa I60 kg/
cm*)).
3) Measure the hydraulic pressure when the
brake pedal and retarder lever are operated.
* After measuring the hydraulic pressure,
install the plug and bleed the air.
2. Front brake actuating pressure
1) Raise the air pressure to the specified pres-

sure.
2) Remove air bleed plug (2) or (3), and install
tool Cl (hydraulic pressure gauge: 39.23 MPa
{400 kg/cm*}).
3) Measure the hydraulic pressure when the
brake pedal is operated.
f After measuring the hydraulic pressure,
install the plug and bleed the air.
eBVH00340
20-40 HD325-6
0
TESTING AND ADJUSTING BLEEDING AIR FROM BRAKE CIRCUIT
BLEEDING AIR FROM BRAKE

CIRCUIT
* Start the engine and wait for the gauge to enter
the green range, then bleed the air from the cir-
cuit as follows.
1. Rear brake
* Bleed the air at the slack ajuster end first.
1) Depress the brake pedal, then loosen air bleed
plug (I) or (2) 3/4 turns. Tghten the plug again,
then release the pedal.
2) Continue this procedure until no more

bubbles come out from the air bleed plug
hole, then bleed the air from the wheel end
(plug (3)).
Ir After bleeding the air, close the plug and
fit the cap.
0716
2. Front brake
Sr The oil tank is separately installed, so always
check the oil level while bleeding the air.
l Loosen plug (4), and bleed the air in the same
way as for the rear brake.
HD3256 20-41
a
TESTING AND ADJUSTING TESTING AND ADJUSTING PARKING BRAKE PERFORMANCE

PARKING BRAKE PERFORMANCE
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 mea-
sure the engine speed when the machine
starts to move.
* When the machine starts to move, release
the accelerator pedal, and depress the
brake pedal and return transmission shift BVH00719
lever to N at the same time.

Ir If the engine speed at the point when the
machine starts to move is less than stan-
dard value, adjustthe parking brake asfol-
lows.
2. Adjusting
!-----
1) Stop the machine on level ground and release
the parking brake (set to the TRAVEL position). /
/
2) Raise the air pressure to the specified pres- ./
,'
sure.
3) Turn bolt (I) clock wise to bring both pads (2)
into tight contact with disc (3).
4) Turn bolt (1)back 240” + 15” (4 clicks) counter-
clockwise from this position.
* Standard clearance:
Total for both clearances: 1.25 f 0.08 mm
* After adjusting the clearances, actuation
stroke @ of the parking brake chamber
will be approx. 40 mm.
5) Replace the pads, set bolt (1) to the initial ad-
justment position in Step 4) with both pads in
tight contact with the disc, then turn bolt (1)
BVH00720
back 360” k 15” (6 clicks) counterclockwise
from this position.
-f Standard clearance:
Total for both clearances: 1.88 +_0.08 mm
Ir After adjusting the clearances, actuation
stroke @ of the parking brake chamber
will be approx. 50 mm.
BVH00721
20-42 HD325-6
0
TESTING AND ADJUSTING TESTING WEAR OF FRONT BRAKE PAD
TESTING WEAR OF FRONT

BRAKE PAD
HD325-6, HD405-6
a Stop the machine on level ground, apply the
parking brake, and put blocks under the tires.
1. Visual check
Checkvisually, 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 pressed
against the disc, then insert inspection gauge
@ into indicator hole (1) of the caliper.
2) If the stepped part of the gauge contacts the
Disk
mouth of the hole, the pad has reached the
wear limit, so replace it.
* Replace the pads on the left and right sides at
the same time.
* The pad wear is not the same for both left
and right sides, so checkthe wear of all pads.
Brake pad
TESTING WEAR OF FRONT
BRAKE DISC
Clearance of pads
reach wear limit TVH0D,86
HD325-6W
AI Remove install the plugs and gauge when the

brake cooling oil temperature is below 60°C and
with the service brake pedal and front brake cut-
off switch at the “OFF” position.
1. Remove front brake air bleed plug (4), then in-

stall disc wear measurement gauge K.
2. Raise the air pressure to the specified pressure.
3. Depress the brake pedal fully, push the rod until
it contacts the piston, then check the position of
the stamped mark on the rod. TVH00526
A If the front brake is depressed suddenly, the

rod will shoot out strongly. This is danger-
d
ous, so hold the rod firmly with your hand,
and take 10 seconds to depress the foot
brake pedal over a period of IO seconds Face of the case
slowly.
* For the front brake, align with the HD205 line
stamped mark.
* If the stamped mark A on the rod goes in be-
yond the end face of the case, the disc has
reached the wear limit.
4. After measuring the wear, install the air bleed
plug, and bleed the air.
For details, see BLEEDING AIR FROM BRAKE CIR-
CUIT.
HD325-6
TESTING AND ADJUSTING TESTING WEAR OF REAR BRAKE DISC
TESTING WEAR OF REAR

BRAKE DISC
a Install and remove plugs and gauges with the
brake cooling oil temperature below 60°C and
with the retarder brake control lever at the OFF
position.
a If the disc is near the wear limit, check the wear
frequently, regardless of the maintenance inter-
val. In addition, check the performance of the
retarder carefully.
BVH00337
1. Remove air bleed plug (1) of the rear brake, then
install disc wear measurement gauge K.
When installing, tighten nipple @completely and
pull rod @ of disc wear measurement gauge K
fu I ly.
* Pull rod @ of gauge K fully before operating
the retarder brake.
2. Turn the starting switch ON, and check that the
air pressure gauge is in the green range.
3. If the air pressure is low, start the engine and run
it at 2000 rpm until the air pressure gauge enters
the green range. When it enters the green range,
turn the starting switch OFF.
4. Pull rod @ of disc wear measurement gauge K
fully, then operate the retarder brake control le-
ver slowly (take approx. 10 sec.) to apply the
brake.
5. In this condition, push in rod @of disc wear mea-
surement gauge K until it contacts the piston.
6. If mark a on disc wear measurement gauge K goes
in beyond the end face (portion b) of the case,
the disc has reached the wear limit.
7. After checking the brake wear, pull back rod @of
wear measurement gauge K fully, then release the
retarder brake.
a After checking the wear, if the retarder brake
control lever is pulled suddenly, there is
seious danger that the rod of the disc wear
measurement gauge may fly out suddenly.
for this reason, when the rod is fully pulled,
release it, then pull the retarder control
lever slowly over a period of approx. 10 sec-
onds. (Release the retarder brake.)
8. After measuring the brake wear, install the air
bleed plug, and bleed the air.
For details, see Bleeding air from brake circuit.
20-44 HD325-6
8
TESTING AND ADJUSTING TESTING REAR BRAKE CAUTION SYSTEM
TESTING REAR BRAKE

CAUTION SYSTEM
1. If the following problems occur in the rear brake
hydraulic circuit, the brake chamber stroke will
become too large. As a result, rod (2) will be
pushed by piston (I), and the brake line caution
will be actuated.
1) Internal leakage of oil in brake chamber
2) Increase in amount of oil needed for brake be-
cause of defective operation of slack adiuster
3) Increase in amount of oil needed for brake be-
I \
cause of wear of brake disc
I 2 BWH00734
4) Internal leakage of oil from brake piston
5) External leakage of oil from hose or piping
2. If the brake line caution is actuated, check or re-

pair the brake hydraulic circuit and related parts.
Sr For details of the method of checking the brake
oil pressure, rear brake disc wear, and capac-
ity of the rear brake, see the respective sec-
tion.
3. After checking and repairing, push in the rod by

hand to actuate the brake and check that there is
no abnormality. If the rod is not pushed in, the
brake line caution will continue to be actuated.
HD325-6 20-44-I
8
TESTING AND ADJUSTING TESTING AND ADJUSTING SUSPENSION CYLINDER

SUSPENSION CYLINDER
* Stop the machine empty on flat ground.
1. Testing length of cylinder

1) Check that the bottom of the cylinder cover is
within the range marked by arrows for the cyl-
inder level.
2) Before adjusting the oil level in the front sus-
pension cylinder, check the condition of the
variable damper valve.
With the ;ruck empty, starting switch ON,
parking brake OFF, and hoist control le- TVHOOIBB
ver at the FLOAT position, check that the

air cylinder of the variable damper valve
is in the soft mode.
If the air cylinder of the variable damper
valve is not in the soft mode when check-
ing, operate as follows to switch to the
soft mode. (Note I)
i) Fill with air, use the retarder brake and
drive the machine several times re- Hard
peatedly forward and in reverse to set
to the soft mode.
Note 1: If the foot brake pedal is used,
the automatic suspension is
Medium TVHOOl89
automatically set to the me-
dium mode, and the resis-
tance of the cylinder in-
creases, so it takes time to
adjust.
2. Releasing nitrogen gas

1) Front suspension cylinder
i) Set hydraulic jack @ (50ton) under the
main frame.
ii) Loosen the oil level valve (I) slowly 2 - 3
turns.
* When releasing the nitrogen gas, there is
danger that releasing the gas from the
valve core of supply valve (I) will dam-
age the valve core, so remove the gas at
the oil level valve.
When the oil level valve is loosened, and
oil and gas spurt out together, tighten the
valve slightly, and allow time for the gas
to escape slowly.
iii) Operate the hydraulic jack @ so that di-
mension a of the cylinder is the specified
dimension for the oil level.
Dimension a: 88 f 3 mm
HD325-6 20-45
2) Rear suspension cylinder

* The precautions when handling the oil
level valve are the same as when releas-
ing the nitrogen gas from the front sus-
pension cylinder.
i) Set block @ between the stopper and
axle housing.
Thickness of block:
26 mm (dimension A: 110 f 3 mm)
Y BEH00023
ii) Disconnect pressure sensor connec-

tor (2) of oil level valve (I), then loosen
the oil level valve 2 or 3 turns.
A When loosening the oil level valve, loosen only

valve (1) itself, and release the nitrogen gas
gradually from slit (6).
A lf the nitrogen gas is not completely released,

the system will always be under pressure from
high pressure gas. To release the pressure,
loosen valve (1) itself; do not loosen the pres-
sure sensor and nipple. 1 BEH00016
6 I
I BVH00348
20-46 HD325-6
0
3. Adjusting of oil level

* Before adjusting the oil level, release the ni-
trogen gas.
1) Remove intake valve (3) and install joint P5.
2) Install fitting P4 to joint P3, and connect hose
P2 and volume pump PI.
3) Operate volume pump PI to fill oil until
bubbles do not come out through the air bleed
oil of the oil level valve any more.
* If a payload sensor is installed to the oil level
valve, loosen only the valve body, and do not
loosen the sensor and nipple.
4) If oil containing no bubbles flows out, install
oil level valve (1).
5) Remove the joint, hose and volume pump,
then install intake valve (3).
w Oil level valve:

44 * 5 Nm (4.5 ? 0.5 kgm}
m Intake valve:
44 k 5 Nm {4.5 f 0.5 kgm}
BEH00017
4. Charging suspension cylinder with gas

I) Remove cap (5) of air supply valve (3).
2) Set tool P as shown in the diagram.
Ir Before installing regulator PIO, blow the
mouthpiece filter with nitrogen gas at
0.981 MPa {IO kg/cm*) or more to remove
all dirt or dust. (Dirt or dust in the system
causes failures.)
3) Open valve @ of nitrogen gas cylinder (6) and
checkthe pressure reading of gauge PlOa (in-
ternal pressure of gas cylinder).
* The pressure indicated must be at least
0.981 MPa {IO kg/cm21 higher than the
pressure inside the suspension cylinder
(max. pressure inside suspension cylin-
der: 2.84 MPa (28 kg/cm*}).
4) Turn handle (d) of regulator PI0 slowly coun-
terclockwise, set the pressure reading of
gauge PlOb to 0.981 MPa I10 kg/cm*} above
the internal pressure of the suspension cylin-
der, then operate valves P6 and P9 to fill the
suspension cylinder with nitrogen gas.
Ir Fill the left and right cylinders in the same
way.
P7
TWH00190
HD325-6
5) When dimension a of the left and right cylin-

ders reaches the standard value, turn handle
@ of regulator PI0 counterclockwise to stop
the flow of nitrogen gas.
* Standard dimension a: Front: 233* 10 mm
Rear:189 + 10 mm
6) Turn handle @ of P9 fully back counterclock-
wise, loosen air bleed plug 0, release the gas
inside the hose, then remove tool P.
* Be careful not lose the O-ring of the sup-
ply valve.
TWH00191
5. Adjusting installed length of cylinder
* 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 cylin-
der (catching of bushing or packing), drive the
machine forward approx. 15 m and stop sud-
denly, then drive in reverse to the original
position and stop again suddenly. Repeat this
cycle 3 - 4 times, and finally, allow the ma-
chine to stop slowly without depressing the
brake. Then measure the installed length.
f Do not use the foot brake when braking
the machine. Use the retarder control le-
ver to brake the machine, and check that
the suspension is in the soft mode.
2) If the result of the check shows that the in-
stalled length is too long, release nitrogen gas
to adjust the length.
* Loosen the oil level valve slightly to re-
lease the nitrogen gas. When doing this,
release only a small amount of gas; do
not make the cylinder move.
* If too much nitrogen gas is released and
the cylinder moves, the installed length
may go below the specified length.
* 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 I) to check the
installed length again.
4) Repeat the above Steps I) - 3) to adjust the
cylinder to the specified length.
20-48 HD325-6
0
5) Finally, check that there is no leakage of gas

from the valve core, oil level valve, and pis-
ton rod gland.
* Use soapy water to check for leakage of
gas.
* If there is any leakage of gas from the
valve core, use tool ($ and remove the
valve core.
w Valve core:
25.5 * 8.8 Nm 12.6 + 0.9 kgm}
6. Checking and adjusting dust cover TWH00193

* To protect the rear suspension if the tirejumps
when hitting a stone during travel, check the
cover and replace or repair as necessary.
1) Checkvisually that there are no cracks in cover
(I).
* If the cover is broken, replace it with a new
part.
2) Check that hook (2) has not come off.
(3 places)
* If the hook has come off, remove any mud
or dirt stuck to it and install it again.
3) Check that band (3) has not come off or come
loose.
* If the band has come off or come loose,
tighten it to the following torque.
w Band:
676.66 +- 49.03 Ncm 169 f 5 kgcm}
Note:l. 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 cylinder until it is satu-
rated, so the volume of gas is reduced
and the installed length of the sus-
pension goes below the specified
limit. Therefore, 48 hours after chang-
BVH00349
ing the oil and gas, checkthe 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 ambi-
ent temperature. Depending on the
ambient temperature when the ma-
chine is working, the gas in the sus-
pension may expand or contract, so
the installed length will also change.
In territories where there are big dif-
ferences in temperature throughout
the year, inspect daily and adjust to
keep the installed length within the
specified range.
HD325-6 20-49
0
7. Testing and adjusting suspension air cylinder

* Fill the air tank completely with air.
I) Testing
i) Check that installed dimension a of the air
cylinder is within the standard value.
Standard dimension a: 352 k 1 mm
ii) With the starting switch ON, check that
lever (I) of the air cylinder is offset b from
horizontal when the hoist lever is oper-
ated to any position except FLOAT.
Air cylinder offset angle b: 9”
2) Adjusting
i) Loosen locknut (2) of the air cylinder, and Port A
adjust rod end (3) to set to installed stan-
dard dimension a, then tighten locknut (2).
ii) With the starting switch ON, check that
lever (1) of the air cylinder is offset b from
horizontal when the hoist lever is oper-
ated to any position except FLOAT.
Air cylinder offset angle b: 9”
1 4
TVH00194
iii) In the correctly installed condition, the slit

of lever (I) must face in the same direc-
tion as the hole in the bracket, and the
range limit must be within 3 mm.
I 4 TVH00195
20-50 HD325-6
0
TESTING AND ADJUSTING TESTING AND ADJUSTING SET PRESSURE OF AIR GOVERNOR
TESTING AND ADJUSTING SET

PRESSURE OF AIR GOVERNOR
TESTING
1. Open the drain valve and drain the air from the
tank.
2. Install tool Cl 2.94 MPa f30 kg/cm*) to tank (3).
3. Close the drain valve and start the engine.
4. Raise the air pressure inside the tank and mea-

sure the pressure when the air governor is actu-
ated and the air compressor is cut off (no-load
operation).
5. With the engine running at low idling, use the

brake pedal to lower the air pressure, and mea-
sure the pressure when the air compressor is cut
in (starts to operate).
ADJUSTING
If the air pressure is not within the standard value,
adjust as follows.
1. Stop the engine.
2. Loosen locknut (I), then turn adjustment screw

(2) to adjust.
* Turn the adjustment screw as follows.
To DECREASE set pressure, TIGHTEN screw
To INCREASE set pressure LOOSEN screw
* After carrying out the above adjustment, mea-
I YI BVH00351
sure again to check that the pressure is within

the standard value.
HD325-6 20-51
0
TESTING AND ADJUSTING ADJUSTING HOIST LEVER LINKAGE
ADJUSTING HOIST LEVER

LINKAGE
HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
fl Lock the control levers inside the cab in the HOLD

position with the lock plate on the console box.
fl Install and connect the push-pull cable so that
there is no twisting or slack.
1. Remove pin (1), and disconnect push-pull cable

(2) and hoist lever (3).
fl When push-pull cable (2) is disconnected,
hoist lever (3) is set to the HOLD position.
2. Remove pin (5) at the hoist control lever end of

push- pull cable (2), and disconnect from lever
(6).
3. Use yoke (4) to adjust the length of the cable to

standard dimension A. Check the position of the
pin hole in hoist lever (3) and push-pull cable (2),
then connect them.
fl Standard dimension A : 196 mm
4. Use yoke (7) to adjust the position of the pin hole

of lever (6) and push-pull cable (2), then connect
them.
fl If the pin hole is not in position, carry out fine
adjustment with yoke (7) to align the pin holes.
fl Standard dimension B : 206 mm
5. After adjusting, release lock plate (8), then oper-

ate the hoist control lever to the RAISE position
and check that the RAISE stroke of the hoist valve
is standard value C.
fl Standard dimension C: 9.5 mm
20-52 HD325-6
8
TESTING AND ADJUSTING ADJUSTING HOIST LEVER LINKAGE

fl Lock the control levers inside the cab in the HOLD

position with the lock plate on the console box.
fl Install and connect the push-pull cable so that
there is no twisting or slack.
1. Remove pin (1), and disconnect push-pull cable

(2) and hoist lever (3).
fl When push-pull cable (2) is disconnected,
hoist lever (3) is set to the HOLD position.
2. Remove pin (5) at the hoist control lever end of

push- pull cable (2), and disconnect from lever
(6).
3. Use yoke (4) to adjust the length of the cable to

standard dimension A. Check the position of the
pin hole in hoist lever (3) and push-pull cable (2),
then connect them.
fl Standard dimension A : 200 mm
4. Use yoke (7) to adjust the position of the pin hole

of lever (6) and push-pull cable (2), then connect
them.
fl If the pin hole is not in position, carry out fine
adjustment with yoke (7) to align the pin holes.
fl Standard dimension B : 206 mm
5. After adjusting, release lock plate (8), then oper-

ate the hoist control lever to the RAISE position
and check that the RAISE stroke of the hoist valve
is standard value C.
fl Standard dimension C: 9.5 mm
HD325-6 20-52-1
8
TESTING AND ADJUSTING ADJUSTING BODY POSITIONER
ADJUSTING BODY POSITIONER

1. Adjust push cable (1) to standard length a. HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
Standard length a: 183 mm HD405-6 Serial No.: 1055 – 2000
HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
Standard length a: 180 mm HD325-6 Serial No.: 6001 and up

HD325-6 Serial No.: 6001 and up HD325-6W Serial No.: 6001 and up
2. With the dump body raised to a point 50 mm be-

fore the end of the hoist cylinder stroke, adjust
plate (2) so that the hoist valve lever is released
from the detent.
Reference dimension b: 136 mm
HD325-6 20-53
8
TESTING AND ADJUSTING HYDRAULIC PRESSURE
TESTING AND ADJUSTING IN STEERING, HOIST CIRCUIT

HYDRAULIC PRESSURE IN
STEERING, HOIST CIRCUIT
¤ Stop the machine on level ground, apply the
¤ Lower the body to the frame, stop the engine,
then remove the cap from the hydraulic tank and
release the pressure inside the cylinder circuit.
1. Measuring hydraulic pressure in steering circuit

1) Raise the hydraulic oil temperature.
fl Oil temperature when measuring :
45 – 55˚C
2) Remove plug (1) and install tool C1 (39.22 MPa
{400 kg/cm2}).
3) Operate the steering wheel fully to the left or
right, and measure the hydraulic pressure
when the circuit is relieved.
2. Adjusting hydraulic pressure in steering circuit

If the hydraulic pressure is not within the stan-
dard value, adjust as follows.
• Steering pressure (adjust with demand valve)
1) Remove cap (2), then loosen locknut (3) and
turn adjustment screw (4) to adjust.
fl To INCREASE pressure, turn CLOCKWISE
To DECREASE pressure, turn COUNTER-
CLOCKWISE
fl One turn of the adjustment screw adjusts
by 2.45 MPa {25 kg/cm2}.
2) After adjusting, hold the adjustment screw
with a screwdriver to prevent it from turning,
then tighten the locknut and install the cap.
3) Check again so that the hydraulic pressure is
within the specified value.
fl The pressure of crossover relief valve (5) can-
not be adjusted when it is installed on the
machine, so do not adjust the pressure.
3. Measuring steering valve charge pressure

{400 kg/cm2}).
2) Measure in the same way as when measur-
ing the hydraulic pressure in the steering cir-
cuit.
20-54 HD325-6
1
TESTING AND ADJUSTING IN STEERING, HOIST CIRCUIT
4. Measuring hydraulic pressure in steering cylin-

der
1) Remove pressure measurement plug (7)
(when turning the steering to the left) or pres-
sure measurement plug (8) (when turning the
steering to the right), and install tool C1 (39.22
MPa {400 kg/cm2}).
ing the hydraulic pressure in the steering cir-
cuit.
5. Measuring hydraulic pressure in hoist circuit

1) Raise the hydraulic oil temperature.
fl Oil temperature when measuring :
45 – 55˚C
2) Remove oil pressure measurement plug (1)
and install tool C1 (39.22 MPa {400 kg/cm2}).
3) Operate the hoist control lever, and move the
dump body to the maximum dump position
to relieve the circuit, then measure the hydrau-
lic pressure with the engine at full throttle.
6. Adjusting hydraulic pressure in hoist circuit

If the hydraulic pressure is not within the stan-
dard value, adjust as follows.
Hoist cylinder pressure (adjust with hoist valve)
1) Remove cap (2), then loosen locknut (3) and
turn adjustment screw (4) to adjust.
fl To INCREASE pressure, turn CLOCKWISE
To DECREASE pressure, turn COUNTER-
CLOCKWISE
fl One turn of the adjustment screw adjusts
by 5.18 MPa {52.9 kg/cm2}.
2) After adjusting, hold the adjustment screw
with a screwdriver to prevent it from turning,
then tighten the locknut and install the cap.
3) Check again so that the hydraulic pressure is
within the specified value.
HD325-6 20-55
8
IN STEERING, HOIST CIRCUIT,
TESTING AND ADJUSTING AIR BLEEDING FROM STEERING CYLINDER
HD325-6 Serial No.: 5680 – 6000

HD325-6W Serial No.: 5706 – 6000
7. Measuring hoist cylinder pressure HD405-6 Serial No.: 1055 – 2000
{400 kg/cm2}).
ing the hydraulic pressure in the hoist circuit.

AIR BLEEDING FROM STEERING

CYLINDER
fl When removing or installing hydraulic cylinders
or pipings, bleed air as follows.
1. Start engine, run engine at low idling 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 cylin-
der 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.
20-56 HD325-6
8
TESTING AND ADJUSTING BLEEDING AIR FROM FRONT DRIVE HYDRAULIC CIRCUIT
BLEEDING AIR FROM FRONT

DRIVE HYDRAULIC CIRCUIT
HD325-6W
. If the front drive hydraulic pump or motor, or the
hydraulic hoses or pipes have been removed, ’ Hydraulic tank
bleed the air as follows after installing the parts
again.
1. When hydraulic pump or piping around pump

have been removed or replaced
a Do not start the engine if there is no oil in-

side the pump case.
Before starting the engine, always fill the
case with oil and bleed the air as follows.
1) Loosen the connector of hose (I), then dis-

connect.
2) Pour in approx. 2 .Qof oil (SAE IOW) through
the connector of hose (I ).
3) Connect hose (I 1 and tighten it.
4) Fill front drive oil tank (2) with oil to a level
slightly above the specified level.
Hydraulic
* The front drive hydraulic circuit is a closed
DUnID
circuit, so when replacing or installing
parts again after removal, it is necessary
to add slightly more than the specified TVHOO62E
amount of oil to the tank.
5) Run the engine at low idling for 5 minutes.
6) After running at low idling, turn the 4-wheel
drive switch ON and drive the machine at low
speed (below 10 km/h) for 10 minutes.
7) Check the oil level in front drive oil tank (2),
and adjust to the specified level.
-k If the air bleeding operation is nor carried
out properly, abnormal pressure will be
generated and this will cause breakage of
the pump or piping.
HD325-6 20-56-l
0
TESTING AND ADJUSTING BLEEDING AIR FROM FRONT DRIVE HYDRAULIC CIRCUIT
2. When motor or piping around motor have been

removed or replaced
+ For the motor, oil is needed inside the motor

case in the same way as for the hydraulic tank,
but oil will flow into the motor case when the
oil is supplied to the front drive tank, so there
is no particular need to pout in oil.
* The front drive hydraulic circuit is a closed

circuit, so when replacing or installing parts
again after removal, it is necessary to add
slightly more than the specified amount of oil
to tank (2).
1) Fill front drive oil tank (2) with oil to a level

slightly above the specified level.
2) Run the engine at low idling for 5 minutes.
3) After running at low idling, turn the 4-wheel
drive switch ON and drive the machine at low
speed (below 10 km/h) for 10 minutes.
4) Check the oil level in front drive oil tank (2),
and adjust to the specified level.
* If the air bleeding operation is nor carried
out properly, abnormal pressure will be
generated and this will cause breakage of
the motor or piping.
20-56-2 HD325-6
0
TESTING AND ADJUSTING ADJUSTING ELECTRONIC MONITOR
ADJUSTING ELECTRONIC
MONITOR (Speedometer,
Tachometer Module)
The speedometer and tachometer on the electronic
monitor are common for all models, but the input sig-
nal corresponding to the travel speed differs accord-
ing to the model, so it is necessary to adjust to match
the model.
Adjustment procedure
Rotary switch
. Turn off the power, then remove the electronic
Rotate
monitor and carry out adjustments at the rear of
the speedometer.
1) demove the rubber saps from 2 at the rear of
the speedometer.
2) When the rubber cap is removed, a rotary
switch can be seen. Using a flat-headed
screwdriver, turn these switches to adjust to
the values in the table below.
L
Tire size Switch 2 TVH00196
18.00 - 33 7or8
3) After adjusting, fit the rubber caps securely

and install the electronic monitor.
Reference: Compensation for switch (2)

0
7
@
Switch position 0 1 2 3 4 5 6 7
2
Compensation (%I I+7 1+6 I+5 I+4 I +3 I +2 I +I I 0
Switch position 8 9 A B C D E F
Compensation (%I I 0 I -1 I -2 I -3 I -4 I -5 I -6 I -7
BVH00361
HD325-6 20-57
0
SETTING ROTARY SWITCH WHEN REPLACING
TESTING AND ADJUSTING TRANSMISSION CONTROLLER
SETTING ROTARY SWITCH

(MODEL DATA, NETWORK
DATA) WHEN REPLACING
If the transmission controller is replaced with a
new controller or the controller is used on another
machine, set the model data and network con-
nection data to match the model and specifica-
tion of the machine.
Remove left and right grommets (1) on the top

face of the old controller (controller being re- BVH00389
placed) and check the settings of built-in rotary
switch (2).
Remove left and right grommets (1) on the top

face of the new (replacement) controller and use
a screwdriver to turn built-in rotary switch (2) to
set the controller settings to the settings of the
old controller (settings before replacement).
Put left and right rubber grommets (1) back in their

original positions on the top face.
(Reference)
The model data are set with the right rotary switch
(switch 1) and the network connection data are set
with the left rotary switch (switch 2).
The relationship of the settings and the model data
and network connection data is as shown in the table
below.
Rotary switch combination table

Rotaryswitch(switch 1, 2) combinations 2_ 1 2_3 4 _ 1 4 _3
(Switch 1 setting) - (Switch 2 setting)
Enqine controller No No Yes Yes
Suspension controller (SVS) 1 Yes 1 No 1 Yes 1 No I
20-58 HD3256
8
METHOD OF DELETING DATA FROM TRANSMISSION
TESTING AND ADJUSTING CONTROLLER MEMORY
METHOD OF DELETING DATA

FROM TRANSMISSION
CONTROLLER MEMORY
(CONTROL FROM MONITOR
PANEL)
fl For details, see MONITOR PANEL USER CODE
AND SERVICE MODE FUNCTION in the Foreword
of the Troubleshooting Section.
1. Outline
fl If the transmission controller is going to be
used on another machine, delete the trouble
data and other data related to the current
machine from the memory of the transmis-
sion controller as follows.
1) This function is used to delete data from the
memory of the transmission controller.
2) This function is effected by operating bulb
check switch (1) and mode change switches
(2) (the red switch at the front of the machine)
and (3) (the black switch at the rear of the
machine) {there are numbers on switch box
(4), so check the numbers}, and using the S-
NET to send the command from the monitor
panel to each controller to delete the data from
memory.
3) The monitor panel accepts the operation for
this function only when the starting switch is
ON and the engine is stopped.
In addition, each controller also accepts the
operation for this function only when the start-
ing switch is ON and the engine is stopped.
4) To prevent the data from being deleted from
the memory of the wrong controller, auto-
matic gearshift mechatronics caution display
(5) lights up to make it possible to confirm
the controller from which the data is being
deleted.
fl For the method of deleting the trouble data
after troubleshooting or for another common
reason, see MONITOR PANEL USER CODE
AND SERVICE MODE FUNCTION, 3.4 Method
of Operating Service Mode, (7) Method of
Deleting Trouble Data from Memory in the
Troubleshooting Section.
HD325-6 20-59
C
2. Deletion method flow chart

1) Change in condition of monitor panel
@ - @ show the condition.
A - D show the method of operation.
0 Memory data deletion mode
Deletion mode entry display
, A Transmission controller Transmission controller

0 D 4
deletion settino display data deletion command issued
TVHOOl97
3. Method of operation )= = ====z=_y

A: Operate bulb check switch (I) and mode
change switches (2) (the red switch at the front
of the machine) and (3) (the black switch at
the rear of the machine) {there are numbers
on switch box (41, so check the numbers}.
Keep the switches pressed to the ON position
at the same time for at least 2.5 seconds, then
release them. (When the switches are re-
leased, they will return automatically to the
OFF position.) 1
B: No particular operation is needed; after A and -3 4 WHO0390
display 0, the display automatically changes
to 0.
D: Operate bulb check switch (I) and mode
change switches (2) (the red switch at the front
of the machine) and (3) (the black switch at
the rear of the machine) {there are numbers
on switch box (41, so check the numbers].
Keep the switches pressed to the ON position
at the same time for at least 5 seconds, then
release them. (When the switches are re-
leased, they will return automatically to the
OFF position.)
20-60 HD325-6
0
4. Monitor panel functions at each condition

/
(1) Normal mode: None in particular
(2) Memory data deletion mode: The total for this
function
(For details, see (31, (41, and (51.)
* When entering the deletion mode, if the
controller detects an error, it will display
a service code, but this is not an abnor-
mality for this function.
(3) Deletion mode entry display:
3 places (engine mechatronics caution display
(6), automatic gearshifting mechatronicscau-
-
tion display (51, and other mechatronics cau-
tion display (7)) light up at the same time for
3 seconds.
(4) Transmission controller deletion setting dis-
play: Automatic gearshifting mechatronics
caution display (5) lights up
(5) Transmission controller data deletion com-
mand-issued
5. Remarks
The memory data deletion mode is also in the
normal mode except for the other mechatronics
caution display (7).
HD325-6 20-6 1
0
METHOD FOR EMERGENCY ESCAPE WHEN
TESTING AND ADJUSTING THERE IS FAILURE IN ELECTRICAL SYSTEM
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE

IN ELECTRICAL SYSTEM
1. Need for emergency escape
The following explains the action to take if it becomes impossible to drive the machine.
If it becomes impossible to drive the machine, and a serious failure has occurred in the engine con-
trol or transmission control system, it is necessary to carry out repairs.
Use the procedure in this section to move the machine to a safe place in order to carry out repairs.
2. Self-diagnostic display and emergency escape method
1) Engine control system
a) If the engine stops when the machine is traveling and cannot be started again, use the flow-
chart below to decide the method for emergency escape.
HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
1
When engine stalled, did engine Check fuel level (is there failure NO
NO
mechatronics caution display on moni- ➤ in engine mechatronics portion)?
tor panel flash?
➤
YES Tow
YES
2
➤
➤
Are power source abnormality service Does engine start again when
code (C010) and controller self-diagnos- YES
➤ fuse unit (FU:30A) and fuse II (BT-
tic display (E.↔1.0) displayed, or our all 2) A (10A) are replaced?
lamps OFF?
Make emergency escape in
NO this condition (turn all ex-
YES
➤ cept minimum necessary
power supply OFF)
3 ✩ Investigate cause later?
➤
Is controller abnormality service code

(C010) and controller self-diagnostic dis- YES NO If there is no controller
➤ Replace controller ➤
play (E.↔1.1) displayed? available, tow
NO
4
➤
Are both service codes (C01b, C01C) for

abnormality in engine speed sensor sys- YES NO If there is no sensor
tems A and B and controller self- diag- ➤ Replace sensor ➤ available, tow
nostic display (E.↔ 1.b, E↔ 1.C) dis-
played?
NO
5
➤
Are service code (C010) for abnormality If there is no solenoid avail-

in governor solenoid system and control- YES NO able or system does not re-
ler self-diagnostic display (E. ↔ 1.4, ➤ Replace solenoid ➤
turn to normal after replac-
E↔1.5) displayed? ing, tow
NO
6
➤
Are service codes (C056, C057) for ab-

normality in solenoid power source sys- YES NO If there is no relay available
tem and controller self-diagnostic display ➤ Replace relay ➤ or system does not return to
(E.↔5.6, E↔5.7) displayed? normal after replacing, tow
NO
7
➤
Are service codes (C019, C01A) for ab-

normality in governor servo system and YES Carry out troubleshooting of
controller self-diagnostic display ➤ engine system (S Mode)
(E.↔1.9, E↔1.A) displayed?
NO
8
➤
Tow
20-62 HD325-6
8

1
When engine stalled, did engine Check fuel level (is there failure NO
NO
mechatronics caution display on moni- ➤ in engine mechatronics portion)?
tor panel flash?
➤
YES Tow
YES
2
➤
Are power source abnormality service Does engine start again when
code (C010) and controller self-diagnos- YES NO
➤ fuse unit (FU:30A) and fuse II (BT- ➤ Replace relay
tic display (E.↔1.0) displayed, or our all 2) A (10A) are replaced?
lamps OFF?
➤
NO YES If there is no relay available
or system does not return to
normal after replacing, tow
Make emergency escape in

this condition (turn all ex-
➤ cept minimum necessary
power supply OFF)
✩ Investigate cause later?
3
➤
Is controller abnormality service code

(C010) and controller self-diagnostic dis- YES NO If there is no controller
➤ Replace controller ➤
play (E.↔1.1) displayed? available, tow
NO
4
➤
Are abnormality service code (C01b,

C01c) and controller self-diagnostic dis- YES NO If there is no sensor
play (E.↔1.b, E↔1.C) displayed for both ➤ Replace sensor ➤ available, tow
NE sensor and G sensor (engine speed
sensor) systems?
NO
5
➤
Are service code (C07A, C07C) of com-

mon rail pressure abnormality (2nd level YES Carry out troubleshooting of
of control system) and controller self-di- ➤ engine system (S Mode)
agnostic display (E.↔7A, E.↔7C) dis-
played?
NO
6
➤
Tow
b) When the starting switch is turned ON, if the automatic shift (mechatronics related) abnor-
mality display is flashing or the shift position display does not light up, or if any other abnor-
mality occurs and the engine does not start, the engine can be started by taking the follow-
ing action.
(With this procedure, the engine will start even when the shift lever is not at the N position,
so be careful when starting.)
If automatic shift (mechatronics Remove transmission neutral

related) abnormality display is
➤ relay
flashing or shift position display Relay No.: R02
does not light up?
HD325-6 20-63
8
2) Transmission control system

• If the transmission suddenly returns to neutral when the machine is traveling and the ma-
chine does not move again, use the table below to decide the method for emergency escape.
(If failure No. 2 occurs when the machine is traveling and the machine does not move again,
do not stop the engine, but use the table below to carry out the method for emergency es-
cape.)
• When emergency escape is carried out using method No. 1 or No. 2, the shift indicator dis-
play [E] on the machine monitor panel and the transmission shift range will be displayed in
turn.
• If the emergency escape cannot be performed when carrying out the re-starting operation
after taking the necessary action, the machine must be towed.
No. Emergency escape method Condition when failure occurs Service
code
1. Stop the machine, move the gearshift lever to the • Speed range remains fixed, and when machine is b010
neutral position, then operate the lever to start the started again, it does not change from speed b011
machine again. range in use when machine stopped. b012
(N → D.5 - 3.L or N → R) (Returns to neutral when lever is at N.)
Note: Remove your foot from your accelerator b052
pedal when operating the lever. b053
b054
b055
b056
b057
b058
b060
b061
b062
• Suddenly returned to neutral when machine was b022
traveling b023
b032
b033
b034
b035
b036
b037
b038
b042
b043
b044
b045
b046
b047
b048
b071
b072
b073
b074
b075
b076
b077
b078
b091
b092
b093
b094
b095
b096
b097
b098
20-64 HD325-6
8
• If there are multiple occurrences of abnormality No. 2, the combination of failures may make
it impossible to carry out the escape even when using the emergency escape method in the
table below. In such cases, do as follows.
(1) For past failures in the transmission that have already been reset, delete the failure (for
details of deleting the failure, see MONITOR PANEL USER CODE AND SERVICE MODE
FUNCTIONS), then carry out the escape operation again.
(2) If it is still impossible to escape using the procedure in Step (1) above, or there is an error
which cannot be restored, it is necessary to tow the machine.
Transmission controller ■ .■■ service code is 2 User Speed range for starting after performing emergency
digits or less (controller LED display) code escape operation (combination of clutches)
1.0 Disconnection in engine shaft speed sensor 02 1.0: Operate lever N → R and start off in R, or operate lever N →
system D.5 - 3.L and start off in F2
1.1 Disconnection in transmission input shaft 02 1.1: Operate lever N → R and start off in R, or operate lever N →
speed sensor system D.5 - 3.L and start off in F2
1.2 Disconnection in transmission intermediate 02 1.2: Operate lever N → R and start off in R, or operate lever N →
shaft speed sensor system D.5 - 3.L and start off in F2
5.2 Failure in flow detection valve for H clutch 02 5.2: Operate lever N → R and start off in equivalent of R (R, High),
or operate lever N → D.5 - 3.L and start off in equivalent of F2
5.3 Failure in flow detection valve for L clutch 02 5.3: Operate lever N → R, or operate lever N → D.5 - 3.L and start
off in F2
5.4 Failure in flow detection valve for 1st clutch 02 5.4: Operate lever N → D.5 - 3.L and start off in F1
5.5 Failure in flow detection valve for 2nd clutch 02 5.5: Operate lever N → D.5 - 3.L and start off in F2
5.6 Failure in flow detection valve for 3rd clutch 02 5.6: Operate lever N → D.5 - 3.L and start off in F4
5.7 Failure in flow detection valve for 4th clutch 02 5.7: Operate lever N → D.5 - 3.L and start off in F6
5.8 Failure in flow detection valve for R clutch 02 5.8: Operate lever N → R and start off in R
6.0 Failure in engine speed sensor 02 6.0: Operate lever N → R and start off in R, or operate lever N →
D.5 - 3.L and start off in F2
6.1 Failure in transmission input shaft speed 02 6.1: Operate lever N → R and start off in R, or operate lever N →
sensor system D.5 - 3.L and start off in F2
6.2 Failure in transmission intermediate shaft 02 6.2: Operate lever N → R and start off in R, or operate lever N →
2.2 Failure in H clutch system 02 2.2: Operate lever N → R and start off in R, or operate lever N →
2.3 Failure in L clutch system 02 2.3: Operate lever N → R and start off in equivalent of R (R, High),
or operate lever N → D.5 - 3.L and start off in equivalent of F2
(1st, High)
3.2 Failure 1 in pressure control valve for H 02 3.2: Operate lever N → R and start off in equivalent of R (R ←
clutch High), or operate lever N → D.5 - 3.L and start off in equiva-
lent of F2 (1st, High)
3.3 Failure 1 in pressure control valve for L 02 3.3: Operate lever N → R and start off in R, or operate lever N →
clutch D.5 - 3.L and start off in F2
3.4 Failure 1 in pressure control valve for 1st 02 3.4: Operate lever N → D.5 - 3.L and start off in F1
clutch
3.5 Failure 1 in pressure control valve for 2nd 02 3.5: Operate lever N → D.5 - 3.L and start off in F2
clutch
3.6 Failure 1 in pressure control valve for 3rd 02 3.6: Operate lever N → D.5 - 3.L and start off in F4
clutch
3.7 Failure 1 in pressure control valve for 4th 02 3.7: Operate lever N → D.5 - 3.L and start off in F6
clutch
3.8 Failure 1 in pressure control valve for R 02 3.8: Operate lever N → R and start off in R
clutch
4.2 Failure 2 in pressure control valve for H 02 4.2: Operate lever N → R and start off in R, or operate lever N →
4.3 Failure 2 in pressure control valve for L 02 4.3: Operate lever N → R and start off in equivalent of R (R, High),
clutch or operate lever N → D.5 - 3.L and start off in equivalent of F2
(1st, High)
4.4 Failure 2 in pressure control valve for 1st 02 4.4: Operate lever N → R and start off in R, or operate lever N →
4.5 Failure 2 in pressure control valve for 2nd 02 4.5: Operate lever N → R and start off in R, or operate lever N →
4.6 Failure 2 in pressure control valve for 3rd 02 4.6: Operate lever N → R and start off in R, or operate lever N →
4.7 Failure 2 in pressure control valve for 4th 02 4.7: Operate lever N → R and start off in R, or operate lever N →
HD325-6 20-65
8
4.8 Failure 2 in pressure control valve for R 02 4.8: Operate lever N → D.5 - 3.L and start off in F2
clutch
7.1 Short circuit in lock-up solenoid output 02 7.1: Operate lever N → R and start off in R, or operate lever N →
circuit D.5 - 3.L and start off in F2
7.2 Short circuit in H clutch solenoid output 02 7.2: Operate lever N → R and start off in R, or operate lever N →
7.3 Short circuit in R clutch solenoid output 02 7.3: Operate lever N → R and start off in equivalent of R (R →
circuit High), or operate lever N → D.5 - 3.L and start off in equiva-
lent of F2 (1st ← High)
7.4 Short circuit in 1st clutch solenoid output 02 7.4: Operate lever N → R and start off in R, or operate lever N →
7.5 Short circuit in 2nd clutch solenoid output 02 7.5: Operate lever N → R and start off in R, or operate lever N →
7.6 Short circuit in 3rd clutch solenoid output 02 7.6: Operate lever N → R and start off in R, or operate lever N →
7.7 Short circuit in 4th clutch solenoid output 02 7.7: Operate lever N → R and start off in R, or operate lever N →
7.8 Short circuit in R clutch solenoid output 02 7.8: Operate lever N → D.5 - 3.L and start off in F2
circuit
9.2 Disconnection solenoid system for H clutch 02 9.2: Operate lever N → R and start off in R, or operate lever N →
pressure control D.5 - 3.L and start off in F2
9.3 Disconnection solenoid system for L clutch 02 9.3: Operate lever N → R and start off in equivalent of R (R, High),
pressure control or operate lever N → D.5 - 3.L and start off in equivalent of F2
(1st, High)
9.4 Disconnection solenoid system for 1st 02 9.4: Operate lever N → R and start off in R, or operate lever N →
clutch pressure control D.5 - 3.L and start off in F2
9.5 Disconnection solenoid system for 2nd 02 9.5: Operate lever N → R and start off in R, or operate lever N →
9.6 Disconnection solenoid system for 3rd 02 9.6: Operate lever N → R and start off in R, or operate lever N →
9.7 Disconnection solenoid system for 4th 02 9.7: Operate lever N → R and start off in R, or operate lever N →
9.8 Disconnection solenoid system for R clutch 02 9.8: Operate lever N → D.5 - 3.L and start off in F2
pressure control
20-66 HD325-6
8
No. Emergency escape method Condition when failure occurs Service
2. Stop the machine, move the gearshift lever to the • Speed range remains fixed and when machine is b013
neutral position, then remove and insert the started again, it does not change from speed b063
emergency escape connectors (A1, A2). (Leave the range in use when machine stopped.
starting switch ON.) (Returns to neutral when lever is at N, but
After doing this, operate the lever to start the remains in neutral.)
machine again. (N → D5 - 3.L or N → R)
Note: Remove your foot from your accelerator
pedal when operating the lever.
• Suddenly returned to neutral when machine was b024

traveling b025
• After machine stops, transmission remains in b026
neutral even when lever is operated, and machine b027
does not start
b028
3. Check for blown fuse (BT2 (R) 30A), check circuit ––
breaker, or replace controller b001
4. Replace transmission cut relay (R25) b002
b006
5. Use modulation checker b007
b015
b016
• After machine stops, transmission remains in b014
neutral even when lever is operated, and machine b0A1
does not start b0C1
6. Tow • Suddenly returned to neutral when machine was b005

traveling
• After machine stops, transmission remains in
neutral even when lever is operated, and machine
does not start
1.3 Disconnection in transmission output shaft 02 1.3: Operate lever N → R and start off in R, or operate lever N →
6.3 Failure in transmission output shaft speed 02 6.3: Operate lever N → R and start off in R, or operate lever N →
sensor system D.5 - 3.L and start off in F2
2.4 Failure in 1st clutch system 02 2.4: Operate lever N → R and start off in R, or operate lever N →
2.5 Failure in 2nd clutch system 02 2.5: Operate lever N → R and start off in R, or operate lever N →
2.6 Failure in 3rd clutch system 02 2.6: Operate lever N → R and start off in R, or operate lever N →
2.7 Failure in 4th clutch system 02 2.7: Operate lever N → R and start off in R, or operate lever N →
2.8 Failure in R clutch system 02 2.8: Operate lever N → D.5 - 3.L and start off in F2
■ .■
■ Abnormality in power source voltage or –– Normal travel possible in R, F1 - F7 if controller returns to normal
failure in controller display
0.1 Drop in power source voltage 04 (After 0.1 failure is reset, stays in neutral until lever is returned to
N)
0.2 Abnormality in solenoid power source 04
system
0.5 Failure in transmission cut relay system 04
0.7 Failure in 12V output system 04 Travel possible in desired speed range using modulation checker
1.5 Failure A in lever signal system 02 (but auto lock-up does not work)
1.6 Failure B in lever signal system 02
1.4 Failure in machine model selection signal 04

system
A.1 Abnormality in machine model selection 02
B.1 Abnormality in connector connection 02
0.5 Double meshing detected 04
HD325-6 20-67
8
TESTING AND ADJUSTING Pm CLINIC CHECK SHEET
Pm CLINIC CHECK SHEET HD325-6 #5680 – #6000

HD325-6W #5706 – #6000
HD405-6 #1055 – #2000
Machine Serial No. #
HOUR INSPECTION Engine Serial No. SAA6D140E-2#
WORK No. DATE SERVICE METER NAME OF INSPECTOR

Year Month Day
hrs
QUESTIONS TO OPERATOR AND INSPECTION AROUND THE MACHINE
Was there any abnormality before start of inspection? Ambient Temperature
.........................................................................................................................................................................................................................................................................
Max. ˚C (˚F)
................................................................................................................................................................................................................................................................... Min. ˚C (˚F)

....................................................................................................................................................................................................................................................................
Altitude m
Coolant tmperature maximum level? Torque converter, transmission oil tempe- Retarder oil temperature maximum
(during operation) rature maximum level? (during operation) level? (during operation)
White Green Green Green Green Red Red White 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
SELF-DIAGNOSTIC
DISPLAY
MEASUREMENT ITEM MEASUREMENT CONDITION RESULT OF TROUBLESHOOTING Sat Us
Rceord-self
T
diagnostic dis-play
/ code related to Starting switch OFF → ON
M problem
AFTER STARTING ENGINE!

MEASUREMENT ITEM MEASUREMENT CONDITION UNIT STD. PMS. RESULT Sat Us
Engine low idring 600 – 700 600 – 700
Engine speed Engine full throttle rpm 2,350 – 2,450 2,350 – 2,450
Torque converter stall 1,870 – 2,020 1,870 – 2,020
kPa Max. 1.47 Max. 2.94
Blow-by pressure Torque converter stall {mmAq} {Max. 150} {Max. 300}
0.34 – 0.49 Min. 0.20
Engine full throttle
ENGIINE
{3.5 – 5.0} {Min. 2.0}

SAE30
Min. 0.15 Min. 0.07
Engine low idling {Min. 1.5} {Min. 0.7}
Engine MPa
{kg/cm2} 0.25 – 0.44 MIn. 0.18
oil pressure Engine full throttle {2.5 – 4.5} {Min. 1.8}
SAE10W
Min. 0.1 Min. 0.07
Engine low idling
{Min. 1.0} {Min. 0.7}
kPa Min. 146.7 Min. 117.3
Boost pressure Torque converter stall
{mmAq} {Min. 1,100} {Min. 880}
Exhaust Ambient temperature -–- -–-
temperature* ˚C
Torque converter stall Max. 700 Max. 700
Engine low idling

Gear shift lever neutral (SAE30) 3.14 – 3.43 3.14 – 3.43
T/C • T/M
{32.0 – 35.0} {32.0 – 35.0}

Main relief oil Oil pressure: 70 – 90°C (level No. 3)
MPa
pressure Engine full throttle {kg/cm2}
3.43 – 3.73 3.43 – 3.73
Gear shift lever neutral (SAE30)
{35.0 – 38.0} {35.0 – 38.0}
Oil pressure: 70 – 90°C (level No. 3)
CHANGE OIL, CLEAN INSIDE OF TRANSMISSION CASE AND STRAINER AT EVERY 1000 HOURS SERVICE
Visual check of Must be no excessive
T/M transmission -–- -–- metallic particles or Rayflex
strainer (black powder)
HD255-5 20-69
C
HD325-6 #5680 – #6000

HD325-6W #5706 – #6000
HD405-6 #1055 – #2000
[ ] : Referance value
Steering operating Engine 1,000rpm Left → Right Max. 4.0 Max. 5.0
STEERING
time sec.
Lock → Lock Engine 1,000rpm Right → Left Max. 4.0 Max. 5.0
Steering relief oil MPa 20.20 – 21.08 20.20 – 21.08
pressure Engine full throttle
{kg/cm2} {20.6 – 215} {206 – 215}
0.66 – 0.72 0.66 – 0.72

Cut-in {6.7 – 7.3} {6.7 – 7.3}
Air governor set MPa
pressure Engine full throttle {kg/cm2} 0.78 – 0.84 0.78 – 0.84
Cut-out
BRAKES
{8.0 – 8.6} {8.0 – 8.6}

Service brake Min. 1,550 Min. 1,550
Apply brake, set gearshift lever to"D",
Retarder brake gradually raise engine speed, and measure Min. 1,200 Min. 1,200
engine speed when machine starts to move rpm
Parking brake Min. 1,600 Min. 1,600
Emergency brake Full Full
Hydraulic oil
temperature ˚C
EQUIPMENT
HYDRAULIC
(-–-) (-–-)
Hoist relief oil MPa
presure {kg/cm2} 20.1 – 21.1 20.1 – 21.1
Engine full throttle {205 – 215} {205 – 215}
Dump body raise Oil temperaure: 45 – 55°C
sec. 8.5 – 11.5 8.5 – 11.5
time
SET DUMP BODY AND STOP ENGINE!

Hydraulic drift of hoist Set dump body with No. 2 cylinder extended mm/
cylinder 200 mm. Max. 85 Max. 170
5 min.
REPLACE DRAIN PLUG WITH SPARE PLUG!
Visual check of There must be no excessive
differential drain plug Stop engine -–- metal powder
Visual check of final Left There must be no excessive

drive drain plug -–- metal powder
Right
EVERY 1000 HOURS SERVICE!

Left 19.5 (Initial 3.0
Front brake
BRAKES
(pad thickness) Right dimensions) 3.0

mm
Rear brake Left +9.5 (Initial Wear limit
(measuring of
disc wear gauge) Right dimensions) Wear limit
Suspension cylinder length

Left front
suspension Oil, gas leakage There must be no leakage
SUSPENSION CYLINDER

Right front
mm
Left rear Suspension cylinder length
Right rear Suspension cylinder length

Contact of rear Left The must be no contact
suspension
stopper Right The must be no contact
MEMO: Write any data or phenomena that you notice during today's check.
......................................................................................................................................................................................................................................................................................
............................................................................................................................... ............................................................................................................................... .......................
............................................................................................................................... ............................................................................................................................... .......................
20-70 HD255-5
C
HD325-6 #6001 and up

Pm CLINIC CHECK SHEET HD325-6W #6001 and up
HD405-6 #2001 and up
Machine Serial No. #
HOUR INSPECTION Engine Serial No. SAA6D140E-3#
WORK No. DATE SERVICE METER NAME OF INSPECTOR

Year Month Day
hrs
QUESTIONS TO OPERATOR AND INSPECTION AROUND THE MACHINE
Was there any abnormality before start of inspection? Ambient Temperature
.........................................................................................................................................................................................................................................................................
Max. ˚C (˚F)
................................................................................................................................................................................................................................................................... Min. ˚C (˚F)

....................................................................................................................................................................................................................................................................
Altitude m
Coolant tmperature maximum level? Torque converter, transmission oil tempe- Retarder oil temperature maximum
(during operation) rature maximum level? (during operation) level? (during operation)
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
SELF-DIAGNOSTIC
DISPLAY
MEASUREMENT ITEM MEASUREMENT CONDITION RESULT OF TROUBLESHOOTING Sat Us
Rceord-self
T
diagnostic dis-play
/ code related to Starting switch OFF → ON
M problem
AFTER STARTING ENGINE!

MEASUREMENT ITEM MEASUREMENT CONDITION UNIT STD. PMS. RESULT Sat Us
Engine low idring 675 – 725 675 – 725
Engine full throttle rpm 2,400 – 2,450 2,400 – 2,450
Engine speed
Torque converter stall (high power mode) 1,815 – 2,015 1,815 – 2,015
Torque converter stall (economy mode) 1,750 – 1,950 1,750 – 1,950
kPa Max. 1.96 Max. 2.94
Blow-by pressure Torque converter stall {mmAq} {Max. 200} {Max. 400}
ENGIINE
0.34 – 0.54 Min. 0.21

Engine full throttle {3.5 – 5.5} {Min. 2.1}
SAE30
Min. 0.12 Min. 0.07
Engine low idling {Min. 1.2} {Min. 0.7}
Engine MPa
oil pressure {kg/cm2} 0.20 – 0.34 MIn. 0.18
Engine full throttle {3.0 – 5.0} {Min. 1.8}
SAE10W Min. 0.1 Min. 0.07
Engine low idling
{Min. 1.0} {Min. 0.7}
kPa Min. 133 Min. 112
Boost pressure Torque converter stall {mmAq} {Min. 1,000} {Min. 840}
Exhaust Ambient temperature -–- -–-
temperature ˚C
Torque converter stall Max. 650 Max. 700
Engine low idling

T/C • T/M
Oil pressure: 70 – 90°C (level No. 3) {32.0 – 35.0} {32.0 – 35.0}

Main relief oil MPa
pressure Engine full throttle {kg/cm2}
{35.0 – 38.0} {35.0 – 38.0}
Oil pressure: 70 – 90°C (level No. 3)
CHANGE OIL, CLEAN INSIDE OF TRANSMISSION CASE AND STRAINER AT EVERY 1000 HOURS SERVICE
Visual check of Must be no excessive metallic
T/M transmission sec.
strainer particles or Rayflex (black powder)
Steering operating Engine full throttle Right → Left Max. 4.0 Max. 5.0
STEERING
time sec.
Lock → Lock Engine full throttle Left → Right Max. 4.0 Max. 5.0
Stering relief oil Engine full throttle MPa 20.20 – 21.08 20.20 – 21.08
pressure {kg/cm2} {206 – 215} {206 – 215}
HD255-5 20-71
C
HD325-6 #6001 and up

HD325-6W #6001 and up
HD405-6 #2001 and up
0.66 – 0.72 0.66 – 0.72
Cut-in {6.7 – 7.3} {6.7 – 7.3}
Air governor set MPa
pressure Engine full throttle {kg/cm2} 0.78 – 0.84 0.78 – 0.84
Cut-out
BRAKES
{8.0 – 8.6} {8.0 – 8.6}

Service brake Min. 1,550 Min. 1,550
Apply brake, set gearshift lever to"D",
Retarder brake gradually raise engine speed, and measure Min. 1,200 Min. 1,200
engine speed when machine starts to move rpm
Parking brake Min. 1,600 Min. 1,600
Emergency brake Full Full
Hydraulic oil
˚C
EQUIPMENT
temperature
HYDRAULIC
Hoist relief oil MPa 20.1 – 21.1 20.1 – 21.1

presure Engine full throttle
{kg/cm2} {205 – 215} {205 – 215}
Dump body raise Engine full throttle sec.
time 8.5 – 11.5 8.5 – 11.5
SET DUMP BODY AND STOP ENGINE!

Hydraulic oil -–- -–- -–-
temperature ˚C
Hydraulic drift of hoist Set dump body with No. 2 cylinder extended mm/
200 mm. 5 min. Max. 85 Max. 170
cylinder
REPLACE DRAIN PLUG WITH SPARE PLUG!

Visual check of There must be no excessive
differential drain plug Stop engine -–- metal powder
Visual check of final Left There must be no excessive

drive drain plug -–- metal powder
Right
EVERY 1000 HOURS SERVICE!

Left 19.5 (Initial 3.0
Front brake
BRAKES
(pad thickness) Right dimensions) 3.0

mm
Rear brake Left +9.5 (Initial Wear limit
(measuring of
disc wear gauge) Right dimensions) Wear limit

Left front
SUSPENSION CYLINDER

Right front
mm
Left rear Suspension cylinder length
Right rear Suspension cylinder length

Contact of rear Left There must be no contact
suspension
stopper Right There must be no contact
MEMO: Write any data or phenomena that you notice during today's check.
20-72 HD255-5
C
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
a Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
a When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
a If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
g Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
a When disconnecting wiring, always disconnect the negative (-1 terminal of the battery first.
a 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 connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent 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 symptoms.
1. When carrying out troubleshooting, do not hurry 3) Other inspection items.

to disassemble the components. 4) Other maintenance items can be checked ex-
If components are disassembled immediately any ternally, so check any item that is considered
failure occurs: to be necessary.
. Parts that have no connection with the fail- 4. Confirming failure
ure or other unnecessary parts will be disas- Confirm the extent of the failure yourself, and
sembled. judge whether to handle it as a real failure or as
. It will become impossible to find the cause a problem with the method of operation, etc.
of the failure. * When operating the machine to reenact the
It will also cause a waste of manhours, parts, or troubleshooting symptoms, do not carry out
oil or grease, and at the same time, will also lose any investigation or measurement that may
the confidence of the user or operator. make the problem worse.
For this reason, when carrying out troubleshoot- 5. Troubleshooting
ing, it is necessary to carry out thorough prior Use the results of the investigation and inspec-
investigation and to carry out troubleshooting in tion in Items 2 - 4 to narrow down the causes of
accordance with the fixed procedure. failure, then use the troubleshooting flowchart to
2. Points to ask user or operator locate the position of the failure exactly.
I) Have any other problems occurred apart from * The basic procedure for troubleshooting is
the problem that has been reported? as follows.
2) Was there anything strange about the ma- 1) Start from the simple points.
chine before the failure occurred? 2) Start from the most likely points.
3) Did the failure occur suddenly, or were there 3) Investigate other related parts or infor-
problems with the machine condition before mation.
this? 6. Measures to remove root cause of failure
4) Under what conditions did the failure occur? Even if the failure is repaired, if the root cause of
5) Had any repairs been carried out before the the failure is not repaired, the same failure will
failure? occur again.
When were these repairs carried out? To prevent this, always investigate why the prob-
6) Has the same kind of failure occurred be- lem occurred. Then, remove the root cause.
fore?
3. Check before troubleshooting
1) Check for symptoms of any abnormality in
the machine.
2) Check the CHECKS BEFORE STARTING items.
20-102 HD325-6
0
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
Jobsite
TEW00180 TEWOOl81
step 2
Examination, confirmation of symptoms
1) When a request for repairs is received, first

-------
ask the following points. Ring! Ring!
-------
. Name of customer
- Type, serial number of machine
* Details of jobsite, etc.
2) Ask questions to gain an outline of the prob-
lem. * Confirm user
. Condition of failure code and service
- Work being carried out at the time of the code on monitor
failure
- Operating environment . Carv out action
- Past history, details of maintenance, etc.
TEPOl348
1) Look at the troubleshooting section of the

shop manual to find locations of possible
causes.
Step 4
Preparation of troubleshooting tools
1) Look at the table of troubleshooting tools in

the shop manual and prepare the necessary
tools.
. T-adapter
. Hydraulic pressure gauge kit, etc.
2) Look in the parts book and prepare the nec-
essary replacement parts.
2) See the Troubleshooting Section of the shop

manual, select a troubleshooting flowchart
that matches the symptoms, and carry out
- Drive and operate the machine to confirm
TEP01351
- Was there anything strange about the ma-

chine before the failure occurred?
Did the failure occur suddenly?
HD325-6
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
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 re-
pairs 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).
1. POINTS TO REMEMBER WHEN HANDLING

ELECTRIC EQUIPMENT
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors 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 fre-
quently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.
TEW00191
Main failures occurring in wiring harness

Defective contact -of connectors (defective
contact between male and female) Improper insertion
Problems with defective contact are likely to
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces.
I TEP01352
Defective crimping or soldering of connec-

tors
The pins of the male and female connectors ImProPer compression
are in contact at the crimped terminal or
soldered portion, but if there is excessive
force brought to bear on the wiring, the plat-
ing at the joint will peel and cause improper
connection or breakage.
TEP01353
zo- 104 HD325-6

0
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 solder-
ing may be damaged, or the wiring may be
broken.
TEWO0194
High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector, depending on the direction of the
water jet.
As already said, 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- TEW00195
circuited by the water, so if any water gets
in, immediately dry the connector or take
other appropriate action before passing elec-
tricity through it.
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 connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con- TEW00196
tact restorer.
* When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
* If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before clean-
ing with compressed air.
HD3256 20-105
a
2) Removing, installing, and drying connectors and

wiring harnesses
l Disconnecting connectors
Hold the connectors when disconnecting. Press liohtlv
when removine
When disconnecting the connectors, hold the
connectors and not the wires. For connec-
tors 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 con- TEP01354
nectors apart.
* Never pull with one hand.
When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
* If the connector is twisted up and down Q
or to the left or right, the housing may
break.
TBW00484
I TBP01355
I
0 Action to take after removing connectors
After removing any connector, cover it with
a vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
Ir If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.
TEW00198
20-106 HD3256
0
l Drying wiring harness

If there is any oil or dirt on the wiring harness,
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 wa-
ter or steam directly on the wiring harness.
If water gets directly on the connector, do as

follows.
@ Disconnect the connector and wipe off the
water with a dry cloth.
Ir If the connector is blown dry with com- TEW00196
pressed air, there is the risk that oil in
the air may cause defective contact, so
remove all oil and water from the com-
pressed air before blowing with air.
Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer
to dry the connector.
Jr 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 connec-
tor.
TEW00202
Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
Ir After completely drying the connector,
blow it with contact restorer and reas-
sem ble. T-adapter
TEP01357
20-108
0
3) Handling control box

The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
Do not open the cover of the control box
unless necessary.
TEW00204
Do not place objects on top of the control

box.
Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with your
hand.
During rainy weather, do not leave the con-
trol box in a place where it is exposed to
rain.
TEW00205
Do not place the control box on oil, water,

or soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand).
Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors con-
nected to the control box. Fit an arc welding
ground close to the welding point.
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
Ir If the power is turned ON with the connectors still disconnected, unnecessary abnormality
displays will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or
current), move the related wiring and connectors several times and check that there is no
change in the reading of the tester.
* If there is any change, there is probably defective contact in that circuit.
HD325-6 20-109
0
3. POINTS TO REMEMBER WHEN HANDLING

HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hy-

draulic equipment, the most common cause of fail-
ure 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.
21 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 confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and main-tenance of hydraulic equip-
ment should be carried out in a specially pre-
pared dustproof workshop, and the performance
should be confirmed 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 en-
tering. 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 leak-
ing oil so never do this.
Do not simply drain oil out on to the ground,
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
TEW00208
Do not let any dirt or dust get in during refilling

4)
operations.
Be careful not to let any dirt or dust get in when
I
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.
TEW00209
20-110
0
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

(1. CHECKS BEFORE STARTING, 2. OTHER CHECK ITEMS)
Item itadard value Action

-
1. Check fuel level Fuel gauge Add fuel
2. Check for dirt or water in fuel - Clean, drain
3. Check for water in air tank - Drain
4. Check transmission oil level Iii level gauge Add oil
5. Check hydraulic oil level Sight gauge Add oil
6. Check engine oil level (Level of oil in oil pan) Xl level gauge Add oil
7. Check cooling water level - Add water
8. Check condition of dust indicator Dust indicator Clean
9. Check front brake oil level (Level of oil in tank) Xl level gauge Add oil
10. Check for water in emergency brake air tank - Drain
11. Check play of steering wheel 100 - 140 mm -
12. Check operation of emergency steering rperation: 20 set Repair
13. Check installation length of suspension cylinder Label Adjust
14. Check tire inflation pressure and damage - Charge air
15. Check hub nuts - Tighten
16. Check efficacy of foot brake - Adjust
17. Check efficacy of parking brake - Adjust or repair
18. Carry efficacy of emergency brake - Adjust or repair
19. Check abnormality of steering - Adjust or repair
20. Check direction of rear and under view mirror - Adjust
21. Check exhaust gas color and abnormal noise - Adjust or repair
22. Check efficacy of retarder brake - Adjust or repair
23. Check abnormality of body rubber mount - Adjust or repair
24. Check air horn - Repair
25. Check function of lamps - Repair or replace
26. Check function of gauges - Adjust or repair
27. Check monitor panel - Adjust or replace
28. Check machine monitor system - Repair or replace
29. Check central warning lamp - Repair or replace
30. Check for loose or corroded battery terminals - Retighten or clean
31. Check for loose or corroded alternator terminals - Retighten or clean
32. Check for loose or corroded starting motor terminals - Retighten or clean
20-112 HD3256
0
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
Item itadard value Action
33. Check abnormal noise or smell - Repair
34. Check for oil leakage - Repair
35. Bleed air from system - Bleed air
36. Check battery voltage (engine stopped) 20-30V Replace
37. Check level of battery electrolyte - Add or replace
38. Check for discolored, burnt, or bare wiring - Replace
39. Check for missing wiring clamps, hanging wire - Repair
40. Checks for water leaking onto wiring - Disconnectconnector

(check carefully water leakage at connectors and terminals) and dry connection
41. Check for broken or corroded fuses - Replace
42. Check alternator voltage

(engine running at over half throttle) 27.5 - 29.5 V Replace
43. Noise when battery relay is operated. -

(Switch starting switch from ON to OFF) Replace
HD325-6 20-113
0
TROUBLESHOOTING TYPE OF CONNECTOR AND POSITION OF INSTALLATION
TYPE OF CONNECTOR AND POSITION OF INSTALLATION

HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
fl The Address column in this table shows the address in the connector pin allocation drawing
(3-dimensional drawing).
Con- Connec- No. Con- Connec- No.
nector tor type of Place of use Add- nector tor type of Place of use Add-
No. pins ress No. pins ress
01 SWP 14 Intermediate connector C7 3PS X 2 Transmission solenoid valve U9
03 X 2 Radiator water level sensor A6 3SW X 1 Fill switch sensor U9
04 X 2 Air conditioner dual switch B2 40 SWP 6 Payload meter display lamp (right) C7
1-pin 1-pin
05-1 connector 1 Horn valve B2 41 connector 1 Right side lamp B6
1-pin
05-2 connector 1 Horn valve B2 4PS X 2 Transmission solenoid valve U9
06L — 3 Left head lamp (Lo) D1 4SW X 1 Fill switch sensor U9
07H — 3 Left head lamp (Hi) C1 51 X 2 Flow switch F1

1-pin
08 connector 1 Left clearance lamp D1 52 X 2 Transmission oil filter sensor J3
1-pin
09 connector 1 Left clearance lamp E1 59 SWP 6 Intermediate connector J9
1-pin
10 connector 1 Left turn signal D1 60 SWP 6 Tail, stop, turn signal lamp K9
1-pin
11 connector 1 Right fog lamp C1 61 X 1 Fuel level sensor F9
Rear suspension cylinder (left)
12 — 2 Washer motor C7 62 X 3 pressure sensor K8
Rear suspension cylinder (right)
13 X 3 Front suspension pressure sensor (left) F1 63 X 3 pressure sensor J9
14 SWP 6 Payload meter display lamp (left) H1 64 X 2 Retarder oil temperature sensor A2
1-pin
15 connector 1 Left side lamp C7 85 SWP 6 Intermediate connector C7
18 — 2 Diode A3 87 SWP 8 Engine stop motor B2
1PS X 2 Transmission solenoid valve W9 AC1 M 4 Intermediate connector N7
1SW X 1 Fill switch sensor V9 AS1 X 2 Exhaust brake switch S5
21 X 1 Steering oil temperature sensor K3 AS2 X 2 Parking brake switch T5
25 X 2 Starting motor A3 AS3 X 2 Retarder brake switch T5
26 X 2 Water temperature sensor A6 AS4 X 2 Emergency brake switch S5
27 Socket 3 Engine oil pressure sensor connector B2 AS5 X 2 Service brake switch T5
2PS X 2 Transmission solenoid valve V9 ATC1 MIC 17 Transmission controller X1
2SW X 1 Fill switch sensor V9 ATC2 MIC 21 Transmission controller X2
30 SWP 4 Right platform wiring harness C7 ATC3A AMP040 20 Transmission controller X2

intermediate connector
32H — 3 Right head lamp (Hi) A4 ATC3B AMP040 16 Transmission controller X1
33L — 3 Right head lamp (Lo) A4 ATC4 AMP040 12 Transmission controller X1

1-pin
34 connector 1 Right clearance lamp A5 ATC5A AMP040 20 Transmission controller X1
1-pin
35 connector 1 Right clearance lamp A5 ATC5B AMP040 13 Transmission controller X1
1-pin
36 connector 1 Right turn signal A5 BLSR X 2 Rear brake chamber stroke sensor E8
1-pin
37 connector 1 Right fog lamp A5 BLSL X 2 Rear brake chamber stroke sensor E8
39 X 3 Front suspension cylinder (right) B7 BT1 — — Fuse box I T1
20-114 HD325-6
8
Con- No. Con- No.

nector Connec-
tor type of Place of use Add- nector Connec-
tor type of Place of use Add-
BT2 — — Fuse box II T2 HAZ Socket 7 Hazard switch P5

1-pin
BT3 — — Fuse box III S2 HN connector 1 Horn Q9
BZ M 2 Alarm buzzer O3 HPS X 2 Transmission solenoid valve T8

1-pin
CG1 connector 1 Cigar lighter M6 HSW X 1 Fill switch T8
1-pin
CG2 connector 1 Cigar lighter M5 HT PA 7 Preheat switch N6
Intermediate connector inside,
CK1 KES1 2 Bulb check switch N7 J01 S 16 outside cab S3
CM S 8 Combination switch Q8 J02 S 16 outside cab S4
CNS S 12 Shift limit switch O2 J03 S 16 outside cab S4
C/VT X 2 Transmission oil temperature sensor W6 J04 S 12 outside cab T5
D1 — 2 Diode B2 J06 S 1 Intermediate connector S3

D05 — 2 Diode X2 J07 Terminal 1 outside cab S3
D06 — 2 Diode X2 J09M S 16 Intermediate connector W1
D08 — 2 Diode O3 L/CT X 2 Transmission solenoid valve T8
D12 — 2 Diode M4 LPS X 2 Transmission solenoid valve T9
D14 — 2 Diode S3 LS M 3 Rheostat R7
DB1 X 4 Body seated switch J9 LSW X 1 Fill switch sensor T9
DLB X 2 Differential lock S4 N1 X 2 Transmission input shaft speed sensor W6

Transmission intermediate shaft
DP01 MIC 5 Monitor panel P9 N2 X 2 speed sensor X8
Transmission output shaft speed
DP02 AMP040 8 Monitor panel P9 N3 X 2 sensor X9
DP03 Socket 2 Monitor panel O6 P15 M 2 MPH selection connector P6
DP04 AMP040 8 Monitor panel P9 PL1 S 10 Monitor lamp N6
DP05 AMP040 12 Monitor panel O6 PL2 S 10 Monitor lamp O6
DP06 Socket 2 Monitor panel P6 PLS M 4 Monitor lamp M3
DP07 Socket 2 Monitor panel Q9 PM1 MIC 21 Payload meter M8
DP08 AMP040 16 Monitor panel Q9 PM2 M 4 Payload meter G1
DP09 Socket 2 Monitor panel R8 PM3 X 3 Clinometer I2

DP10 AMP040 8 Monitor panel R8 PM4 M 6 Intermediate connector M9
DP11 AMP040 16 Monitor panel R8 PM5 MIC 13 Payload meter (card type) N9
Suspension pressure sensor FR
DP12 M 4 Monitor panel R5 PM6 — 2 selection connector V1
DP13 Socket 2 Monitor panel R5 PM6 AMP040 12 Payload meter (card type) O9
D4 — 2 Diode S2 PM7 MIC 9 Payload meter (card type) O9
E6 X 2 Engine speed sensor A3 PM8 MIC 5 For connecting PC M7
EXH Socket 7 Exhaust brake switch P5 PMCD M 2 For off-board PMC power source U1
FB PA 7 Front brake cut switch P5 PMC6 M 3 For S-NET monitor U1
FCS PA 7 Fuel cut switch Q5 PW PA 7 Power mode switch R1

FL PA 7 Fog lamp switch O6 PWR — 2 selection connector W1
HD325-6 20-115
8

R01 Socket 5 Engine starting relay U1 RT-6 Terminal 1 Timer relay for emergency steering —
R02 Socket 5 Transmission neutral relay T1 RT-7 Terminal 1 Timer relay for emergency steering —
R03 Socket 5 Service brake relay S2 RT-8 Terminal 1 Timer relay for emergency steering —
R05 Socket 5 Backup alarm relay S3 SCF — 2 Selection connector for each suspen- X3
sion pressure sensor specification
R06 Socket 5 Head lamp relay (Hi) X3 SCFR — 2 Selection connector for each suspen- X2
sion pressure sensor specification
R07 Socket 5 Marker lamp relay U1 SF S 2 Gearshift lever O1
R08 Socket 5 Head lamp relay T2 SH Socket 7 Shift limit switch O2
R09 Socket 6 Rear brake pilot relay S3 SL1 X 2 Suspension control solenoid W4
R11 Socket 6 Payload relay S4 SL2 X 2 Suspension control solenoid V4
R16 Socket 5 Payload lamp display relay X3 SL3 X 2 Suspension control solenoid U5
R17 Socket 5 Payload lamp display relay W4 SL4 X 2 Overrun prevention solenoid W4
R18 Socket 5 Payload lamp display relay V5 SL5 X 2 Exhaust brake solenoid V5
R19 Socket 5 Payload lamp display relay U5 SL6 X 2 Front brake cut-off solenoid U5
R20 Socket 5 Payload lamp display relay S4 SL7 X 2 Front brake cut-off solenoid U5
1-pin
R21 Socket 5 Parking brake relay X3 SP5 connector 1 Speaker (right) E9
1-pin
R22 Socket 5 Engine stop relay W4 SP6 connector 1 Speaker (right) F9
1-pin
R25 Socket 5 Transmission cut relay V5 SP7 connector 1 Speaker (left) H1
1-pin
R27 Socket 5 Hazard relay T5 SP8 connector 1 Speaker (left) I1
R28 Socket 6 Hazard lamp relay X4 SR2 X 3 Steering sensor E1
R29 Socket 6 Hazard lamp relay W4 SR3 X 2 Tilt sensor T1
RAD — 9 AM radio O6 SR4 M 3 Bimetal timer S2
RE1 Socket 1 Resistor R6 SR5 X 2 Air pressure sensor S5
RE2 Socket 1 Resistor R6 SSP1 MIC 21 Suspension controller X3
RH1 S 10 Intermediate connector X3 SSP2A AMP040 20 Suspension controller X3
RH2 S 12 Intermediate connector W1 SSP2B AMP040 16 Suspension controller X2
RH4 S 8 Intermediate connector X4 SU3 S 16 Intermediate connector X1

1-pin Selection connector for each suspen-
RL connector 1 Room lamp E8 SU6 — 2 sion pressure sensor specification V1
Torque converter oil temperature
RPS X 2 ECMV solenoid U9 TC.SE X 2 sensor V5
RSW X 2 Switch sensor U9 TM2 SWP 14 Transmission controller intermediate L4
RT-1 Terminal 1 Timer relay for emergency steering — TM3 SWP 14 Transmission controller intermediate L4
RT-2 Terminal 1 Timer relay for emergency steering — TM4 SWP 14 Transmission controller intermediate K3
RT-3 Terminal 1 Timer relay for emergency steering — TMA S 16 Transmission controller intermediate U1
RT-4 Terminal 1 Timer relay for emergency steering — TMB S 16 Transmission controller intermediate V1
RT-5 Terminal 1 Timer relay for emergency steering — TMC S 12 Transmission controller intermediate W1
20-116 HD325-6
8
No.
“F$ir Connec- k!d
Place of use Place of use
No. tar me ress
TMD S 16 Intermediate connector x2
WPl s 8 Wiper switch N3
WP2 Relay 6 Wiper motor relay El
WP3 Relay 6 Intermittent wiper relay R7
WAS21 X 3 1 Acceleration sensor ICI1
WL M 2 Caution lamp (central warning lamp) P4
HD325-6 20-117
0
FOR ARSC (AUTOMATIC RETARDER SPEED CONTROL)
“pc& Connec- %. Add ,c,O,:o, Connec- 2. P&b

Place of use Place of use
No. tar Wpe Dins rest No. tar type pins ress
l-8 Selection connector d4 R5 Terminal 1 Travel speed display -

I x III
8s I x III Selection connector 1d4 R6 /Terminal 1 1 I Travel speed display I-I
250 -1 - 1 2 I Resistor I a3 RB /For relay1 5 1 RBrelay Id
1020 - 2 Resistor 23 RW For relay 6 RW relay Y6
Al J$iector 1 ARSC caution lamp 23 RZ For relay 5 RZ relay Y6

l-pin
A2 connector 1 ARSC caution lamp 23 SHIFT X 1 Selection connector c4
A6 ,&P,‘&r.tor
. 1 ARSC stand-by lamp Y4 SHUT - 2 Air shut-off valve D8
ARC1 MIC 21 ARSC controller Y6 sosw 1 x 1 2 1Air. switch (air shut-off valve)
Id
ARC2 AMP040 20 ARSCcontroller Y6
ARC3 AMP040 16 ARSCcontroller a7
BRJ M 8 Intermediate controller a8
BRR X 2 Air switch (brake solenoid) D8
BSOR - 2 Brake solenoid valve (right) D8 SPSW M 3 ARSC set switch b3
BT3 - - Fuse box d4 SW - 7 ARSC system switch c3
BZ-EL1 M Tire large diameter/small diameter

2 Buzzer b3
BZ-EL2 M 2 Buzzer Tire large diameter/small diameter

b3
CR1 M 1 For clearing error code a8
CR2 M 1 For clearing error code b8
DO1 - 2 Diode d6 TMBI X 16 Intermediate connector dJ
DO2 - 2 Diode d5 TMB2 X 16 Intermediate connector d5
DO3 - 2 Diode d6 TMCI X 12 Intermediate connector dJ
FSI $$ector 1 Spare terminal d5 TMC2 X 12 Intermediate connector d5
JO&EL1 S 16 Intermediate connector b8 TMDI X 16 Intermediate connector dJ
J02-EL2 1 S ) 16 1 ntermediate connector c8 TMD2 X 16 Intermediate connector d6
JO&EL1Il 12 I Intermediateconnector I c8 WL-ELI ( M I 2 I Warning lamp

lb4
J04-EL2 S 12 Intermediate connector cJ WL-EL2 M 2 Warning lamp b3
KO &$iector 1 ARSC stand-by lamp Y4
PHI-EL11 S 1 10 1 Intermediateconnector t d6
PHl-EL2 S 10 Intermediate connector d6
PM41 M 6 Payload meter Y5
PM4-2 M 6 Payload meter Y5
R2 Terminal 1 Travel speed display -
fierminall 1 I Travel speed display )-

R4 ITerminal 1 I Travel speed display I-
20-118 HD325-6
0
TROUBLESHOOTING CONNECTOR ALLOCATION CHART
CONNECTOR ALLOCATION CHART

HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
20-120 HD325-6
8
HD325-6 20-121
8
20-122 HD325-6
8
HD325-6 20-123
8
TYPE OF CONNECTOR AND POSITION OF INSTALLATION

fl The Address column in this table shows the address in the connector pin allocation drawing
(3-dimensional drawing).
Con- No. Con- Connec- No.
nector Connec-
tor type of Place of use Add- nector tor type of Place of use Add-
01 DT-T 12 Junction connector C7 18 DT-T 2 Air conditioner compressor diode A3
02 DT-T 12 Junction connector — 19 Terminal 1 Diode ground —
03 DT-T 2 Radiator water level sensor A6 25 DT-T 2 Starting motor safety relay A3
04 DT-T 2 Air conditioner dual switch B2 29 Terminal 1 Right lamp ground —

1-pin Right platform wiring harness
05-1 connector 1 Horn B2 30 DT-T 12 junction connector B7
1-pin
05-2 connector 1 Horn B2 32H — 3 Right headlamp (Hi) A4
06L — 3 Left headlamp (Lo) D1 33L — 3 Right headlamp (Lo) A4

1-pin
07H — 3 Left headlamp (Hi) C1 34 connector 1 Right clearance lamp A5
1-pin 1-pin
08 connector 1 Left clearance lamp D1 35 connector 1 Right clearance lamp A5
1-pin 1-pin
09 connector 1 Left clearance lamp — 36 connector 1 Right turn signal A5
1-pin
1 DT 2 No. 1 fuel injector [A] — 37 connector 1 Right fog lamp A5
Front suspension cylinder
1.PS DT-T 2 Transmission ECMV (1) Q4 39 DT-T 3 pressure sensor B7
1.SW DT-T 2 Transmission ECMV (1, fill switch) Q4 40 DT 6 Payload meter indicator lamp (Right) C7
1-pin
2 DT 2 No. 2 fuel injector [E] — 41 connector 1 Right side lamp B6
2.PS DT-T 2 Transmission ECMV (2) P4 42 Terminal 1 Battery relay (–) —
2.SW DT-T 2 Transmission ECMV (2, fill switch) P4 44 Terminal 1 Battery relay BR (+) —
3 DT 2 No. 3 fuel injector [C] — 46 Terminal 1 Emergency steering relay BR (+) —
3.PS DT-T 2 Transmission ECMV (3) P4 47 Terminal 1 Emergency steering relay BR (+) —
3.SW DT-T 2 Transmission ECMV (3, fill switch) O4 48 Terminal 1 Emergency steering relay E (–) —
4 DT 2 No. 4 fuel injector [F] — 49 Terminal 1 Emergency steering relay E (–) —
4.PS DT-T 2 Transmission ECMV (4) O4 51 DT-T 2 Emergency steering flow switch E1
4.SW DT-T 2 Transmission ECMV (4, fill switch) O4 52 DT-T 2 Transmission filter sensor J3
5 DT 2 No. 5 fuel injector [B] — 56B Terminal 1 Backup alarm —
6 DT 2 No. 6 fuel injector [D] — 56R Terminal 1 Backup alarm —

1-pin
10 connector 1 Left turn signal D1 57 Terminal 1 Backup lamp —
1-pin
11 connector 1 Left fog lamp C1 59 DT-T 6 Stop lamp, tail lamp J9
12 — 2 Windshield washer motor C7 60 DT-T 6 Stop lamp, tail lamp K9
13 DT-T 3 Front suspension pressure sensor (Left) E1 61 DT-T 2 Fuel level sensor F9
14 DT 6 Payload meter indicator lamp (Left) D7 62 DT-T 3 Rear suspension pressure sensor (Left) L8
1-pin
15 connector 1 Left side lamp — 63 DT-T 3 Rear suspension pressure sensor (Right) J9
16 Terminal 1 Left lamp ground — 64 DT-T 2 Retarder oil temperature sensor A2

1-pin
17 connector 1 Air conditioner compressor — 67 Terminal 1 Rear lamp ground —
HD325-6 20-125
8
Con- No. Con- No.

nector Connec-
68 Terminal 1 Alternator terminal B — BF1 Terminal 1 Body float switch T1
69 Terminal 1 Service power source (Battery relay B) — BF2 Terminal 1 Body float switch T1
70 Terminal 1 Circuit breaker — BLSL DT-T 2 Brake chamber stroke sensor (Left) E8
71 Terminal 1 Ground (Controller) — BLSR DT-T 2 Brake chamber stroke sensor (Right) E8
73 Terminal 1 Battery relay M — BR Terminal 1 Starting switch —
75 Terminal 1 Alternator terminal R — BT1 — 10 Fuse box U5

1-pin
76 connector 1 Automatic drain valve — BT2 — 10 Fuse box T6
78 Terminal 1 Emergency steering relay M — BT3 — 6 Fuse box T6
80 Terminal 1 Starting motor terminal B — BU1 Terminal 1 Body RAISE switch T1
A1 — 1 Emergency escape switch U1 BU2 Terminal 1 Body RAISE switch T1
A2 — 1 Emergency escape switch U1 BZ M 2 Buzzer O4
AC1 M 4 Air conditioner unit N7 C Terminal 1 Starting switch —
ACC Terminal 1 Starting switch — C/V.T DT-T 2 Transmission oil temperature sensor Q1
AI PA 1 AISS switch — C23 Terminal 1 Ribbon heater relay 20G

1-pin
AS1 DT 2 Exhaust brake switch S9 CA– connector 1 AM/FM radio with cassette recorder —
1-pin
AS2 DT 2 Parking brake switch T9 CA+ connector 1 AM/FM radio with cassette recorder —
1-pin
AS3 DT 2 Retarder switch T9 CAB connector 1 AM/FM radio with cassette recorder —
AS4 DT 2 Emergency brake switch S9 CAN1 DT-T 3 Resistor 49K
AS5 DT 2 Service brake switch T9 CAN2 DT-T 3 Resistor 49o

1-pin
ATC1 MIC 17 Transmission controller U4 CG1 connector 1 Cigarette lighter M6
1-pin
ATC2 MIC 21 Transmission controller U3 CG2 connector 1 Cigarette lighter M6
ATC3A AMP040 20 Transmission controller U3 CK1 — 2 Monitor lamp test switch M7
ATC3B AMP040 16 Transmission controller U4 CM S 8 Combination switch Q9
ATC4 AMP040 12 Transmission controller V3 CN1 AMP070 12 Engine controller S2
ATC5A AMP040 20 Transmission controller V3 CN2 AMP070 18 Engine controller S2
ATC5B AMP040 16 Transmission controller V3 CN4 AMP070 20 Engine controller S1
ATC6 DT 4 Transmission controller T1 CN6 AMP070 10 Engine controller S2
B Terminal 1 Starting switch — CN7 AMP070 14 Engine controller S2
B 4 Differential lock-up switch 22P CNS S 12 Center console junction connector V3
B1 — 1 Payload meter printer type 33B D04 — 2 Diode S6
B2 — 1 Payload meter printer type 33B D05 — 2 Diode X6
B79 Terminal 1 Ribbon heater relay — D06 — 2 Diode X5
BD1 — 1 Intermediate connector 29o D08 — 2 Diode N4
BD2 — 1 Intermediate connector 29o D14 — 2 Diode S7
20-125-1 HD325-6
8

DB1 DT-T 4 Body sitting switch J9 1-pin

FS2 connector 2 Spare (Fuse box) —
DL DT 2 Differential lock-up S8 FU — 2 Service power source fuse —
DL DT-T 12 50P G — 2 G sensor —
DLC 1-pin 1 Intermediate connector 23P

connector H.PS DT-T 2 Transmission ECMV (H) O3
DLD — 2 Diode 24P H.SW DT-T 2 Transmission ECMV (H, fill switch) O3
DLV — 2 Diode 24P HAZ PA 7 Hazard switch O6
DP01 MIC 5 Monitor panel O9 HEAT X 1 For heater N7
DP02 AMP040 8 Monitor panel O9 1-pin

HN connector 1 Horn Q9
DP03 Socket 2 Monitor panel O6 J01 S 16 Junction connector S7
DP04 AMP040 8 Monitor panel P9 J02 S 16 Junction connector S8
DP05 AMP040 12 Monitor panel O6 J03 S 16 Junction connector S8
DP06 Socket 2 Monitor panel P6 J04 S 12 Junction connector (Payload meter) T9
DP07 Socket 2 Monitor panel P9 J06 Terminal 1 Controller ground S7
DP08 AMP040 16 Monitor panel Q9 J07 Terminal 1 Power source for cab S7
DP09 Socket 2 Monitor panel Q9 J09 S 12 Junction connector (Engine controller) W4
DP10 AMP040 8 Monitor panel R8 J10 HD 31 Engine control junction connector R4
DP11 AMP040 16 Monitor panel R8 J11 HD 31 Engine control junction connector R4
DP12 M 4 Monitor panel Q5 JC01 DT-T 6 Joint connector —
DP13 Socket 2 Monitor panel R8 JC02 DT-T 6 Joint connector —
E1 Terminal 1 Alternator ground — JC03 DT-T 6 Joint connector —
E2 Terminal 1 Alternator ground — JC04 DT-T 6 Joint connector —

A3
E6 DT-T 2 Engine speed sensor R3 JC05 DT-T 6 Joint connector —
ECA S 16 Junction connector (Engine controller) W4 JC06 DT-T 6 Joint connector —
ER Terminal 1 Chassis ground — JC07 DT-T 6 Joint connector —
ER Terminal 1 Ground — JC08 DT-T 6 Joint connector —
EXH PA 7 Exhaust brake switch O5 JC09 DT-T 8 Joint connector —
FB PA 7 Front brake cut switch O5 JC10 DT-T 6 Joint connector —
FL PA 7 Fog lamp switch O6 JC11 DT-T 6 Joint connector —

1-pin
FLB connector 1 Flasher R6 JC12 DT-T 6 Joint connector —
1-pin
FLL connector 1 Flasher R6 JC13 DT-T 6 Joint connector —
1-pin
FOG1 connector 1 Fog lamp switch — JCE DT-T 8 Joint connector —
1-pin
FOG2 connector 1 Fog lamp switch — L.PS DT-T 2 Transmission ECMV (L) O4
1-pin
FOG3 connector 1 Fog lamp switch — L.SW DT-T 2 Transmission ECMV (L, fill switch) O3
1-pin
FS1 connector 2 Spare (Fuse box) — L/C.T DT-T 2 Torque converter lock-up solenoid N3
HD325-6 20-125-2
8

LS M 3 Rheostat R7 PM7 MIC 9 Card-type payload meter N7
MC1 M 1 Clearing memory — PM8 MIC 5 For connection of personal computer M8
MC2 M 1 Clearing memory — PMC6 M 3 For S-NET monitor V5
MS M 3 Monitor panel selector switch N4 PMCD M 2 For power supply for off-board PMC V4
MS11 F 1 Model selection connector (1) — 1-pin

PSH connector 1 Engine oil pressure switch (High) —
MS11 Terminal 1 Monitor panel selector switch 1 N4 1-pin

PSL connector 1 Engine oil pressure switch (Low) —
MS12 M 1 Model selection connector (1) — PW PA 7 Power mode switch X4
MS12 Terminal 1 Monitor panel selector switch 1 N4 Suspension pressure sensor FR

PWR — 2 selection connector S1
MS21 F 1 Model selection connector (2) — R.PS DT-T 2 Transmission ECMV (R) P4
MS21 Terminal 1 Monitor panel selector switch 2 N4 R.SW DT-T 2 Transmission ECMV (R, fill switch) P4
MS22 M 1 Model selection connector (2) — R01 Socket 5 Engine starting relay W4
MS22 Terminal 1 Monitor panel selector switch 2 N4 R02 Socket 5 Transmission neutral relay U5
MS31 F 1 Model selection connector (3) — R03 Socket 5 Service brake relay U6
MS32 M 1 Model selection connector (3) — R04 Socket 5 Front brake cut relay S7
N1 DT-T 2 Transmission input shaft speed sensor Q1 R05 Socket 5 Backup alarm relay S7
Transmission intermediate shaft
N2 DT-T 2 speed sensor R3 R06 Socket 5 Headlamp relay (Hi) X4
N3 DT-T 2 Transmission output shaft speed Q4

sensor R07 Socket 5 Marker lamp relay X4
NE — 2 NE sensor — R08 Socket 5 Headlamp relay (Lo) U5
P15 M 2 MPH selection connector P6 R09 Socket 6 Rear brake pilot relay T6
PCV1 F 2 Supply pump 1 — R11 Socket 6 Payload meter relay S8
PCV2 F 2 Supply pump 2 — Payload meter external indicator

R16 Socket 5 lamp relay X6
Payload meter external indicator
PFUEL AMP17 3 Common rail pressure sensor — R17 Socket 5 lamp relay X6
PIM AMP17 3 Boost pressure sensor — Payload meter external indicator

R18 Socket 5 lamp relay W8
PL1 S 10 Monitor lamp N7 Payload meter external indicator

R19 Socket 5 lamp relay V9
PL2 S 10 Monitor lamp O6 Payload meter external indicator

R20 Socket 5 lamp relay S8
PLS M 6 Monitor lamp N7 R21 Socket 5 Parking relay X7
PM1 S 12 Payload meter junction connector M9 R22 Socket 5 Engine controller ACC power relay X7
PM1A MIC 21 Printer-type payload meter M8 R23 Socket 5 Preheater relay W8
PM2 M 4 Model selection connector G1 R25 Socket 5 Transmission cut relay V9
PM3 X 3 Inclination sensor I2 R27 Socket 5 Hazard relay U9
PM4 M 6 Payload meter junction connector M9 R28 Socket 6 Hazard lamp relay X7
PM5 MIC 13 Card-type payload meter M8 R29 Socket 6 Hazard lamp relay X8
PM6 — 2 selection connector S1 R30 Socket 5 Horn relay W8
PM6 AMP040 12 Card-type payload meter M8 RAD — 9 AM/FM radio O7
20-125-3 HD325-6
8
Con- No. Con- No.

nector Connec-
1-pin
RE1 connector 1 Resistor R6 SSP1 MIC 21 Suspension controller T4
1-pin
RE2 connector 1 Resistor R6 SSP2A AMP040 20 Suspension controller T4
RH1 S 10 Junction connector X7 SSP2B AMP040 16 Suspension controller U4
RH2 S 12 Junction connector V2 ST1 Terminal 1 Emergency steering switch W1
RH4 S 8 Junction connector X7 ST2 Terminal 1 Emergency steering switch X1

1-pin
RL connector 1 Room lamp E8 ST3 Terminal 1 Emergency steering switch W1
RT2 Terminal 1 Emergency steering timer (2) — ST4 Terminal 1 Emergency steering switch X1
RT6 Terminal 1 Emergency steering timer (6) — SU3 S 16 Junction connector X5

Suspension pressure sensor
RT7 Terminal 1 Emergency steering timer (7) — SU6 — 2 specification selection connector S1
RT8 Terminal 1 Emergency steering timer (8) — SW22 Terminal 1 Ribbon heater relay —
1-pin Torque converter oil temperature
RUP– connector 1 For RUP U2 TC.SE DT-T 2 sensor Q1
1-pin
RUP+ connector 1 For RUP U1 TEL DT-T 12 50P
Automatic suspension pressure 1-pin
SCFR — 2 junction connector X5 TG connector 1 Tachograph U5
Automatic suspension pressure
SCR — 2 junction connector X6 THL DT 2 Fuel temperature sensor —
SF S 12 Transmission shift lever V1 TM2 HD 16 Transmission controller junction L4

connector
SH PA 7 Shift limit switch W4 TM3 HD 31 Transmission controller junction L4
connector
SL1 DT 2 Suspension control solenoid valve A W8 TMA S 16 Transmission controller junction W4
connector
SL2 DT 2 Suspension control solenoid valve B W8 TMB S 16 Transmission controller junction V4
connector
SL3 DT 2 Suspension control solenoid valve C U9 TMC S 12 Transmission controller junction X4
connector
SL4 X 2 Overrun prevention solenoid W8 TMD S 16 Transmission controller junction X5
connector
SL5 X 2 Exhaust brake solenoid V9 TWH DT 2 Water temperature sensor (High) —
SL6 X 2 Front brake cut-off solenoid V9 TWL DT 2 Water temperature sensor (Low) —
SL7 X 2 Front brake cut-off solenoid U9 WAS1 X 6 Accelerator pedal —

1-pin
SP1 connector 1 AM/FM radio with cassette recorder — WAS2 X 3 Accelerator pedal C1
1-pin
SP2 connector 1 AM/FM radio with cassette recorder — WL M 2 Warning lamp O5
1-pin
SP3 connector 1 AM/FM radio with cassette recorder — WP1 S 8 Windshield wiper switch N6
1-pin
SP4 connector 1 AM/FM radio with cassette recorder — WP2 — 6 Windshield wiper motor E1
1-pin
SP5 connector 1 Speaker (Right) F9 WP3 — 6 Intermittent windshield wiper relay R7
1-pin
SP6 connector 1 Speaker (Right) F9 — — 6 Winker, stop lamp, tail lamp 37F
1-pin
SP7 connector 1 Speaker (Left) H1 — — 2 Differential lock-up solenoid 25B
1-pin
SP8 connector 1 Speaker (Left) I2 — — 2 Diode for heater relay 19G
SR2 X 3 Steering sensor E1 — X 1 Air conditioner compressor 12H
SR3 X 2 Inclination sensor U5
SR5 X 2 Air pressure sensor S8
HD325-6 20-125-4
8
FOR ARSC (AUTOMATIC RETARDER SPEED CONTROL)

nector tor type of Place of use Add- Add-
ress
nector tor type of Place of use ress
No. pins No. pins
1-8 X 1 Selection connector d4 R5 Terminal 1 Travel speed display —
8S X 1 Selection connector d4 R6 Terminal 1 Travel speed display —
250 — 2 Resistor a3 RB For relay 5 RB relay Y7
1020 — 2 Resistor Z3 RW For relay 6 RW relay Y6
A1 1-pin 1 ARSC caution lamp Z3 RZ For relay 5 RZ relay Y6

connector
A2 1-pin 1 ARSC caution lamp Z3 SHIFT X 1 Selection connector c4
connector
A6 1-pin 1 ARSC stand-by lamp Y4 SHUT — 2 Air shut-off valve D8
connector
ARC1 MIC 21 ARSC controller Y6 SOSW DT-T 2 Air switch (air shut-off valve) D8
ARC2 AMP040 20 ARSC controller Y6 SP2 M 2 Suspension pressure selection Z7

connector
ARC3 AMP040 16 ARSC controller a7 SP4 M 2 Power source for suspension pres- c8
sure sensor/sensor GND connection
BRJ M 8 Intermediate controller a8 SP5 M 2 Power source for suspension pres- c8
sure sensor/sensor GND connection
BRR DT-T 2 Air switch (brake solenoid) D8 SPR M 2 Suspension pressure selection Z7
connector
BSOR — 2 Brake solenoid valve (right) D8 SPSW M 3 ARSC set switch b3
BT3 — — Fuse box d4 SW — 7 ARSC system switch c3
BZ-EL1 M 2 Buzzer b3 TIRE1 X 1 Tire large diameter/small diameter c4

selection
BZ-EL2 M 2 Buzzer b3 TIRE2 X 1 Tire large diameter/small diameter c4
selection
CR1 M 1 For clearing error code a8 TMA1 X 16 Intermediate connector d7
CR2 M 1 For clearing error code b8 TMA2 X 16 Intermediate connector d5
D01 — 2 Diode d6 TMB1 X 16 Intermediate connector d7
D02 — 2 Diode d5 TMB2 X 16 Intermediate connector d5
D03 — 2 Diode d6 TMC1 X 12 Intermediate connector d7
FS1 1-pin 1 Spare terminal d5 TMC2 X 12 Intermediate connector d5

connector
J02-EL1 S 16 Intermediate connector b8 TMD1 X 16 Intermediate connector d7
J02-EL2 S 16 ntermediate connector c8 TMD2 X 16 Intermediate connector d6
J04-EL1 S 12 Intermediate connector c8 WL-EL1 M 2 Warning lamp b3
J04-EL2 S 12 Intermediate connector c7 WL-EL2 M 2 Warning lamp b3
K0 1-pin 1 ARSC stand-by lamp Y4

connector
PH1-EL1 S 10 Intermediate connector d6
PH1-EL2 S 10 Intermediate connector d6
R2 Terminal 1 Travel speed display —
20-125-5 HD325-6
8
CONNECTOR ALLOCATION CHART

20-125-7 HD325-6
8
HD325-6 20-125-8
8
20-125-9 HD325-6
8
HD325-6 20-125-10
8
ARSC SYSTEM
20-125-11 HD325-6
8
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

* 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.
No.
of
T X type connector
pins Male (female housing) Female (male housing)
1
c
BEH00148 BEH00149
TEW00221 TEwoo222
1 3
TEWOO223 TEW00224
3 1
4 2
TEW00225 SEW00226
20- 126 HD3256

0
No.
of
r M type connector
1 1
BLFOOO3S BLFU0039
3 2
q!l 1
@
TEwoo243 TEwoo244
1 3 3 1
JZZI @z&
2 4 4 2
TEWOU245 TEwoo246
4 1
TEWO0247
4 1
8
El 8 5
BLFWO40
5 -8 BLFuOO41
HD325-6 ZO-127
0
No.
of
T AMP040 type connector
8 4
5 1 BLFVOO54
6 12 12 6
BLF’OM55 7 i BLPoOO56
16
ii i
TEW00234
20- 128 HD325-6
a
No.
of
T S type connector
TEW00249
1 6
10
6 io TEW00251
f
12
5 12
BLPoOO43 Ii TEW00254
1 8 8 1
16
7 16BLPU0044 TEW00256
HD3256 20-129
0
No. SWP type connector

of
3 6
6 3 BLmOO33
TEWOO235
4 8 8 4
TEwoo237 TEW00238
1
4
@fliifl
1
.-_
____-_
i
12 5
0 5 8
0
9 9 12
BLrn0034
1 4 8 11 11 8 4 1
14
3 i io ?4 Id Id i
TEW00239 TEWOO240
1 4
5 8
16
9 2
BLmO036
20-130 HD325-6
0
No.
of
T MIC type connector
I-J BLpooo45
1 5
OIJPUO
on no
9
6
9
hnr-I BLpoOo47
7
1
13 8
8
13
I BLPOOO49
9
BLpooO5O
17
17
I I BLPOO051 BLPOO052
21
i 1 TEW00259 TEWOO260
HD3256 20-131
0
No. Automobile connector

of
, J
3 1
BEHOOI 50
BEHOOI 51
BLPco064
EB BDHOOI 52
2
BDHOO
3
153
I 2
3 4
4. .3 BDH00154 BDH00155
BLPOOO69 BLPWO70
20-132 HD325-6
0
No.
of
T Relay connector (socket)
2 5
n \
6
I \3
BLFuOO73 BLPWO74
-
6 5
BLWOO71
BLWOO76
HD3256 20-133
0
No.
of
T Fuse box
12
BVH00397
I I!
20
I \
2 20
BVH00398
zo- 134 HD325-6

0
No.
of
T PA connector
BVH00666 WHO0667
5 9
BVH00666 BVH00669
HD325-6 20-135
0
No. AMP070 type connector

of
10
12
14
18
20
20-135-1 HD325-6
8
No. L type connector

of
HD325-6 20-135-2
8
Type HD30 series connector


 Shell 
 size
 code
 Body (Plug) Body (Receptacle)
Pin (male terminal) Pin (female terminal)
18-8
Pin (female terminal) Pin (male terminal)
(1)
18-14
(2)
20-135-3 HD325-6
8


 Shell 
 size
 code
18-20
(3)
18-21
(4)
HD325-6 20-135-4
8


 Shell 
 size
 code
24-9
(5)
24-16
(6)
20-135-5 HD325-6
8


 Shell 
 size
 code
24-21
(7)
24-23
(8)
HD325-6 20-135-6
8
Type
 HD30 series connector
 Shell 
 size
 code
24-31
(9)
20-135-7 HD325-6
8
[Number is printed on each connector (Wire inserting end).]

No. DT, DT-T series connector
of
pins Body (Plug) Body (Receptacle)
HD325-6 20-135-8
8

No. DT, DT-T series connector
of
12
20-135-9 HD325-6
8

No. DTM series connector
of
HD325-6 20-135-10
8
No. DTHD series connector

of
20-135-11 HD325-6
8
TROUBLESHOOTING CEXPLANATIONS OF FUNCTIONS OF ELECTRICAL SYSTEM
EXPLANATIONS OF FUNCTIONS (CONTROL MECHANISM) OF

ELECTRICAL SYSTEM
This section gives the necessary knowledge for fl The engine controller (of electronic governor
troubleshooting of the electrical system, and ex- specification) is applied to HD325-6 Serial No.
plains the functions and nature of checks for en- 6001 and up, HD325-6W Serial No. 6001 and
gine controller (of electronic governor specifica- up, HD405-6 Serial No. 2001 and up.
tion), the transmission controller, suspension con-
troller, and monitor panel.
1. Mechanical governor specification

HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
1) Explanation of functions
The control mechanism of the electrical sys- The monitor panel informs the operator of the
tem consists of the transmission controller, abnormality when there is a failure in the
suspension controller, and the monitor panel. mechatronics equipment of each system. At
It carries out various controls such as chang- the same time, it uses the service mode to
ing the output of the engine (power mode), monitor the input and output, such as the in-
providing the most suitable transmission put voltage from the switch sensors of each
clutch oil pressure (full electronic modulation), controller and the output current to the sole-
and changing the damping of the suspension noids, and a monitor function for the failure
(auto suspension). data stored in the memory of each controller.
Input/output signal system for monitor and controller
Network data (fl1)

(Display items)
1 Troubleshooting data (user code, other
mechatronics caution display)
2 Suspension mode display
20-136 HD325-6
8
(Control data) pushing the bulb check switch.

1 Travel speed compensation data In addition, the controllers share some of the
2 Model selection data sensor signals, such as the transmission out-
Network data (fl2) put shaft speed signal, so if any abnormality
(Display items) occurs in these sensor signals, the same type
1 Troubleshooting data (user code, trans- of failure display may be given at the same
mission mechatronics caution display) time.
2 Engine speed display With the input signal systems from A to J,
3 Speed display even if there is an abnormality, the self-diag-
4 Shift position display nostic display is not given, so in cases where
5 Mode selector display there is no abnormality display but the move-
6 Speed range display ment of the machine is abnormal, to check if
7 Shift limit display the cause is in the electrical system or in the
8 Lock-up display hydraulic, air, or mechanical system, go to
9 Air pressure level display Section 3 Method of checking actuation of
0 Retarder oil temperature level display electrical system, and check if the signals are
A Engine water temperature level display being input.
B Fuel level display
C Torque converter oil temperature
leveldisplay 2. Electronic governor specification
D Caution/pilot lamp output HD325-6 Serial No.: 6001 and up
Sensor signals (ª) HD325-6W Serial No.: 6001 and up
1 Air pressure HD405-6 Serial No.: 2001 and up
2 Engine water temperature 1) EXPLANATION OF FUNCTIONS
3 Torque converter oil temperature The control mechanism of the electrical sys-
4 Retarder oil temperature tem consists of engine controller the trans-
5 Radiator water temperature mission controller, suspension controller, and
6 Engine oil pressure the monitor panel. It carries out various con-
7 Fuel level trols such as changing the output of the en-
8 Steering oil temperature gine (power mode), providing the most suit-
9 Transmission filter clogging able transmission clutch oil pressure (full elec-
0 Brake chamber stroke tronic modulation), and changing the damp-
ing of the suspension (auto suspension).
The monitor panel informs the operator of the
2) EXPLANATION OF SELF-DIAGNOSTIC abnormality when there is a failure in the
DISPLAY FUNCTIONS mechatronics equipment of each system. At
Each controller is equipped with a self-diag- the same time, it uses the service mode to
nostic troubleshooting display function, so if monitor the input and output, such as the in-
any electrical abnormality (disconnection, put voltage from the switch sensors of each
short circuit, internal short, or short circuit controller and the output current to the sole-
between wires, etc.) occurs in output signal noids, and a monitor function for the failure
systems from No. (1) to (12) and Nos. *1 to data stored in the memory of each controller.
*14, and input signal systems from A to J, or
there is input or output that does not match
the operation of the machine, the nature of
the abnormality is displayed.
When the self-diagnostic display function is
actuated, the abnormality occurrence data is
transmitted from each controller to the net-
work, and the monitor panel displays the user
code. The mechatronics abnormality display,
warning lamp, and buzzer may also be actu-
ated. The service codes which display the
causes of these problems can be seen by
HD325-6 20-137
8
Input/output signal system for monitor and controller
Network data (fl1)

(Display items)
1 Troubleshooting data (user code, other
mechatronics caution display)
2 Suspension mode display
20-137-1 HD325-6
8
(Control data) ated. The service codes which display the

1 Travel speed compensation data causes of these problems can be seen by
2 Model selection data pushing the bulb check switch.
3 Real-time monitoring data In addition, the controllers share some of the
Network data (fl2) sensor signals, such as the transmission out-
(Display items) put shaft speed signal, so if any abnormality
1 Troubleshooting data (user code, trans- occurs in these sensor signals, the same type
mission mechatronics caution display) of failure display may be given at the same
2 Engine speed display time.
3 Speed display With the input signal systems from A to J,
4 Shift position display even if there is an abnormality, the self-diag-
5 Mode selector display nostic display is not given, so in cases where
6 Speed range display there is no abnormality display but the move-
7 Shift limit display ment of the machine is abnormal, to check if
8 Lock-up display the cause is in the electrical system or in the
9 Air pressure level display hydraulic, air, or mechanical system, go to
0 Retarder oil temperature level display Section 3 Method of checking actuation of
A Engine water temperature level display electrical system, and check if the signals are
B Fuel level display being input.
C Torque converter oil temperature
leveldisplay
D Caution/pilot lamp output
E Real-time monitoring data
Network data (fl3)
(Displayed items)
1 Troubleshooting information (User code
and engine mechatronics caution display)
2 Engine water temperature level display
3 Real-time monitoring data
(Control information)
1 AISS signal
2 Brake signal
3 Retarder signal
4 Mode selection signal
2) EXPLANATION OF SELF-DIAGNOSTIC
DISPLAY FUNCTIONS
Each controller is equipped with a self-diag-
nostic troubleshooting display function, so if
any electrical abnormality (disconnection,
short circuit, internal short, or short circuit
between wires, etc.) occurs in output signal
systems from No. (1) to (12) and Nos. *1 to
*14, and input signal systems from A to J, or
there is input or output that does not match
the operation of the machine, the nature of
the abnormality is displayed.
When the self-diagnostic display function is
actuated, the abnormality occurrence data is
transmitted from each controller to the net-
work, and the monitor panel displays the user
code. The mechatronics abnormality display,
warning lamp, and buzzer may also be actu-
HD325-6 20-137-2
8
3. CHECKING OPERATION OF ELECTRICAL SYSTEM

When a sequence of operations is carried out using the procedure below, if the monitor panel, trans-
mission controller, suspension controller, and payload meter controller carry out the actions given
below, the input and output signals, and the monitor panel and controllers are normal.
Carry out the actuation check with the machine unloaded. (The actuation of the suspension control-
ler differs when the machine is loaded or unloaded, but it is possible to check all of the mode selec-
tions with the machine unloaded.)
Check items (when normal)

Sequence of operations and
condition of machine Engine Transmission Suspension Payload meter
Monitor panel controller controller controller controller
(1) Turn starting switch OFF All OFF All OFF All OFF All OFF All OFF
(2) Turn starting switch to ACC Monitor panel 8.8 is displayed 8.8 is displayed 2-digit LED dis- 8.8, 8.8 display,
liquid crystal dis- for 3 seconds. for 3 seconds plays 0.0 (nor- external display
play lights up Self-diagnostic Self-diagnostic mal) lamps all light
• Parking only with parking brake Suspension mode result is dis- display lights up up
soft portion lights played for 5.2 for 4.2 seconds, Buzzer sounds
seconds, then then goes out, for 3 seconds
up past troubles are and details of 9 items, such as
• Bulb check switch ON Caution, pilot displayed for 3 past failures are payload meter
lamps all light up seconds each. If displayed for 3 switch settings,
• Power mode selection switch • Power mode engine is normal seconds each. are displayed
Economy ON/OFF display currently, 0.0 is After that, if the for 3 seconds
displayed. condition is nor- each.
Economy/high mal, 0.0 or 0.C After that, pay-
power lights
up (in cold weather) load display is
is displayed. given
• Shift limiter switch ON/OFF Shift limiter liq-
uid crystal dis-
play lights up/
goes out
• Shift lever set to N Shift indicator N
• Shift position
display N
(3) Start engine • Engine speed • Engine speed: When transmis-
• If water temperature is below is displayed 945 rpm sion oil
40˚C, automatic warming-up • On cooling wa- temperature is
operation is actuated ter tempera- below 10˚, 0.0 is
ture display, dis-played
only lowest
segment lights
up
• If water temperature is above When water tem- • Engine speed: When oil tempera-
70˚C after completion of warm- perature display 650 rpm ture is below 10˚,
ing-up operation is in green range 0.0 is displayed
(4) Release parking brake and stop Engine speed rises • Engine speed: When oil tempera- Suspension
machine with service brake only Parking lamp goes 945 rpm ture is below 10˚, mode switched
out 0.0 is displayed Soft → medium
Rear brake lamp
lights up
Suspension mode
display
Soft → medium
Release service brake and pull re- • Rear brake • Engine speed: Suspension mode
tarder lever lamp lights up 650 rpm stays at soft
• Suspension
mode soft
portion lights
up
(5) Apply parking brake and raise Suspension 2 LED units dis- Suspension b-FL displayed,
body mode display play 0.0 (Normal) mode selection buzzer sounds
Soft → hard Soft → hard
(6) In condition (5), set shift lever to Shift indicator N Body FLOAT RE-
R • Shift position VERSE safety ac-
display R tuated
• Body caution • When body is
lamp lights up at FLOAT, ma-
Warning lamp, chine travels in
buzzer are reverse
actuated
20-138 HD325-6
8
Check items (when normal)

Sequence of operations and
condition of machine Monitor panel Engine Transmission Suspension Payload meter
controller controller controller controller
(7) Lower body, release parking Shift indicator 1 2 LED units dis- Travel speed range Suspension Changes from
brake, then set shift lever to L and • Shift position play 0.0 (Normal) F1 - F2 mode selection payload display
travel forward display L Hard → soft to time display
• Release brake
• After machine moves off, de-
press accelerator pedal
• Shift limiter switch ON/OFF Shift indicator Shift limiter func-
display 1/1 - 2 tion actuated F1
fixed/shifts up to
F2
(8) Set shift lever to D and shift up Shift indicator 3 Travel speed range
to F3 or above • Shift position F2 - F7
display D
• Lock-up liquid
crystal display
• Turn exhaust brake switch • Exhaust brake
(EXH.BRAKE) ON and release is actuated even
accelerator pedal when retarder
lever is not ac-
tuated
• Turn exhaust brake switch Change in exhaust
(EXH.BRAKE) OFF and release brake logic
accelerator pedal / Release ac- • Not actuated/
celerator pedal and operate re- actuated
tarder lever
(9) Check lock-up function Monitor panel Transmission controller
• Set shift lever to R Lock-up display does not light up Lock-up is not actuated when traveling in
reverse
• Set shift lever to D or 5 – L Lock-up range is F1 - F7
I 65. Set to F1 or F2, release ac- Lock-up display does not light up Lock-up is not actuated
celerator pedal, and move ma-
chine off without operating
brake
II Depress Engine speed 1500 Lock-up display lights up Lock-up is actuated
accelerator rpm or more
pedal or Engine speed 1200 Lock-up display does not light up Lock-up is not actuated
operate rpm or less
brake
Shift gear After switching shift indicator display, lock- Lock-up is canceled when shifting gear
up display goes out temporarily
III Release Shift down Lock-up display stays lighted up until shift From F4 and up, transmission shifts down
accelerator indicator display is 4 with engaging lock-up
pedal and do Lock-up display stays out after shift indica- From F3 and down, transmission shifts
not operate tor display becomes 3 down without engaging lock-up
brake
HD325-6 20-139
8
TROUBLESHOOTING MONITOR PANEL USER CODES AND SERVICE MODE FUNCTION
MONITOR PANEL USER CODES AND SERVICE MODE

FUNCTION
1. OUTLINE
HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
If a failure is detected when the monitor panel is in the normal mode, the lamp or caution display for
the applicable location lights up, and a user code is displayed according to the failure to aid the
operator in taking suitable action. When a user code is displayed, the operator should follow the
recommended action, and should also follow the Operation and Maintenance Manual to display the
service codes on the monitor panel to check the cause of the user code. In addition, to make trouble-
shooting easier, there is a service mode on the monitor panel. This can display trouble data saved in
the memory of the controllers on the network and display the recognized values for the input and
output signals from each controller.

In addition to the above functions, function of stopping fuel injection for each engine cylinder (re-
duced cylinder mode function) is provided.
2. USER CODE DISPLAY

If any controller on the network detects an abnormality or confirms that the system has been re-
stored, the controller LED displays or turns off the service codes, and also transmits data about the
occurrence or restoration to the network. The monitor panel displays the user code according to the
occurrence data transmitted to the network, and continues to display it until the condition is restored.
(Example of display)
1) Displaying occurrence of failure (E–) 2) Displaying user code (03)
The above displays 1) and 2) are repeated in turn for 1 second each.
However, if new failure occurrence data are sent while the user code is being displayed, and the user
code for the new failure has priority over the existing user code being displayed, the display will
change to the new code. If the new code has a lower priority, the display stays unchanged. In other
words, the user code with the highest priority is always displayed.
There are seven types of user code from 01 to 07. (A decal showing the content is stuck to the top left
of the window glass at the front of the cab to show the operator the content of the failure.)
If a user code is displayed, have the operator check the service code for the failure that is the cause of
the user code as follows, and then have him inform the serviceman.
While the user code is being displayed, if lamp check switch (1) is kept pressed for at least 2.5 sec-
onds and then released, the applicable service code is displayed. If more than one problem has
occurred, each problem is displayed in turn for 3 seconds, and when all of the service codes have
been displayed, the system returns automatically to the normal display (in other words, to the user
code display).
20-140 HD325-6
8
When service code for existing failure is [A111]
3. SERVICE MODE
HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
The service mode on the monitor panel is used when it is desired to know the service codes for
existing failures or failures that have occurred in the past, and to monitor the values recognized for
the signals from the controllers.

The service mode is used to stop fuel injection for each engine cylinder (in the reduced cylinder
mode), too.
The service mode contains the following:

1) Machine data monitoring mode (this mode displays the values for the inputs and outputs recog-
nized by the controller on the network)
2) Service codes, trouble data display mode (this mode displays the abnormality occurrence data
saved in the memory of the controllers on the network)
The modes are switched by using the mode change switch.
If the starting switch is turned off when there is a display, it is possible to start again from the normal
mode after the starting switch is turned ON again. If the monitor panel or other controllers detect a
failure while the system is in the service mode, the system automatically returns to the normal mode
and displays the user code.
3) Reduced cylinder mode (to stop fuel injection for each engine cylinder) (Only HD325-6 Serial No.
6001 and up, HD325-6W Serial No. 6001 and up, HD405-6 Serial No. 2001 and up)
3.1 Machine data monitoring mode

fl This is the mode to display the input values of the sensors and switches recogized by the
controllers, and the output values of the controllers. Each controller can monitor several tens of
sensor and switch input values and electric current or other output values, so these can be used
as reference values when checking the machine or carrying out troubleshooting.
fl For the list of items that can be monitored by the controllers, see 3.4 Monitoring items in
machine data monitoring mode.
fl The order for displaying the controllers depends on the order of the controller code (*1), but
controllers that are options and are not installed are automatically omitted and are not dis
HD325-6 20-141
8
1) When engine speed recognized by trans- 2) When switch input condition recognized
mission controller is being monitored by transmission controller is being moni-
• When monitoring engine speed tored
• When monitoring input of switch
1. Controller code
2. Monitor item code
3. Monitor value
4. Bit number
(display)
• The display is in units of 10 rpm, so the display means 2,050 rpm.

• 1 and 13 of bit No. 4 are ON. This means that the body seated switch is ON (not seated) and model
selection signal 3 is ON (GND).
• For details, see 3.5 Monitoring items in machine data monitoring mode.
fl The controller code and monitor item code are displayed in turn for one second each.
fl For details of the machine data monitoring mode and method of proceeding (going back)
with the monitor items, see Section 4 Display method for service mode.
(ª1) Controller codes
A: Monitor panel b: Transmission controller
C: Engine controller d: Suspension controller
(To make it possible to display the controller code with the 7-segment LED, a mixture of
large and small letters is used.)
3.2 Service code and trouble data display mode

fl For details of the method of operation, see 3.3 Method of operating service mode.
This mode displays the time elapsed since the deletion operation, and gives the service code
and trouble data display. With the service code and trouble data display, the service code is
displayed for each controller for failures that currently exist and failures that occurred in the
past and have been remedied.
In the same way as with the machine data monitoring code, the order for displaying the control-
lers depends on the order of the controller code, but controllers that are options and are not
installed are automatically omitted and are not displayed.
1) Display of elapsed time from deletion operation
(1) Content of display
• The display shows the time elapsed (service meter reading) since the latest trouble
data item was deleted from memory. For details of the method of deletion, see 3-3-6.)
(2) Display timing
• Immediately the system enters the service code and trouble data display mode, the
display is given once only and it then goes automatically to the next service code
and trouble data display.
20-142 HD325-6
8
(3) Example of display
1) DELETE display (2 seconds) 2) The time elapsed (101h) since the last
deletion is displayed (2 seconds)
fl When the deletion operation is carried out, the elapsed time is reset and starts again from 0,
so if necessary, note down the elapsed time before deleting any item.
2) Service code and trouble data display

1 Details of display 2 Order of display
(1) The following trouble data i) - iv) (1) The four items in (1)-1)-i) – iv)
are displayed for each controller above are displayed in order for
and each service code. each controller.
i) Service code (the controller (2) Data for currently existing failures
code explained above (A, b, c, (service mode, elapsed time (1),
....) + 3 digit number) elapsed time (2), number of occur-
ii) Elapsed time 1 (elapsed time rences) inside the same control-
(service meter reading) since ler are displayed first, then data
that failure first occurred) for failures that have already been
iii) Elapsed time 2 (elapsed time corrected are displayed.
(service meter reading) since (3) For failures that are currently ex-
that failure last occurred) isting and failures that have al-
iv) Number of occurrences (the ready been corrected, the data are
number of times that the fail- displayed in turn starting for each
ure has occurred up to now) type from the failure that occurred
(2) When the data for a failure that is most recently (the smallest value
currently existing are displayed, for elapsed time (2)).
the high beam pilot lamp lights • Example of order of display
up. When the trouble data in the memory of one
(3) Unless the display item is of the controllers is as follows:
changed by operating the switch, Service code A111 A121 A131 A141
the above four items will continue Elapsed time 2 5 2 6 12
to be displayed in turn. For de- Existing Existing corrected existing corrected
tails of the method of operating /corrected
the switch, see the following Order of display 1 2 3 5
method of operating service A111 A121 A131 A141
mode. The data are displayed in order according to
(4) If there is no trouble data, or it has the above rule for each controller.
all been deleted, — — is displayed.
(5) Only for the trouble data display
for the suspension controller (con-
troller code: d), the above elapsed
time is displayed as — —.
HD325-6 20-143
8
3 Example of display (display of existing failure)

High beam pilot lamp (1) lights up: This shows that the trouble data are for a currently exist-
ing failure.
High beam pilot lamp (1) is out: This shows that the trouble data are for a failure that has
been corrected.
(1) Service code (A111) (4) Number of occurrences 3

This shows that A111 currently exists. This shows that within a period of
1151h before and 1 hour before, this
failure occurred 3 times.
(2) Elapsed time 1 (1151h) (3) Elapsed time 2 (1h)

This shows that the failure first oc- This shows that the failure last oc-
curred 1151h before. curred 1h before.
fl The above displays 1) – 4) are displayed repeatedly in turn for 2 seconds each. {After display-
ing Item 4), the display returns to Item 1).}
fl For details of the service code, see TABLE OF SERVICE CODES AND USER CODES (page 20-
161).
20-144 HD325-6
1
3.3 Reduced cylinder mode

fl For REDUCED CYLINDER MODE OPERATION OF ENGINE, see TESTING AND ADJUSTING.
fl For the [method for changing the indicated items in the reduced cylinder mode (method for
operating the indicated items)] and [method for setting the reduced cylinder mode], see 4) of 3.4
METHOD FOR OPERATING SERVICE MODE.
• The mode to stop fuel injection for each cylinder is called the reduced cylinder mode, which is
used to cut out the fuel injected through each fuel injector to find out a cylinder where combus-
tion is abnormal (fuel does not burn normally).
fl You can cut out the fuel to be injected in any one or multiple cylinders from the 1st cylinder to
the sixth cylinder.
fl When the reduced cylinder mode is finished (When it is finished with the mode change switch
or a failure code is detected or the starting switch is turned to the OFF position), the reduced
cylinder mode is cancelled totally.
1) Display made when MACHINE INFORMA-

TION MONITORING MODE or SERVICE
CODE AND FAILURE HISTORY MODE is
changed to REDUCED CYLINDER MODE
fl For the method for setting the reduced
cylinder mode, see 3.4.4).
(1) Display made just after reduced cyl-
inder mode is selected
• The items shown at right are dis-
played for 2 seconds, then [selec-
tion of 1st cylinder] shown in ii)
below is displayed automatically.
(2) Display of selectable cylinders

The No. of the cylinder to be set for
the reduced cylinder mode is dis-
played in the user code display sec-
tion (1).
fl The screen to set the 1st cylinder
for the reduced cylinder mode (se-
lection of 1st cylinder) is displayed
first, however.
fl [C] denotes the initial letter of CYL-
INDER.
fl [C1] in the example at right de-
notes that the 1st cylinder is se-
lected.
fl For the method for selecting the
next or previous cylinder for the
reduced cylinder mode, see 3.4.4).
HD325-6 20-144-1
8
2) Display of cylinder selected for reduced

cylinder mode
If a cylinder is selected for the reduced cyl-
inder mode, its No. is displayed in the 7
segments (2) on the left of the speed dis-
play section (speedometer section).
• In the example, the 1st cylinder is se-
lected.
3) Display of reduced cylinder mode opera-

tion
The cylinder(s) operated in the reduced
cylinder mode is (are) displayed in the 7
segments (3) on the right of the speed dis-
play section (speedometer section).
• In the example, the 1st cylinder is op-
erated in the reduced cylinder mode.
4) Display of condition of reduced cylinder

mode
Among the 7 segments in the shift indi-
cator section (4), those corresponding to
the cylinders selected for the reduced cyl-
inder mode light up.
1: 1st cylinder
2: 2nd cylinder
3: 3rd cylinder
4: 4th cylinder
5: 5th cylinder
6: 6th cylinder
5) Display of engine speed in reduced cylin-

der mode
The engine speed in the reduced cylinder
mode is displayed in the tachometer sec-
tion (5).
20-144-2 HD325-6
8
3.4 Method of operating service mode

fl A summary is given in the Table of meth- for at least 0.2 seconds, then turn them
ods of operating switches in Item 4), so off (operation A) to switch the mode in
use this for reference. turn as follows:
The service mode is operated by using the Normal mode → machine data moni-
mode change switch at the bottom left toring mode → service code, trouble
inside the dashboard. data display mode → normal mode
There are two types of mode change fl Apply the reduced cylinder mode to
switches ((1) and (2)): Switch (1) is at the only HD325-6 Serial No.: 6001 and up,
rear (red color at front of machine) and HD325-6W Serial No.: 6001 and up,
switch (2) is at the front (black color at rear HD405-6 Serial No.: 2001 and up.
of machine).
(The numbers are shown on the switch
box, so check the switch box.)
To operate the mode change switches,
move the switch to the right to the ON
position; when the switch is released, it
will automatically return to the OFF posi-
tion.
1) Method of entering service mode, method
of switching mode
Operate both mode change switches (1)
and (2) to the ON position at the same time
Diagram of change in service mode
fl For details of Operation A, see the Table of methods of operating switches in Item 4).
Note:
In the normal mode, if a failure is currently existing, and the user code for that failure is displayed,
when Operation A above is carried out, that user code will go out first.
If a failure with a user code of a lower priority than the user code being displayed occurs at the same
time, even when Operation A is carried out, the user code will not go out, but the display will change
to the code with the lower priority.
In addition, even if a failure with the same user code has occurred several times, Operation A must be
carried out the same number of times as the number of occurrences for the user code display go out,
so continue to carry out Operation A until it goes out.
If Operation A is carried out, it is possible to enter the machine data monitoring mode.
HD325-6 20-145
8
2) Method of changing display items in machine sition.) (Operation C) The system will then
data monitoring mode move to the next controller and display
• When the system enters the machine data the first item of data.
monitoring mode, it automatically dis- • After keeping mode change switch (2)
plays the first item (standard service pressed to the ON position for at least 2.5
meter) on the monitor panel (controller seconds, turn it OFF. (When it is released,
code: A). it will return automatically to the OFF po-
• To go on to the next item, keep mode sition.) (Operation E) The system will then
change switch (1) pressed to the ON posi- move to the previous controller and dis-
tion for 0.2 – 2.5 seconds, then turn it OFF. play the first item of data.
(When it is released, it will return automati- • For reference, see the diagram in Item 5)
cally to the OFF position.) (Operation B) showing the cycle of operation.
• To go back to the previous item, keep
mode change switch (2) pressed to the ON 4) Method for changing indicated items in
position for 0.2 – 2.5 seconds, then turn it reduced cylinder mode and method for
OFF. (When it is released, it will return setting reduced cylinder mode
automatically to the OFF position.) (Opera- (HD325-6 Serial No.: 6001 and up, HD405-
tion D)
6 Serial No.: 2001 and up)
• After keeping mode change switch (1)
(1) If the reduced cylinder mode is se-
pressed to the ON position for at least 2.5
seconds, turn it OFF. (When it is released, lected, the 1st cylinder is selected for
it will return automatically to the OFF po- the reduced cylinder mode first auto-
sition.) (Operation C) The system will then matically.
move to the next controller and display (2) To select the next cylinder, turn [ON]
the first item. the mode change switch (1) for 0.2 -
• After keeping mode change switch (2) 2.5, then turn it [OFF]. (Just release
pressed to the ON position for at least 2.5 this switch, and it returns to the [OFF]
seconds, turn it OFF. (When it is released, position automatically.) (Operation B)
it will return automatically to the OFF po- (3) To select the previous cylinder, turn
sition.) (Operation E) The system will then
[ON] the mode change switch (2) for
move to the previous controller and dis-
0.2 - 2.5, then turn it [OFF]. (Just re-
play the first item.
• For reference, see the following diagram lease this switch, and it returns to the
showing the cycle of operation. [OFF] position automatically.) (Opera-
tion D)
3) Method of changing display items in service (4) To set or cancel the reduced cylinder
code and trouble data display mode mode, press and hold the lamp check
• When the system enters the service code switch for at least 0.2 seconds, then
and trouble data display mode, it first dis- release it (For the lamp check switch,
plays the elapsed time since the latest de- see the section of display of the user
letion {see Item 3-2.1)}. Then it automati- codes).
cally displays the first item of trouble data
fl To see if each cylinder is selected for
on the monitor panel (controller code: A).
the reduced cylinder mode, see 3) DIS-
• If there are no trouble data in the monitor
panel memory, — — is displayed. PLAY OF REDUCED CYLINDER MODE
• To go on to the next item, keep mode OPERATION and 4) DISPLAY OF CON-
change switch (1) pressed to the ON posi- DITION OF REDUCED CYLINDER
tion for 0.2 – 2.5 seconds, then turn it OFF. MODE in 3.3.
(When it is released, it will return automati-
cally to the OFF position.) (Operation B)
• To go back to the previous item, mode
change switch (2) pressed to the ON posi-
tion for 0.2 – 2.5 seconds, then turn it OFF.
(When it is released, it will return automati-
cally to the OFF position.) (Operation D)
• After keeping mode change switch (1)
pressed to the ON position for at least 2.5
seconds, turn it OFF. (When it is released,
it will return automatically to the OFF po-
20-146 HD325-6
8
5) Table of methods of operating switches

Name of Method of operation Function
operation
Switches display mode
{See diagram for operation cycle for
service mode in Section 3.3-1)
Keep switches (1) and (2)

pressed to the ON position
at the same time for at least
0.2 seconds
Advances to next display item in-
side same mode
{See diagram for operation cycle in
Section 3.4-5)}
(In the machine data monitoring
mode go to the next monitoring
B item; in the trouble data display, go
to the next service code.)
Keep switch (1) (red)

pressed to the ON posi-
tion for 0.2 – 2.5 seconds
Advances to next display control-

ler inside same mode
{See diagram for operation cycle
in Section 3.4-5)}
Keep switch (1) (red)

for at least 2.5 seconds
Goes back to previous display item
inside same mode
(In the machine data monitoring
mode, it goes back to the previous
monitoring item; in the trouble data
display, it goes back to the previ-
ous service code.)
D
in Section 3.4-5)}
Keep switch (2) (black)

tion for 0.2 – 2.5 seconds
HD325-6 20-147
8
Name of Method of operation Function

operation
Goes back to previous display con-
troller inside same mode
in Section 3.4-5)}
Keep switch (2) (black)

for at least 2.5 seconds
Deletes failure data from memory
inside service code and trouble
data display mode
{For details, see 3.4-6) Method of
deleting trouble data from
memory}
F
Keep switches (1) and (2)

tion at the same time for
at least 5 seconds
20-147-1 HD325-6
8
6) Cycle diagram for machine data monitoring mode and service code, trouble data display mode
fl This chart displays the method for operations B to E.

fl In the first item, only the machine data monitoring mode moves to the final item with Operation
D (ª), but in the service code and trouble data display mode, the display does not change (it does
not move to the final item).
fl For details of the controller codes marked , see Controller codes (ª1) in Item 3-1.
20-148 HD325-6
8
Example 1) Checking that fill signal for 2nd clutch is correctly recognized by transmission controller
Operation of machine Operation of mode change switch Monitor panel display
Turn starting switch ON Normal mode is displayed after 3 seconds

↓ Normal mode remains displayed
Start engine
→ Operation A Monitor panel item code 1 (standard service meter)
(Switch mode and enter ser- of machine data monitoring mode is displayed
vice mode)
↓
Operation C Transmission controller item code 1 (model recogni-
(Go to next controller) tion) of machine data monitoring mode is displayed
↓
Operation B Transmission controller item code 2 (service meter)
(Go to next item code) of machine data monitoring mode is displayed
↓
Operation B Transmission controller item code 3 (switch check)
(Go to next item code) of machine data monitoring mode is displayed
↓
Operation B Transmission controller item code 4 (fill signal
(Go to next item code) check) of machine data monitoring mode is dis-
played
↓
Check that parking brake and Shifts to F2. L clutch (bit No. 1) and 2nd clutch (bit
retarder brake are applied, No. 5) are engaged and applicable portion lights up
then operate shift lever to D
position
Return shift lever to N L clutch (bit No. 1) and 2nd clutch (bit No. 5) are
position disengaged and applicable portion goes out
→ Operation A After elapsed time since deletion operation is dis-

(Switch mode and enter ser- played (2 seconds), displays Item 1 of transmis-
vice code, trouble data dis- sion controller trouble data in service code, trouble
play mode) data display mode
↓
Operation A Displays normal mode
(Switch mode and return to
normal mode)
fl At any stage in the above process, if the starting switch is turned OFF, and then ON again, the
monitor panel will return to the normal display (normal mode).
fl While the system is in the service mode, if the monitor panel or other controller detects any failure,
the system will automatically return to the normal mode and display the user code.
HD325-6 20-149
1
Example 2) Checking trouble data in engine controller memory
Operation of machine Operation of mode change switch Monitor panel display
Turn starting switch ON Normal mode is displayed after all display lights
up for 3 seconds
→ Operation A Monitor panel item code 1 (standard service meter)
(Switch mode and enter ser- of machine data monitoring mode is displayed
vice mode)
↓
Operation A After elapsed time from deletion operation is dis-
(Switch mode and enter ser- played (2 seconds), displays monitor panel trouble
vice code, trouble data dis- data No. 1 of service code, trouble data display
play mode) mode
↓
Operation C Displays transmission controller trouble data No.
(Go to next controller) 1 of service code, trouble data display mode
↓
Operation C Displays engine controller trouble data No. 1 of
(Go to next controller) service code, trouble data display mode
↓
Operation B Displays transmission controller trouble data No.
(Go to next item code) 2 of service code, trouble data display mode
↓
Operation A Displays normal mode
(Switch mode and return to
normal mode)
fl At any stage in the above process, if the start- monitor panel will judge that it is operation
ing switch is turned OFF, and then ON again, A and the system will return to the normal
the monitor panel will return to the normal dis- mode without deleting the data from
play (normal mode). memory.
fl While the system is in the service mode, if the If the data is deleted correctly, the system
monitor panel or other controller detects any fail- will automatically switch to the next trouble
ure, the system will automatically return to the data display, so the deletion operation can
normal mode and display the user code. be checked. If all the trouble data inside the
7) Method of deleting trouble data from controller are deleted, “– –” is displayed, so
memory the completion of the deletion operation
In the service code and trouble data display can be checked.
mode, it is possible to delete the displayed 2) If you enter the service mode or operate
trouble data from memory. However, the mode change switch (1) or (2) in order to
data for currently existing problems cannot switch something in the service mode, if it
be deleted. overlaps the timing of detection of occur-
(Method of deletion) rence or restoration of a failure on the moni-
Enter the service code and trouble data dis- tor panel or controllers, it may take time for
play mode, and display the trouble data that the service mode display to switch. In such
is to be deleted. cases, return to the normal mode and try
Press mode change switches (1) and (2) to again.
the ON position at the same time for at least
5 seconds, then turn them off (Operation F).
The display trouble data will be deleted from
memory and the display will automatically
switch to the next trouble data.
When the deletion operation is carried out,
the elapsed time is reset and starts again
from 0, so if necessary, note down the
elapsed time before deleting any item.
3.5 Precautions when operating service mode

1) When deleting the trouble data from
memory, if mode change switches (1) and
(2) are not kept pressed to the ON position
at the same time for at least 5 seconds, the
20-150 HD325-6
8
3.6 Monitoring items in machine data monitoring mode

Monitoring item values are useful when-cheking or troubleshooting the machine.
fl For details of the method for going on to the next monitor item (or going back to the previous monitor item)
in the machine data monitoring mode, see 3.3 Method of operating service mode.
Control- Monitor Item Display unit Remarks
ler code item code
Monitor panel
1 Standard service meter 10h After 10000h, shows units of 100h, and left turn signal lamp lights up
2 Switch check ª1 The 1), 2), etc. in the item corresponds to the bit number. When ON,
applicable bit number lights up, See Table 1-a (ª1-a)
1) KPH/MPH selector signal ON/OFF ON: MPH displayed
A 2) Exhaust brake switch ON/OFF Only when exhaust brake is installed
3) AISS switch ON/OFF
4) Mode selector switch 1 ON/OFF
5) Mode selector switch 2 ON/OFF
3 Rotary switch setting 0–F Applicable item in Table 1-b lights up (ª1-b)
1 Model recognition ª2 See Table 2 (ª2)
2 Service meter 10h For details, see Item 3) Service meter for each controller (ª5)
After 10000h, shows units of 100h, and left turn signal lamp lights up
applicable bit number lights up. See Table 1-a (ª1-a)
1) Body seated switch ON/OFF ON: When not seated
2) Not used —
3) Not used —
4) Not used —
5) Not used —
6) Not used —
7) Not used —
8) Spare —
9) Not used —
10) Model selection signal 1 ON/OFF OFF : OPEN
13) Model selection signal 4 ON/OFF ON : GND
14) Connector check 1 ON/OFF OFF : OPEN
15) Connector check 2 ON/OFF ON : GND
16) Emergency escape switch ON/OFF
17) Starting switch ON/OFF ON : When cranking (START position)
4 Fill signal switch ª1 The 1), 2), etc. in the item corresponds to the bit number. When ON, applicable bit number
lights up. See Table 1-a (ª1-a) For details of the relationship between the speed range and the
clutches, see ECMV Clutch Actuation Table in the section on the transmission valve.
1) L clutch ON/OFF
2) Spare —
3) H clutch ON/OFF
4) 1st clutch ON/OFF
5) 2nd clutch ON/OFF
6) 3rd clutch ON/OFF
b 7) 4th clutch ON/OFF
8) R clutch ON/OFF
5 Engine speed 10rpm
6 Transmission input shaft speed 10rpm
7 Transmission intermediate shaft speed 10rpm
8 Transmission output shaft speed 10rpm
9 Accelerator sensor 0.02 V When at Li : 180–200, when at Hi : 50–70
10 Brake air pressure ª3 See Table 3 (ª3)
11 Spare —
12 Spare —
13 Rear brake cooling oil temperature 1˚C Lo display when less than 60˚C, see Table 4 (ª4)
14 Engine water temperature 1˚C Lo display when less than 60oC (mechanical governor specification machine only), see Table 4 (ª4)
15 Torque converter outlet port oil temperature 1˚C Lo display when less than 60˚C, see Table 4 (ª4)
16 Fuel level 1Ω 4 – 100 (Full: Less than 13; EMPTY: More than 75)
17 Spare —
18 ECMV oil temperature 1˚C Lo display when less than 60oC, see Table 4 (ª4)
19 Spare —
20 Spare —
21 Spare —
22 Engine oil pressure 9.81kPa{0.1kg/cm2} Mechanical governor specification machine only
23 Max. speed range 4 –7 4 – 7: F4 – F7 (no limit)
24 Max. speed range (when body is raised) 0–3 1 – 3: F1 – F3, 0: default (F2 only when lever is at D, F1 only when lever is at position other than D)
25 Caution setting (when body is raised) 1 or 2 1: OFF, 2: ON,
26 Spare —
27 Solenoid H output 4 mmA When actuated : 139–144
28 Solenoid L output 4 mmA When actuated : 150–156
29 Solenoid 1 output 4 mmA When actuated : 203–211
33 Spare —
34 Spare —
HD325-6 20-151
8
Control- Monitor Item Display unit Remarks

ler code item code
Engine controller
1 Spare 10h
2 Engine speed 10rpm
3 Acceleration sensor 1% At Li: 0, At Hi: 100
4 Spare 1%
5 Acceleration sensor 0.01 V At Li: 0.3 – 0.55, At Hi: 3.55 – 4.55
6 Fuel temperature 1 ˚C
7 Target fuel injection rate 1 mm3
8 Target common rail pressure 1 MPa
9 Target fuel injection timing 1˚
C
10 Common rail pressure 1 MPa
11 Boost pressure 1 MPa
12 Operation mode 0 – 255
13 Engine water temperature 1 ˚C
(Sensor for high temperature)
14 Engine water temperature 1 ˚C
(Sensor for low temperature)
15 Converted torque 1%
16 Q adjustment switch 1–F
Suspension controller
1 Service meter 10h For details, see Item 3) Service meter for each controller (ª5)
After 10000h, shows units of 100h, and left turn signal lamp lights up
applicable bit number lights up, See Table 1-a (ª1-a)
1) Auto suspension solenoid 1 output ON/OFF ON : When at M mode or H mode
2) Auto suspension solenoid 2 output ON/OFF ON : When at M mode
3) Auto suspension solenoid 3 output ON/OFF ON : When at S mode or H mode
4) Rear brake ON/OFF
5) Body FLOAT switch ON/OFF ON: GND (when not at FLOAT position)
d 6) Body selection switch ON/OFF ON: GND (HD465) OFF: OPEN (HD605)
3 Suspension pressure (left) 0.098MPa{1kg/cm2} (ª6)
4 Suspension pressure (right) 0.098MPa{1kg/cm2} (ª6)
5 Steering angle speed 1 rpm
6 Spare —
7 Spare —
8 Spare —
9 Spare —
10 Spare —
11 Transmission output shaft speed 10 rpm
• Items marked “Not used” in the Item column are used for other models.
20-152 HD325-6
8
Table 1-a Bit number (ª1-a)

Of the machine data monitoring mode items, with the displays for the switch checks (monitor
panel item code 2, transmission controller 3, 4, engine controller 2, suspension controller 2),
the values 1), 2), 3)... with each signal in the item corrspond to the number of each pin in the
chart below.
Table 1-b Rotary switch set (ª1-b)
HD325-6 20-153
6
fl When it is difficult to judge which bit number is lighted up (in particular, numbers 3 and 8 or 5 and
14), it is possible to press the burned-out bulb check switch (1) to light up all the segments and
check the bit position.
Table 2 Controller model recognition (ª2)
Model display value Model display value

for machine data Machine specification for machine data Machine specification
monitoring mode monitoring mode
325 HD325/405 mechanical governor 785 HD785 mechanical governor
32b HD325/405 electronic governor 78b HD785 electronic governor
465 HD465/605 electronic governor 985 HD985 mechanical governor
98b HD985 electronic governor
Table 3 Pressure display of brake air pressure sensor (ª3)

The brake air pressure sensor is not an analog output but a level output, so the value for the
pressure display corresponding to the air pressure level display is the fixed value in the table
below.
Pressure display value in machine data monitoring mode MPa {kg/cm2}

Caution level Gauge level When pressure is rising and at When pressure is rising and at
present level present level
Red 7 0.932 {9.5}
Green 6 0.814 {8.3} 0.912 {9.3}
Green 5 0.716 {7.3} 0.794 {8.1}
Green 4 0.618 {6.3} 0.696 {7.1}
Green 3 0.510 {5.2} 0.598 {6.1}
Red 2 0.245 {2.5} 0.510 {5.2}
Red 1 0 {0} 0.226 {2.3}
20-153-1 HD325-6
8
Table 4 Example of display (torque converter

outlet port oil temperature) (ª4)
fl This shows that item code 15 (torque
converter outlet port oil temperature)
on the transmission controller (con-
troller code b) is below 60˚C.
3) Service meter for each controller (ª5)
The service meter holds individual val-
ues for each controller and those val-
ues are displayed. However, basically,
the values are the same for all con-
trollers. However, if the controller is
replaced with a new controller, the
service meter for that controller will
have lower values than the other con-
trollers.
In such cases, the service meter used
for the time of occurrence of a trouble
data display is standardized as the
standard time for the network system
(service meter on the monitor panel).
Therefore, even if a controller is re-
placed with a new part, when the fail-
ure detected by the controller is dis-
played, the service meter display is
the standard time for the network sys-
tem, so there is no difference from the
other controllers.
4) Pressure display value (ª6)
To obtain the SI unit (kPa, MPa), mul-
tiply the displayed value by a coeffi-
cient of 9.81 (0.0981).
(With a coefficient of 0.1(1), the value
is equivalent to the non-SI unit of kg/
cm2.)
HD325-6 20-153-2
6
SELF-DIAGNOSTIC DISPLAY METHOD FOR
TROUBLESHOOTING MONITOR PANEL AND CONTROLLERS
SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL

AND CONTROLLERS
fl For details of the display on the monitor panel, see Monitor panel user code and service mode function.
1. MONITOR PANEL
After the starting switch is turned ON, the monitor itself carries out self-diagnosis. After that, it goes
to the normal display.
Check the bulbs of the pilot and caution lamps by pressing the switch at the right edge of the panel.
fl For details of the service codes, see SERVICE CODE TABLE.
2. TRANSMISSION CONTROLLER
1) Self-diagnostic display, warning display
The content of the self-diagnosis and warning is displayed by a 2-digit LED code.
..... If any abnormality is detected during self-diagnosis, the abnormality occurrence data is sent
to the network and the user code is displayed on the monitor panel. The mechatronics abnor-
mality display on the monitor panel may also light up and the warning lamp and buzzer may
also be actuated.
..... The warning display is the detection of failures in the pilot lamp display sensor systems and
warnings and warning actuations. If problems are detected, the warning lamp and buzzer
may also be actuated.
Self-diagnostic display code table
Actuation of
Abnormal system Display code Re-enaction controller
Defective controller power source system 0.1, d.A

0.2, d.b
Neutral safety 0.3
Defective controller system 0.4

0.5
Defective transmission cut relay system 0.6
Defective rear brake solenoid system 0.8
Defective exhaust brake solenoid system 0.9
Defective engine speed sensor system 1.0, 6.0
Defective transmission input shaft speed sensor system 1.1, 6.1
Defective transmission intermediate shaft speed
sensor system 1.2, 6.2
Defective transmission output shaft speed sensor system 1.3, 6.3

Clutch slipping or defective speed sensor system 2. ←2–8
Defective model selection signal system 1.4, A.1
0.7
Defective shift lever system 1.5
1.6
Defective accelerator sensor system 1.7
Defective transmission valve oil temperature sensor system 1.9
3. ←2–8
Defective pressure control valve system
4. ←2–8
Defective oil flow control valve system 5. ←2–8
7. ←1–8
Defective pressure control solenoid system
9. ←1–8
A.2, A.3
Defective monitor panel display sensor system b.3, b.4
b.2, b.7
Mistaken connector connection C.1
20-154 HD325-6
8
Warning display table

Actuation of
Abnormal system Display code Re-enaction controller
Pilot lamp warning

Transmission filter clogging d.1 — ( )
Tilt warning d.5 — ( )
Drop in radiator water level d.6 — ( )
Battery charge d.7 — ( )
Steering oil level (overheating) E.5 — ( )
Drop in engine oil pressure F.5
Drop in rear brake oil pressure F.6 — ( )
Actuation warning
Engine overrun prevention actuated d.8 —
Engine overshoot actuated d.9 —
Overheat warning
Torque converter oil temperature d.2 —
Retarder oil temperature d.3 —
Engine water temperature d.3 —
Pressure drop warning

Drop in air pressure d.9 —
Explanation of symbols: [ ] ← 1 – 8: indicates that there are display patterns from 1 to 8 that appear in
the [ ] portion.
1 : Lock-up clutch related parts
2 : H clutch related parts
3 : L clutch related parts
4 : 1st clutch related parts
5 : 2nd clutch related parts
6 : 3rd clutch related parts
7 : 4th clutch related
8 : R clutch related parts
: Blank (no display)
fl See the next page for explanation of the symbols used in the controller actuation column.
HD325-6 20-155
8
. Method of re-enacting failure display

Using the following procedure, it is possible to re-enact the abnormality display and carry out in-
spection.
0 System: Turn the starting switch OFF + ON.
q System: Turn the starting switch OFF -+ ON, and operate the lever slowly in turn to N, R, N, D,
5,4,3, L. (Stop for at least 3 seconds at each position, then go to the next position.)
n System: Set the lever to N and start the engine.
q System: Use the clutch specified in the failure display (set to the speed range using that
clutch) and carry out a travel test.
Display Applicable clutch Speed range
Either 7 or 9 0 .I Lock-up clutch L/U

(inside [ I) ,-
cl .2 H clutch F3, F5, F7
0 .3 L clutch Fl, F2, F4, F6
cl .4 1st clutch Fl
One of 2,3,4, 5, 2nd clutch F2, F3
0 -5
7,9 (inside [ I)
0 .6 3rd clutch F4, F5
0 .7 4th clutch F6, F7
0 .6 R clutch R
- (i$;;;;diate shaft F2
1.2
q System: Apply exhaust brake during travel test. (When traveling in lock-up, operate the brake
with the accelerator released)
( 0) System: System: If there is a failure in the sensor system, turn the starting switch OFF -+ ON.
. Operation of controller when abnormality is detected

If an abnormality is detected, the transmission controller displays the failure and carries out the
following action.
r a System: Transmission neutral -there is a failure in the power source or controller, so the
transmission is set to neutral.
A System: Transmission neutral -the electrical system on the machine and the controller may
be broken, so the controller automatically turns the output
OFF.
A System: Transmission neutral -there is probably a failure in the hydraulic or mechanical

system, so to avoid fatal damage to the transmission, the
controller automatically turns the output OFF.
A System: Speed range held, ------- because of the abnormal condition, the controller judges
but when lever is that it is impossible to shift gear, so it holds the speed range.
at N, N is held
A System: Travel possible, ----------- the controller automatically stops the functions in the ab-
but some functions normal system.
stopped
~ a System: Travel possible -----------the controller works normally.
ZO-156 HD325-6
0
2) Actuation mode display

The transmission controller always displays if the transmission is being controlled in the normal
temperature mode or in the low temperature mode.
Actuation mode displav
When normal When abnormality is detected
Normal temperature mode 0.0 After E. Ll is displayed, code is displayed to show abnormality
r ~~ Normal temperature mode I_ ~~0.c 1 After E.C is displayed, code is displayed to show abnormality )
3) Saving self-diagnostic display to memory

Once an abnormality is detected, even if the abnormality is removed, the self-diagnostic display
remains displayed for 5 minutes.
(However, the user code display on the monitor panel, the mechatronics abnormality display,
warning lamp, and buzzer stop when the abnormality is removed.)
l Even when two or more failures occur at the same time, all the abnormality occurrence data
are transmitted to the network and the self-diagnostic display is given.
Display method: The code display starts with the abnormalities that have occurred in order,
and after completing the display of the content of all the abnormalities, the
display returns to the first code display.
It continues to repeat this order. (If the abnormality is corrected, it returns
to the normal display 5 minutes after the abnormality is corrected.)
HD325-6 20- 157

0
4) Saving service code to memory

The transmission controller has a function to save the service code, time of occurrence (service
data) and number of occurrences to memory, and keep them in memory even after the starting
switch is turned OFF.
When the starting switch is turned ON, it is possible to check the details of the abnormalities that
have occurred up to that point with the trouble data display mode of the monitor panel service
function and the controller LEDs.
Method of saving and displaying service code (transmission controller LED display)
To make full use of the memory function to clearly display when the failure occurred and what
failures have already been corrected, keep strictly to the procedure given below.
• Deleting service code from memory

For details of the method of deletion, see Method of deleting trouble data from memory (page
20-150).
Carry out troubleshooting, and when the failure has been corrected and the self-diagnostic dis-
play has returned to normal, delete the transmission controller service codes from memory.
Turn the starting switch OFF, then turn it ON again, and check that the past failures in memory
have been deleted.
For details, see MONITOR PANEL USER CODES AND SERVICE MODE FUNCTION, Section 3.4-7
Method of deleting trouble data from memory (page 20-150).
(If the data have been deleted, 8.8 is displayed for 3 seconds, then the display shows the part
number, and after 3.5 seconds, the display returns to the normal display of 0.0 or 0.C)
20-158 HD325-6
8
3. ENGINE CONTROLLER, SUSPENSION CONTROLLER

fl The engine controller is applied to HD325-6(W) Serial No. 6001 and up and HD405-6 Serial No. 2001
and up.
The controller carries out self-diagnosis of the system and displays any abnormality.
The abnormality display shows a 2-digit service code with LEDs. When the condition is normal, it
displays 0 0. ...... it uses the network to light up the user code on the monitor panel and the
mechatronics abnormality display, and actuates the warning lamp and alarm buzzer.
2) Saving self-diagnostic display to memory
Once an abnormality is detected, even if the abnormality is corrected, the results of the self-diagno-
sis are saved in the controller memory, and can be displayed later on the monitor panel as the trouble
data. (For details, see MONITOR PANEL USER CODES AND MODE FUNCTION.)
fl For details of the service codes, see table of [user codes and service codes].
4. PAYLOAD METER
4.1 Payload meter (printer type)
1) Self-diagnostic when power is switched ON
When the payload meter power is switched ON, self-diagnosis is carried out for the display por-
tion and printer portion.
When this is done, if the system is normal, the display returns to the time display after the self-
diagnosis is carried out.
Note: The external display lamps are actuated as shown in the table when the dump lever is at
FLOAT.
Details of the self-diagnosis are displayed as a 2-digit code on the display panel (weight display
portion).
For a comparison of the details of the self-diagnosis and the failure codes, see table of [user
codes and service codes].
• If two or more abnormalities occur at the same time, they are displayed in order starting from
the lowest number.
• When an abnormality is detected and the failure code is displayed, the failure code remains
TOTAL
on display until the power is turned OFF or the switch is pressed.
SET
fl For details of the service codes, see Table of [user codes and service codes]. (When the condition
is normal, the system returns to the weight display or the time display.)
HD325-6 20-159
8
4.2 Payload meter II (card type)

1) Self-diagnostic when power is switched ON
When the payload meter power is switched ON, self-diagnosis is carried out for the display por-
tion.
When this is done, if the system is normal, the display returns to the normal operation display
after the self- diagnosis is carried out.
Details of the self-diagnosis are displayed as a 2-digit code on the display panel (weight display
portion).
For a comparison of the details of the self-diagnosis and the failure codes, see table of [user
codes and service codes].
• If two or more abnormalities occur at the same time, they are displayed in order starting from
the lowest number.
• When an abnormality is detected and the failure code is displayed, the failure code remains
on display until the power is turned OFF or the TOTAL switch is pressed.
SET
fl For details of the service codes, see Table of [user codes and service codes]. (When the condition
is normal, the system returns to the weight display or the time display.)
20-160 HD325-6
1
TROUBLESHOOTING TABLE OF SERVICE CODES AND USER CODES
TABLE OF SERVICE CODES AND USER CODES

1. TABLE OF SERVICE CODES AND USER CODES RELATED TO MONITOR PANEL
Monitor panel display
Service code
Other
When only lamp mechatro- Central
Display in warning
No. Details of failure check switch is
service code, User code nics
kept pressed for caution lamp
at least 2.5 sec trouble data
and then released display mode lamp
(Existing) (Existing) (Existing) (Existing) (Existing)
1 Short circuit in lamp output system A001 A000 02 ON FLASHES
2 Short circuit in central warning lamp output system A002 A000 02 ON FLASHES
3 Short circuit in alarm buzzer output system A003 A000 02 ON FLASHES
4 Connection data for network system does not match A012 A011 02 ON FLASHES
5 Abnormality in network system (transmission controller) A013 A011 02 ON FLASHES
6 Abnormality in network system (PMC) A014 A011 02 ON FLASHES
7 Abnormality in network system (engine controller) A015 A011 02 ON FLASHES
8 Abnormality in network system (suspension controller) A016 A011 02 ON FLASHES
9 Abnormality in model selection data A018 A011 04 ON FLASHES
10 Abnormality in option data A019 A011 04 ON FLASHES
Note 1: “Existing” means that the problem is still occurring; “Reset” means that the problem occurred in the past.
Note 2: If the problem is still existing, the alarm buzzer will also sound. (When the central warning lamp is FLASHES.)
2. SERVICE CODES AND USER CODES RELATED TO ENGINE CONTROLLER

Engine Central
No. Details of failure Service code User code mechatronics warning Controller LED display
caution lamp
lamp
(Existing, reset) (Existing) (Existing) (Existing) (Existing) (Reset)

1 Abnormality in Ne rotation sensor system C01b 02 ON FLASHES E. ↔ 1.b 1.b
2 Abnormality in G rotation sensor system C01C 02 ON FLASHES E. ↔ 1.C 1.C
3 Abnormal model selection C020 02 ON FLASHES E. ↔ 2.0 2.0
4 Overrun C022 03 OFF FLASHES E. ↔ 2.2 2.2
5 Overheating C023 05 OFF FLASHES E. ↔ 2.3 2.3
6 Low engine oil pressure C024 04 OFF FLASHES E. ↔ 2.4 2.4
7 Abnormality in idle validation signal system C030 01 OFF OFF E. ↔ 3.0 3.0
8 Abnormality in acceleration sensor system C031 02 ON FLASHES E. ↔ 3.1 3.1
9 Abnormality in water temperature (high temperature) sensor system C034 01 OFF OFF E. ↔ 3.4 3.4
10 Abnormality in engine oil pressure switch system C036 01 OFF OFF E. ↔ 3.6 3.6
11 Abnormality in boost pressure sensor system C03C 01 OFF OFF E. ↔ 3.C 3.C
12 Abnormality in fuel temperature sensor system C03d 01 OFF OFF E. ↔ 3.D 3.D
13 Abnormality in preheater relay contact system C050 02 ON FLASHES E. ↔ 5.0 5.0
14 Abnormality in preheater relay coil system C051 02 ON FLASHES E. ↔ 5.1 5.1
15 Short circuit in starting switch C-signal system C054 02 ON FLASHES E. ↔ 5.4 5.4
16 Abnormality in network C055 02 ON FLASHES E. ↔ 5.5 5.5
17 Abnormality in power supply system 1 C056 04 ON FLASHES E. ↔ 5.6 5.6
18 Abnormality in power supply system 2 C057 01 OFF OFF E. ↔ 5.7 5.7
19 Abnormality in Q adjustment switch signal system C05A 01 OFF OFF E. ↔ 5.A 5.A
20 Abnormality in water temperature (low temperature) sensor system C06A 01 OFF OFF E. ↔ 6.A 6.A
21 Overcurrent in fuel supply pump PCV1 system C070 02 ON FLASHES E. ↔ 7.0 7.0
22 Overcurrent in fuel supply pump PCV2 system C071 02 ON FLASHES E. ↔ 7.1 7.1
23 Disconnection in fuel supply pump PCV1 system C074 02 ON FLASHES E. ↔ 7.4 7.4
HD325-6 20-161
8
Engine Central
No. Details of failure Service code User code mechatronics warning Controller LED display
caution lamp
lamp
(Existing, reset) (Existing) (Existing) (Existing) (Existing) (Reset)

24 Disconnection in fuel supply pump PCV2 system C075 02 ON FLASHES E. ↔ 7.5 7.5
25 Abnormality in common rail fuel pressure sensor system C077 02 ON FLASHES E. ↔ 7.7 7.7
26 Abnormally high fuel pressure in common rail 1 C079 02 ON FLASHES E. ↔ 7.9 7.9
27 Abnormally high fuel pressure in common rail 2 C07A 04 ON FLASHES E. ↔ 7.A 7.A
28 Supply of no fuel by fuel supply pump 1 C07b 02 ON FLASHES E. ↔ 7.b 7.b
29 Supply of no fuel by fuel supply pump 2 C07C 04 ON FLASHES E. ↔ 7.C 7.C
30 Abnormal fuel pressure in common rail C07d 02 ON FLASHES E. ↔ 7.d 7.d
31 Defective controller C080 04 ON FLASHES E. ↔ 8.0 8.0
32 Disconnection in No. 1 fuel injector system C081 02 ON FLASHES E. ↔ 8.1 8.1
38 Short circuit in No. 1, No. 2, No. 3 fuel injector systems C08A 02 ON FLASHES E. ↔ 8.A 8.A
39 Short circuit in No. 4, No. 5, No. 6 fuel injector systems C08b 02 ON FLASHES E. ↔ 8.b 8.b
Note 3: For details of the method of display of the service code for reset failures on the monitor panel, see MONITOR PANEL
USER CODE AND SERVICE MODE FUNCTION, Section 3.2 SERVICE CODE AND TROUBLE DATA DISPLAY MODE in the
Foreword to the Troubleshooting Section.
3. TABLE OF SERVICE CODES AND USER CODES RELATED TO TRANSMISSION CONTROLLER

HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
Monitor panel display Controller LED display
Automatic Transmission oil

gearshifting Central temperature
Service code User
No. Details of failure code mechatronics warning
caution lamp
lamp
15˚ or Below
above 15˚
(Existing, reset) (Existing) (Existing) (Existing) (Existing) (Existing) (Reset)
1 Abnormality in battery power source voltage system b001 04 ON FLASHES E. ↔ 0.1 E.C ↔ 0.1 0.1
2 Abnormality in solenoid power source system b002 04 ON FLASHES E. ↔ 0.2 E.C ↔ 0.2 0.2
3 Abnormality in neutral safety system b003 — ON FLASHES E. ↔ 0.3 E.C ↔ 0.3 0.3
4 Double engagement of clutches b005 04 ON FLASHES E. ↔ 0.5 E.C ↔ 0.5 0.5
5 Abnormality in transmission cut relay b006 04 ON FLASHES E. ↔ 0.6 E.C ↔ 0.6 0.6
6 Abnormality in shift lever assembly power source (12V) b007 04 ON FLASHES E. ↔ 0.7 E.C ↔ 0.7 0.7
7 Abnormality in engine overrun solenoid system b008 02 ON FLASHES E. ↔ 0.8 E.C ↔ 0.8 0.8
8 Abnormality in exhaust brake solenoid system b009 02 ON FLASHES E. ↔ 0.9 E.C ↔ 0.9 0.9
9 Disconnection in engine speed sensor system b010 02 ON FLASHES E. ↔ 1.0 E.C ↔ 1.0 1.0
10 Disconnection in transmission input shaft speed sensor system b011 02 ON FLASHES E. ↔ 1.1 E.C ↔ 1.1 1.1
11 Disconnection in transmission intermediate shaft speed sensor system b012 02 ON FLASHES E. ↔ 1.2 E.C ↔ 1.2 1.2
12 Disconnection in transmission output shaft speed sensor system b013 02 ON FLASHES E. ↔ 1.3 E.C ↔ 1.3 1.3
13 Abnormality in model selection signal system b014 04 ON FLASHES E. ↔ 1.4 E.C ↔ 1.4 1.4
14 Multiple input of shift lever signal b015 02 ON FLASHES E. ↔ 1.5 E.C ↔ 1.5 1.5
15 Disconnection in shift lever signal b016 02 ON FLASHES E. ↔ 1.6 E.C ↔ 1.6 1.6
20-162 HD325-6
8

Service code User
caution lamp
lamp
15˚ or Below
above 15˚
16 Abnormality in accelerator signal b017 02 ON FLASHES E. ↔ 1.7 E.C ↔ 1.7 1.7
17 Abnormality in transmission valve oil temperature sensor system b019 02 ON FLASHES E. ↔ 1.9 E.C ↔ 1.9 1.9
18 Abnormality in H clutch system b022 02 ON FLASHES E. ↔ 2.2 E.C ↔ 2.2 2.2
19 Abnormality in L clutch system b023 02 ON FLASHES E. ↔ 2.3 E.C ↔ 2.3 2.3
20 Abnormality in 1st clutch system b024 02 ON FLASHES E. ↔ 2.4 E.C ↔ 2.4 2.4
21 Abnormality in 2nd clutch system b025 02 ON FLASHES E. ↔ 2.5 E.C ↔ 2.5 2.5
22 Abnormality in 3rd clutch system b026 02 ON FLASHES E. ↔ 2.6 E.C ↔ 2.6 2.6
23 Abnormality in 4th clutch system b027 02 ON FLASHES E. ↔ 2.7 E.C ↔ 2.7 2.7
24 Abnormality in R clutch system b028 02 ON FLASHES E. ↔ 2.8 E.C ↔ 2.8 2.8
25 Abnormality 1 in pressure control valve system for H clutch b032 02 ON FLASHES E. ↔ 3.2 E.C ↔ 3.2 3.2
26 Abnormality 1 in pressure control valve system for L clutch b033 02 ON FLASHES E. ↔ 3.3 E.C ↔ 3.3 3.3
27 Abnormality 1 in pressure control valve system for 1st clutch b034 02 ON FLASHES E. ↔ 3.4 E.C ↔ 3.4 3.4
28 Abnormality 1 in pressure control valve system for 2nd clutch b035 02 ON FLASHES E. ↔ 3.5 E.C ↔ 3.5 3.5
29 Abnormality 1 in pressure control valve system for 3rd clutch b036 02 ON FLASHES E. ↔ 3.6 E.C ↔ 3.6 3.6
30 Abnormality 1 in pressure control valve system for 4th clutch b037 02 ON FLASHES E. ↔ 3.7 E.C ↔ 3.7 3.7
31 Abnormality 1 in pressure control valve system for R clutch b038 02 ON FLASHES E. ↔ 3.8 E.C ↔ 3.8 3.8
39 Abnormality in oil flow detection valve system for H clutch b052 02 ON FLASHES E. ↔ 5.2 E.C ↔ 5.2 5.2
40 Abnormality in oil flow detection valve system for L clutch b053 02 ON FLASHES E. ↔ 5.3 E.C ↔ 5.3 5.3
41 Abnormality in oil flow detection valve system for 1st clutch b054 02 ON FLASHES E. ↔ 5.4 E.C ↔ 5.4 5.4
42 Abnormality in oil flow detection valve system for 2nd clutch b055 02 ON FLASHES E. ↔ 5.5 E.C ↔ 5.5 5.5
43 Abnormality in oil flow detection valve system for 3rd clutch b056 02 ON FLASHES E. ↔ 5.6 E.C ↔ 5.6 5.6
44 Abnormality in oil flow detection valve system for 4th clutch b057 02 ON FLASHES E. ↔ 5.7 E.C ↔ 5.7 5.7
45 Abnormality in oil flow detection valve system for R clutch b058 02 ON FLASHES E. ↔ 5.8 E.C ↔ 5.8 5.8
46 Abnormality in engine speed sensor system b060 02 ON FLASHES E. ↔ 6.0 E.C ↔ 6.0 6.0
47 Abnormality in transmission input shaft speed sensor system b061 02 ON FLASHES E. ↔ 6.1 E.C ↔ 6.1 6.1
48 Abnormality in transmission intermediate shaft speed sensor system b062 02 ON FLASHES E. ↔ 6.2 E.C ↔ 6.2 6.2
49 Abnormality in transmission output shaft speed sensor system b063 02 ON FLASHES E. ↔ 6.3 E.C ↔ 6.3 6.3
50 Short circuit in lock-up clutch solenoid system b071 02 ON FLASHES E. ↔ 7.1 E.C ↔ 7.1 7.1
51 Short circuit in H clutch solenoid b072 02 ON FLASHES E. ↔ 7.2 E.C ↔ 7.2 7.2
52 Short circuit in L clutch solenoid b073 02 ON FLASHES E. ↔ 7.3 E.C ↔ 7.3 7.3
53 Short circuit in 1st clutch solenoid b074 02 ON FLASHES E. ↔ 7.4 E.C ↔ 7.4 7.4
54 Short circuit in 2nd clutch solenoid b075 02 ON FLASHES E. ↔ 7.5 E.C ↔ 7.5 7.5
55 Short circuit in 3rd clutch solenoid b076 02 ON FLASHES E. ↔ 7.6 E.C ↔ 7.6 7.6
56 Short circuit in 4th clutch solenoid b077 02 ON FLASHES E. ↔ 7.7 E.C ↔ 7.7 7.7
57 Short circuit in R clutch solenoid b078 02 ON FLASHES E. ↔ 7.8 E.C ↔ 7.8 7.8
58 Disconnection in lock-up clutch solenoid system b091 02 ON FLASHES E. ↔ 9.1 E.C ↔ 9.1 9.1
59 Disconnection in H clutch solenoid b092 02 ON FLASHES E. ↔ 9.2 E.C ↔ 9.2 9.2
60 Disconnection in L clutch solenoid b093 02 ON FLASHES E. ↔ 9.3 E.C ↔ 9.3 9.3
61 Disconnection in 1st clutch solenoid b094 02 ON FLASHES E. ↔ 9.4 E.C ↔ 9.4 9.4
62 Disconnection in 2nd clutch solenoid b095 02 ON FLASHES E. ↔ 9.5 E.C ↔ 9.5 9.5
63 Disconnection in 3rd clutch solenoid b096 02 ON FLASHES E. ↔ 9.6 E.C ↔ 9.6 9.6
HD325-6 20-163
8

Service code User
caution lamp
lamp
15˚ or Below
above 15˚
64 Disconnection in 4th clutch solenoid b097 02 ON FLASHES E. ↔ 9.7 E.C ↔ 9.7 9.7
65 Disconnection in R clutch solenoid b098 02 ON FLASHES E. ↔ 9.8 E.C ↔ 9.8 9.8
66 Abnormality in model selection system rotary switch b0A1 04 ON FLASHES E. ↔ A.1 E.C ↔ A.1 A.1
67 Abnormality in torque converter oil temperature sensor system b0A2 02 ON FLASHES E. ↔ A.2 E.C ↔ A.2 A.2
68 Abnormality in fuel sensor system b0A3 02 ON FLASHES E. ↔ A.3 E.C ↔ A.3 A.3
69 Abnormality in cooling water temperature sensor system b0b2 02 ON FLASHES E. ↔ b.2 E.C ↔ b.2 b.2
70 Abnormality in air pressure sensor system b0b3 02 ON FLASHES E. ↔ b.3 E.C ↔ b.3 b.3
71 Abnormality in retarder brake oil level sensor (right) system b0b4 02 ON FLASHES E. ↔ b.4 E.C ↔ b.4 b.4
72 Abnormality in engine oil pressure sensor system b0b7 04 ON FLASHES E. ↔ b.7 E.C ↔ b.7 b.7
73 Abnormality in connector connection b0C1 04 ON FLASHES E. ↔ C.1 E.C ↔ C.1 C.1
74 Transmission filter clogging warning b0d1 01 OFF FLASHES E. ↔ d.1 E.C ↔ d.1 d.1
75 Torque converter oil temperature overheat warning b0d2 05 OFF FLASHES(ª) E. ↔ d.2 E.C ↔ d.2 d.2
76 Engine water temperature overheat warning b0d3 05 OFF FLASHES E. ↔ d.3 E.C ↔ d.3 d.3
77 Tilt warning b0d5 07 OFF FLASHES E. ↔ d.5 E.C ↔ d.5 d.5
78 Radiator water level drop warning b0d6 01 OFF FLASHES E. ↔ d.6 E.C ↔ d.6 d.6
79 Abnormality in charging circuit system b0d7 01 ON FLASHES(ª) E. ↔ d.7 E.C ↔ d.7 d.7
80 Engine overrun prevention brake actuated b0d8 03 OFF FLASHES E. ↔ d.8 E.C ↔ d.8 d.8
81 Engine overshoot b0d9 02 ON FLASHES E. ↔ d.9 E.C ↔ d.9 d.9
82 Drop in battery direct power source voltage b0dA 04 ON FLASHES E. ↔ d.A E.C ↔ d.A d.A
83 Drop in main power source voltage b0db 04 ON FLASHES E. ↔ d.b E.C ↔ d.b d.b
84 Steering oil temperature overheat warning b0E5 05 OFF FLASHES E. ↔ E.5 E.C ↔ E.5 E.5
85 Drop in air pressure b0E9 05 OFF FLASHES E. ↔ E.9 E.C ↔ E.9 E.9
86 Retarder overheat warning b0F3 05 OFF FLASHES E. ↔ F.3 E.C ↔ F.3 F.3
87 Drop in engine oil pressure b0F5 04 OFF FLASHES E. ↔ F.5 E.C ↔ F.5 F.5
88 Abnormality in brake circuit system b0F6 04 OFF FLASHES E. ↔ F.6 E.C ↔ F.6 F.6
For items marked ª, the alarm buzzer does not sound.
Note 3: Reset failures are kept as existing failures for 5 minutes by the transmission controller only; after that, they are saved
as a service code for past failures.
USER CODE AND SERVICE MODE FUNCTION, Section 3.2 SERVICE CODE AND TROUBLE DATA DISPLAY MODE in
the Foreword to the Troubleshooting Section. For the method of displaying with the transmission controller LED
display, see SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL AND CONTROLLERS, Section 2.4 SAVING
SERVICE CODE TO MEMORY in the Foreword to the Troubleshooting Section.
20-163-1 HD325-6
8


User gearshifting Central temperature
No. Details of failure Service code mechatronics warning
code lamp
caution
lamp
15˚ or Below
above 15˚
1 Abnormality in battery power source voltage system b001 04 ON FLASHES E. ↔ 0.1 E.C ↔ 0.1 0.1
2 Abnormality in solenoid power source system b002 04 ON FLASHES E. ↔ 0.2 E.C ↔ 0.2 0.2
3 Abnormality in neutral safety system b003 — ON FLASHES E. ↔ 0.3 E.C ↔ 0.3 0.3
4 Double engagement of clutches b005 04 ON FLASHES E. ↔ 0.5 E.C ↔ 0.5 0.5
5 Abnormality in transmission cut relay b006 04 ON FLASHES E. ↔ 0.6 E.C ↔ 0.6 0.6
6 Abnormality in shift lever assembly power source (12V) b007 04 ON FLASHES E. ↔ 0.7 E.C ↔ 0.7 0.7
7 Abnormality in engine overrun solenoid system b008 02 ON FLASHES E. ↔ 0.8 E.C ↔ 0.8 0.8
8 Abnormality in exhaust brake solenoid system b009 02 ON FLASHES E. ↔ 0.9 E.C ↔ 0.9 0.9
9 Disconnection in engine speed sensor system b010 02 ON FLASHES E. ↔ 1.0 E.C ↔ 1.0 1.0
10 Disconnection in transmission input shaft speed sensor system b011 02 ON FLASHES E. ↔ 1.1 E.C ↔ 1.1 1.1
11 Disconnection in transmission intermediate shaft speed sensor system b012 02 ON FLASHES E. ↔ 1.2 E.C ↔ 1.2 1.2
12 Disconnection in transmission output shaft speed sensor system b013 02 ON FLASHES E. ↔ 1.3 E.C ↔ 1.3 1.3
13 Abnormality in model selection signal system b014 04 ON FLASHES E. ↔ 1.4 E.C ↔ 1.4 1.4
14 Multiple input of shift lever signal b015 02 ON FLASHES E. ↔ 1.5 E.C ↔ 1.5 1.5
15 Disconnection in shift lever signal b016 02 ON FLASHES E. ↔ 1.6 E.C ↔ 1.6 1.6
16 Abnormality in accelerator signal b017 02 ON FLASHES E. ↔ 1.7 E.C ↔ 1.7 1.7
17 Abnormality in transmission valve oil temperature sensor system b019 02 ON FLASHES E. ↔ 1.9 E.C ↔ 1.9 1.9
18 Abnormality in H clutch system b022 02 ON FLASHES E. ↔ 2.2 E.C ↔ 2.2 2.2
19 Abnormality in L clutch system b023 02 ON FLASHES E. ↔ 2.3 E.C ↔ 2.3 2.3
20 Abnormality in 1st clutch system b024 02 ON FLASHES E. ↔ 2.4 E.C ↔ 2.4 2.4
21 Abnormality in 2nd clutch system b025 02 ON FLASHES E. ↔ 2.5 E.C ↔ 2.5 2.5
22 Abnormality in 3rd clutch system b026 02 ON FLASHES E. ↔ 2.6 E.C ↔ 2.6 2.6
23 Abnormality in 4th clutch system b027 02 ON FLASHES E. ↔ 2.7 E.C ↔ 2.7 2.7
24 Abnormality in R clutch system b028 02 ON FLASHES E. ↔ 2.8 E.C ↔ 2.8 2.8
39 Abnormality in oil flow detection valve system for H clutch b052 02 ON FLASHES E. ↔ 5.2 E.C ↔ 5.2 5.2
40 Abnormality in oil flow detection valve system for L clutch b053 02 ON FLASHES E. ↔ 5.3 E.C ↔ 5.3 5.3
41 Abnormality in oil flow detection valve system for 1st clutch b054 02 ON FLASHES E. ↔ 5.4 E.C ↔ 5.4 5.4
42 Abnormality in oil flow detection valve system for 2nd clutch b055 02 ON FLASHES E. ↔ 5.5 E.C ↔ 5.5 5.5
43 Abnormality in oil flow detection valve system for 3rd clutch b056 02 ON FLASHES E. ↔ 5.6 E.C ↔ 5.6 5.6
44 Abnormality in oil flow detection valve system for 4th clutch b057 02 ON FLASHES E. ↔ 5.7 E.C ↔ 5.7 5.7
45 Abnormality in oil flow detection valve system for R clutch b058 02 ON FLASHES E. ↔ 5.8 E.C ↔ 5.8 5.8
HD325-6 20-163-2
8

Service code User
caution lamp
lamp
15˚ or Below
above 15˚
46 Abnormality in engine speed sensor system b060 02 ON FLASHES E. ↔ 6.0 E.C ↔ 6.0 6.0
47 Abnormality in transmission input shaft speed sensor system b061 02 ON FLASHES E. ↔ 6.1 E.C ↔ 6.1 6.1
48 Abnormality in transmission intermediate shaft speed sensor system b062 02 ON FLASHES E. ↔ 6.2 E.C ↔ 6.2 6.2
49 Abnormality in transmission output shaft speed sensor system b063 02 ON FLASHES E. ↔ 6.3 E.C ↔ 6.3 6.3
50 Short circuit in lock-up clutch solenoid system b071 02 ON FLASHES E. ↔ 7.1 E.C ↔ 7.1 7.1
51 Short circuit in H clutch solenoid b072 02 ON FLASHES E. ↔ 7.2 E.C ↔ 7.2 7.2
52 Short circuit in L clutch solenoid b073 02 ON FLASHES E. ↔ 7.3 E.C ↔ 7.3 7.3
53 Short circuit in 1st clutch solenoid b074 02 ON FLASHES E. ↔ 7.4 E.C ↔ 7.4 7.4
54 Short circuit in 2nd clutch solenoid b075 02 ON FLASHES E. ↔ 7.5 E.C ↔ 7.5 7.5
55 Short circuit in 3rd clutch solenoid b076 02 ON FLASHES E. ↔ 7.6 E.C ↔ 7.6 7.6
56 Short circuit in 4th clutch solenoid b077 02 ON FLASHES E. ↔ 7.7 E.C ↔ 7.7 7.7
57 Short circuit in R clutch solenoid b078 02 ON FLASHES E. ↔ 7.8 E.C ↔ 7.8 7.8
58 Disconnection in lock-up clutch solenoid system b091 02 ON FLASHES E. ↔ 9.1 E.C ↔ 9.1 9.1
59 Disconnection in H clutch solenoid b092 02 ON FLASHES E. ↔ 9.2 E.C ↔ 9.2 9.2
60 Disconnection in L clutch solenoid b093 02 ON FLASHES E. ↔ 9.3 E.C ↔ 9.3 9.3
61 Disconnection in 1st clutch solenoid b094 02 ON FLASHES E. ↔ 9.4 E.C ↔ 9.4 9.4
62 Disconnection in 2nd clutch solenoid b095 02 ON FLASHES E. ↔ 9.5 E.C ↔ 9.5 9.5
63 Disconnection in 3rd clutch solenoid b096 02 ON FLASHES E. ↔ 9.6 E.C ↔ 9.6 9.6
64 Disconnection in 4th clutch solenoid b097 02 ON FLASHES E. ↔ 9.7 E.C ↔ 9.7 9.7
65 Disconnection in R clutch solenoid b098 02 ON FLASHES E. ↔ 9.8 E.C ↔ 9.8 9.8
66 Abnormality in model selection system rotary switch b0A1 04 ON FLASHES E. ↔ A.1 E.C ↔ A.1 A.1
67 Abnormality in torque converter oil temperature sensor system b0A2 02 ON FLASHES E. ↔ A.2 E.C ↔ A.2 A.2
68 Abnormality in fuel sensor system b0A3 02 ON FLASHES E. ↔ A.3 E.C ↔ A.3 A.3
69 Abnormality in air pressure sensor system b0b3 02 ON FLASHES E. ↔ b.3 E.C ↔ b.3 b.3
70 Abnormality in retarder brake oil level sensor (right) system b0b4 02 ON FLASHES E. ↔ b.4 E.C ↔ b.4 b.4
71 Abnormality in connector connection b0C1 04 ON FLASHES E. ↔ C.1 E.C ↔ C.1 C.1
72 Transmission filter clogging warning b0d1 01 OFF FLASHES E. ↔ d.1 E.C ↔ d.1 d.1
73 Torque converter oil temperature overheat warning b0d2 05 OFF FLASHES(ª) E. ↔ d.2 E.C ↔ d.2 d.2
74 Tilt warning b0d5 07 OFF FLASHES E. ↔ d.5 E.C ↔ d.5 d.5
75 Radiator water level drop warning b0d6 01 OFF OFF E. ↔ d.6 E.C ↔ d.6 d.6
76 Abnormality in charging circuit system b0d7 02 ON FLASHES E. ↔ d.7 E.C ↔ d.7 d.7
77 Engine overrun prevention brake actuated b0d8 03 OFF FLASHES E. ↔ d.8 E.C ↔ d.8 d.8
78 Engine overshoot b0d9 02 ON FLASHES E. ↔ d.9 E.C ↔ d.9 d.9
79 Drop in battery direct power source voltage b0dA 04 ON FLASHES E. ↔ d.A E.C ↔ d.A d.A
80 Drop in main power source voltage b0db 04 ON FLASHES E. ↔ d.b E.C ↔ d.b d.b
81 Steering oil temperature overheat warning b0E5 05 OFF FLASHES E. ↔ E.5 E.C ↔ E.5 E.5
82 Drop in air pressure b0E9 05 OFF FLASHES E. ↔ E.9 E.C ↔ E.9 E.9
83 Retarder overheat warning b0F3 05 OFF FLASHES E. ↔ F.3 E.C ↔ F.3 F.3
84 Abnormality in brake circuit system b0F6 04 OFF FLASHES E. ↔ F.6 E.C ↔ F.6 F.6
Note 3: Reset failures are kept as existing failures for 5 minutes by the transmission controller only; after that, they are saved
as a service code for past failures.
USER CODE AND SERVICE MODE FUNCTION, Section 3.2 SERVICE CODE AND TROUBLE DATA DISPLAY MODE in
the Foreword to the Troubleshooting Section. For the method of displaying with the transmission controller LED
display, see SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL AND CONTROLLERS, Section 2.4 SAVING
SERVICE CODE TO MEMORY in the Foreword to the Troubleshooting Section.
Note 5: [6003] (Abnormality in neutral safety system) and [60E9] (Low air pressure) are not displayed (saved) in the failure
history.
20-163-3 HD325-6
8
4. TABLE OF SERVICE CODES AND USER CODES RELATED TO SUSPENSION CONTROLLER

HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
Other
gearshifting Central Controller
No. Details of failure Service code User code mechatro- warning LED display
nics caution lamp
lamp
(Existing, reset) (Existing) (Existing) (Existing) (Existing)

1 Abnormality in power source system d001 — OFF OFF E. ↔ 0.1
2 Abnormality in controller d002 — OFF OFF E. ↔ 0.2
3 Abnormality in pressure sensor (right) system d011 02 ON FLASHES E. ↔ 1.1
4 Abnormality in pressure sensor (left) system d012 02 ON FLASHES E. ↔ 1.2
5 Abnormality in travel speed sensor system d015 02 ON FLASHES E. ↔ 1.2
6 Abnormality in steering sensor system d016 02 ON FLASHES E. ↔ 1.6
7 Abnormality in solenoid 1 system d021 02 ON FLASHES E. ↔ 2.1
10 Abnormality in network system d0C1 — OFF OFF E. ↔ C.1
11 Defective model selection data d0C2 — OFF OFF E. ↔ C.2
12 Defective travel speed compensation data d0C3 — OFF OFF E. ↔ C.3
Note 4: Reset failures are not displayed on the suspension controller LED display.

Other
gearshifting Central Controller
No. Details of failure Service code User code mechatro- warning LED display
nics caution lamp
lamp
(Existing, reset) (Existing) (Existing) (Existing) (Existing)

1 Abnormality in power source system d001 — OFF OFF E. ↔ 0.1
2 Abnormality in controller d002 — OFF OFF E. ↔ 0.2
3 Abnormality in pressure sensor (right) system d011 01 OFF OFF E. ↔ 1.1
4 Abnormality in pressure sensor (left) system d012 01 OFF OFF E. ↔ 1.2
5 Abnormality in travel speed sensor system d015 01 OFF OFF E. ↔ 1.2
6 Abnormality in steering sensor system d016 01 OFF OFF E. ↔ 1.6
7 Abnormality in solenoid 1 system d021 01 OFF OFF E. ↔ 2.1
10 Abnormality in network system d0C1 — OFF OFF E. ↔ C.1
11 Defective model selection data d0C2 — OFF OFF E. ↔ C.2
12 Defective travel speed compensation data d0C3 — OFF OFF E. ↔ C.3
Note 4: Reset failures are not displayed on the suspension controller LED display.
HD325-6 20-163-4
8
4. PAYLOAD METER (Printer type)

This is shown on the payload meter display. (It is not shown on the monitor panel display.)
j, When the condition is normal, the display shows the weight display or the time display.
“,:y$ttf Display Content
1 --- 8 Internal CPU stopped (CPU is reset) (Controller power source etc. normal)
E-31 Abnormal sensor power source (18V)
2 1 E -32 1 Short circuit in relay
1 E - 33 1 Drop in back-up battery voltage

E-01 Rear right wheel l Disconnection in pressure sensor signal wire
E - 02 Rear left wheel l Signal wire in contact with chassis
3
E-03 Front right wheel l Defect inside sensor
E-II Rear right wheel
l Pressure sensor signal wire in contact with power source line
E-41 Disconnection in clinometer signal wire or signal wire in contact with chassis
5
E-42 Clinometer sional wire in contact with electric line
6 PAPE Printer REDY signal not given (paper jam)
7 FULL Data saved in memory has reached 200 cycles (overflow)
8 CAL _ Calibration needed
E-21 Rear right wheel I

E-22 Rear left wheel l When sensor check is carried out, abnormality in sensor
9
E - 23 Front right wheel system is detected.
Note 1: Once an error is displayed, the error continues to

be displayed until CAL switch (I) is pressed.
Continues to display service code in display por-
tion (2).
Note 2: If the controller detects the abnormalities in the
above table, all the display lamps light up.
-J JJ
111 I
AD61
9760
20-164 HD325-6
0
6. PAYLOAD METER II (Card type)

This is shown on the payload meter II (card type) display. (It is not shown on the monitor panel
display.)
fl When the condition is normal, the display shows the weight display or the time display.
Order of
priority for Content Service code External display lamps
display
Dump lever at position other than FLOAT b-FL lights up All light up
1 (other than dumping soil) b-FL lights up
2 Memory card missing Cd flashes —
3 Drop in backup battery voltage F-09 flashes —
Cycle data memory FULL
Engine ON/OFF data FULL See next page —
4
Abnormality warning data memory FULL (*1)
Aggregate payload total cycle number data memory FULL
5 Disconnection in terminal R F-18 flashes All flash
6 Abnormality in sensor power source (18V) F-20 flashes All flash
Short circuit with ground, disconnection in front left suspen-
7 sion pressure sensor system F-21 flashes All flash
Short circuit with ground, disconnection in front right suspen-
Short circuit with ground, disconnection in rear left suspen-
Short circuit with ground, disconnection in rear right suspen-
Short circuit with power source of front left suspension pres-
11 sure sensor system F-25 flashes All flash
Short circuit with power source of front right suspension pres-
Short circuit with power source of rear left suspension pres-
Short circuit with power source of rear right suspension pres-
15 Short circuit with ground, disconnection in clinometer system F-31 flashes All flash
16 Short circuit with power source in clinometer system F-32 flashes All flash
17 Calibration not carried out or abnormality in RAM F • CAL flashes All flash
18 Short circuit in external display lamp No. 1 relay F-41 flashes Applicable lamp
Machine stopped: Always ON
19 Short circuit in external display lamp No. 2 relay F-42 flashes Traveling: OFF
20 Short circuit in external display lamp No. 3 relay F-43 flashes Other lamps
When loading: Specified actuation
21 Short circuit in external display lamp No. 4 relay F-44 flashes When stopped but not loading:
Flashes
22 Short circuit in external display lamp No. 5 relay F-45 flashes Traveling: OFF
23 Defective cycle data payload [see (*2) on page after next] L.bad flashes —
24 Over limit speed SP : SP flashes —
F-71 flashes
F-73 flashes
F-80 flashes
F-81 flashes
F-91 flashes
25 Defective communications or defective option code setting F-92 flashes —
F-93 flashes
F-94 flashes
F-95 flashes
F-96 flashes
F-97 flashes
F-98 flashes
HD325-6 20-165
8
(*I) Warning displays when memory is FULL

1. Cycle data 3) If more data are added, the 231st,
Ii When more than 2600 cycles are 232nd, . .. are saved. But each time
saved (remaining capacity less than new data are saved, the earliest ab-
300 cycles), the following cycle is re- normality and warning data are de-
peated. leted in turn. (The display is kept at
L : FUL flashes 7 times the condition in 2) above.)
flashes 1 time
2) When the machine is used more and 4. Aggregate payload, total cycle number
2900 cycles are saved in memory (re- data
maining capacity 0), the following 1) When the count for the total number
cycle is repeated. of cycles goes above 9994 (remaining
L : FUL lights up (3 seconds) capacity less than 5) or the difference
flashes 1 time between the aggregate payload and
3) If more cycles are added, the 2901st, 999900 tons (upper limit) goes below
2902nd, . . . are saved. But each time a 5 rated loads, the following cycle is
new cycle is saved, the data for the repeated.
oldest cycle are deleted in turn. (The H : FUL flashes 7 times
display is kept at the condition in 2) flashes 1 time
above.) 2) If the operation is continued and the
count for the total number of cycles
2. Engine ON/OFF data goes above 9997 (remaining capacity
1) When more than 105 times are saved less than 2) or the difference between
(remaining capacity less than 10 the aggregate payload and 999900
times), the following cycle is repeated tons (upper limit) goes below 5 rated
2 times and then the display goes out. loads, the following cycle is repeated.
E : FUL flashes 7 times E : FUL lights up (3 seconds)
flashes 1 time flashes 1 time
2) When the machine is used more and 3) If the operation is continued and the
115 times are saved in memory (re- total number of cycles reaches 9999
maining capacity 0), the following or the aggregate payload goes above
cycle is repeated 2 times and then the 999900 tons, both the aggregate pay-
display goes out. load and total cycle number will au-
E : FUL lights up (3 seconds) tomatically be cleared and set to 0.
flashes 1 time After this, the count for both values
3) If the engine is turned ON/OFF more will start again from 0.
times, the 116th, 117th, . . . are saved. (The display will return to the normal
But each time a new time is saved, the operation display.)
data for the earliest time are deleted
in turn. 5. To cancel the data FULL condition in Items
1 - 3, see the Payload Meter II (card type)
3. Abnormality, warning data Operation and Maintenance Manual, “8.3
1) When more than 220 times are saved Operator check mode”.
(remaining capacity less than 10 For Item 4, if data FULL is displayed, it is
times), the following cycle is repeated. not canceled until the system is automati-
E : FUL flashes 7 times cally cleared and set to 0. Clear the data
flashes 1 time and set to 0 forcibly before data FULL is
2) When the machine is used more and displayed. For details of the method of
230 times are saved in memory (re- operation, see the Payload Meter II Op-
maining capacity 0), the following eration and Maintenance Manual, “8.2
cycle is repeated. Forcible display of aggregate payload, to-
E : FUL lights up (3 seconds) tal cycle number”.
flashes 1 time
20-166 HD325-6
0
6. For the display of Items 1 - 4, there is no

order of priority. If multiple cases of data
FULL occur at the same time, they are dis-
played at any time except when loading.
(‘21 Defective cycle data payload

1. Detection of the payload by the payload
meter is based on the suspension pres-
sure sensor signals. This detection is al-
ways carried out, but during loading op-
erations or immediately after loading op-
erations, the dynamic friction of the sus-
pension causes some instability. To en-
sure that accurate data forthe payload are
saved to memory, when recording the
payload data, the payload meter detects
and saves the payload data immediately
before the load is dumped. In this way,
the dynamic friction of the suspension
occurring during loading is canceled when
the machine travels loaded.
(It is saved as part of the cycle data.)
2. For this reason, if the operator starts the

dumping operation (operates the dump
lever) before the swaying (pitching) of the
machine has stabilized when the machine
is stopped at the dumping point, there is
danger that the payload data saved in the
payload meter will not be accurate.
3. In addition, if the brakes are applied sud-

denly to stop the machine at the dump-
ing point or the wheels mount or hit the
wheels stoppers when stopping, there is
also danger that the payload data will not
be recorded accurately.
4. If the load is dumped before the swaying

of the machine has stabilized in the con-
ditions above, the payload meter will dis-
play [Insufficient cycle data payload] on
the abnormality and warning item display
to advise the operator to be careful. Even
in this case the detected payload is saved
to memory.
HD325-6 20-167
0
7. ARSC (Auto Retarder Speed Controller)

This system has a self-diagnostic function, and a failure code is displayed on the controller LEDs
under the assistant’s seat.
Controller LED Central ARSC Alarm

No. display Details of failure warning caution buzzer
(Existing) (Reset) lamp lamp (Existing)
1 0.1 — Abnormality in power source voltage ON Flashes Sounds
2 1.0 1.0 Disconnection, short circuit with ground, short circuit in engine speed sensor system ON Flashes Sounds
Disconnection, short circuit with ground, short circuit in transmission out-
3 1.3 1.3 put shaft speed sensor system ON Flashes Sounds
4 1.5 1.5 Short circuit with ground in retarder oil temperature sensor system ON Flashes Sounds
5 1.7 1.7 Disconnection, short circuit with ground, short circuit in accelerator signal system ON Flashes Sounds
6 1.8 1.8 Disconnection, short circuit with ground in suspension pressure sensor (left) system ON Flashes Sounds
7 1.9 1.9 Disconnection, short circuit with ground in suspension pressure sensor (right) system ON Flashes Sounds
8 4.2 4.2 Disconnection, short circuit in exhaust brake signal system ON Flashes Sounds
9 4.3 4.3 Disconnection, short circuit in ARSC caution lamp system ON Flashes Sounds
10 4.4 4.4 Disconnection in READY lamp system ON Flashes Sounds
11 4.5 4.5 Disconnection, short circuit in central warning lamp system or buzzer system system ON Flashes Sounds
12 5.2 5.2 Short circuit with ground in exhaust brake signal system ON Flashes Sounds
13 5.3 5.3 Short circuit with ground in ARSC caution lamp system ON Flashes Sounds
14 5.4 5.4 Short circuit with ground in READY lamp system ON Flashes Sounds
15 5.5 5.5 Short circuit with ground in central warning lamp system or buzzer system system ON Flashes Sounds
16 6.0 6.0 Failure in engine speed sensor system ON Flashes Sounds
17 7.0 7.0 Disconnection, short circuit in travel speed display up output system ON Flashes Sounds
18 7.1 7.1 Disconnection, short circuit in travel speed display down output system ON Flashes Sounds
19 7.2 7.2 Disconnection, short circuit in travel speed display clear output system ON Flashes Sounds
20 7.3 7.3 Short circuit with ground in travel speed display up output system ON Flashes Sounds
21 7.4 7.4 Short circuit with ground in travel speed display down output system ON Flashes Sounds
22 7.5 7.5 Short circuit with ground in travel speed display clear output system ON Flashes Sounds
23 8.1 8.1 Short circuit with ground in pressure control system ON Flashes Sounds
24 8.3 8.3 Disconnection, short circuit in pressure control system ON Flashes Sounds
Failure in pressure control valve (retarder remains applied) or failure in pres-
25 8.5 8.5 sure switch 1 system ON Flashes Sounds
Failure in pressure control valve (retarder is not applied) or failure in pres-
26 8.7 8.7 sure switch 1 system ON Flashes Sounds
27 8.9 8.9 Short circuit with ground in pressure switch valve ON Flashes Sounds
28 9.0 9.0 Disconnection, short circuit in pressure switch valve ON Flashes Sounds
29 9.1 9.1 Failure in pressure switch valve (remains open) or in pressure switch 2 system ON Flashes Sounds
30 9.2 9.2 Failure in pressure switch valve (does not open) or in pressure switch 2 system ON Flashes Sounds
31 9.3 9.3 Disconnection, short circuit in system switch ON Flashes Sounds
32 9.4 9.4 Short circuit with ground in system switch ON Flashes Sounds
33 9.5 9.5 Disconnection, short circuit with ground in travel speed setting switch system ON Flashes Sounds
34 E. 1(ª) — Abnormality in CPU ON Flashes Sounds
35 E. 2(ª) — Abnormality in memory ON Flashes Sounds
Note 2: The ARSC controller does not communicate with the monitor panel and other controllers through the S-NET, so the service
code is displayed independently on the ARSC controller LED display (it is not displayed on the monitor panel).
Note 3: The (ª) mark is an abnormality in the set travel speed display, and is displayed on the set travel speed display portion.
Note 4: When the system is normal, the display shows 0.0 (when the accelerator pedal is being depressed) or 0.0. (when the
accelerator pedal is not being depressed).
Note 5: For details of the method of clearing the service code, see the section on troubleshooting the ARSC system (page 20-703).
20-168 HD325-6
8
TROUBLESHOOTING METHOD OF USING JUDGMENT TABLE
METHOD OF USING JUDGMENT TABLE

This judgment table is a tool to determine if the problem with the machine is caused by an abnormality
in the electrical system or by an abnormality in the hydraulic or mechanical system.
The symptoms are then used to decide which troubleshooting table (A-00, H-00, etc.) matches the
symptoms.
The judgment table is designed so that it is easy to determine from the self-diagnostic display which
troubleshooting table to go to.
* For problems with the monitor panel system, go directly to troubleshooting of the monitor panel
system (P-00). (See the Contents for troubleshooting of the monitor panel.)
[Method of using judgment table]

l A 0 mark is put at the places where the failure mode and self-diagnostic display match, so check if an
error display is given on the monitor panel, and
l If an error display is given, go to the troubleshooting code at the bottom (L)
of the judgment table . . .. . . .. . . .. . . .. . .. . . . . . .. . . . . . . . . . . . .. .. . . . . . . .. . . . .. . . . .. . .. . .. .. .. . . . .. . .. .. . . . .. . .. . .. . . . .. . . .. . .. .. . .. .. . . (A-00).
l If a problem has appeared but no error display is given, go to the troubleshooting
code on the right side (+) . . . . . . .. . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . . . . .. . .. .. .. . . . . .. . . .. . . . . .. . . . .. . . . .. . .. . .. .. . . . . . .. . .. . .. . . . .. . (H-00).
l If no input signal is displayed, go to the troubleshooting code at the bottom
of the judgment table . .. . . . .. . . .. . . .. .. . . . . . . .. . . . . . . .. . . . .. .. . . . . . . .. . . . . .. . . . . . .. . .. . . .. . .. . . . . . . . . . . . .. .. .. . .. . . . . . . . . .. . . . . . . .. . (F- 00).
l If there is no 0 mark, go directly to the troubleshooting code on the right side (+I.
<Example> Failure mode “Excessive shock when starting”.
[Procedure1 Check if an error code is given on the depth display of the monitor panel or on the
controller display.
udgmentl l If error code [I*71 is given on the display .. . . . .. .. . . .. go to troubleshooting A-5 for
_I_ . ~~ --* . II
rnerransmrsston conrrorier system.
l If no error code is given on the display, and there is excessive shock
when moving the machine . . . . . . . . Go to troubleshooting H-4 of the hydraulic system.
HD325-6 20- 169

0
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
<Example>
(I) A-l Abnormality in power source system
(3) * When fuse BTI (No. IO) is normal.

If it is blown, check for a short circuit with the ground between the fuse and controller.
* When the battery is normal.
* Before carrying out troubleshooting, check that all the related connectors are properly in-
serted.
* Always connect any disconnected connectors before going on to the next step.
(2) a) [OFF] Controller self-diagnostic display LED does not light up
(4)
2 YES
<
Defective controller Replace
Defective contact or
disconnection in wiring Repair or
harness between fuse BTl replace wiring
~~ (No.lO)-TMB(ll)-ACT1 harness
(female) (9),(17)
harness between battery replace wiring
switch ON. NO relay M - circuit breaker harness
JO7 - BTl (19)
A-l a) Related electrical circuit diagram
cry
Y
~__ box1
Fuse ,. Circuit
IBTl) JO7 breaker
ransmission PW (PA)
Power mode
ontrol ler A selector
switch
power source
I Transmission
cut relay
GND
Power source
R26
Transmission cut relay
TWH00220
HD3256 20-171
0
TROUBLESHOOTING OF ENGINE SYSTEM
(S MODE)
HD325-6 Serial No.: 5680 – 6000

HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
Method of using troubleshooting charts ............................................................................................... 20-202

S- 1 Starting performance is poor (starting always takes time) ....................................................... 20-206
S- 2 Engine does not start ................................................................................................................... 20-208
(1) Engine does not turn ............................................................................................................. 20-208
(2) Engine turns but no exhaust smoke comes out (fuel is not being injected) ..................... 20-209
(3) Exhaust smoke comes out but engine does not start (fuel is being injected) .................. 20-210
S- 3 Engine does not pick up smoothly (follow-up is poor) ............................................................. 20-211
S- 4 Engine stops during operations ................................................................................................. 20-212
S- 5 Engine does not rotate smoothly (hunting) ............................................................................... 20-213
S- 6 Engine lacks output (or lacks power) ......................................................................................... 20-214
S- 7 Exhaust smoke is black (incomplete combustion) .................................................................... 20-215
S- 8 Oil consumption is excessive (or exhaust smoke is blue) ........................................................ 20-216
S- 9 Oil becomes contaminated quickly ............................................................................................. 20-217
S-10 Fuel consumption is excessive .................................................................................................... 20-218
S-11 Oil is in cooling water, or water spurts back, or water level goes down ................................. 20-219
S-12 Oil pressure caution lamp lights up (drop in oil pressure) ....................................................... 20-220
S-13 Oil level rises ................................................................................................................................. 20-221
S-14 Water temperature becomes too high (overheating) ................................................................ 20-222
S-15 Abnormal noise is made ............................................................................................................. 20-223
S-16 Vibration is excessive ................................................................................................................... 20-224
fl As for HD325-6 Serial No. 6001 and up, HD325-6W Serial No. 6001 and up, HD405-6 Serial No. 2001
and up, see the Shop Manual of engine for troubleshooting.
HD325-6 20-201
8
METHOD OF USING TROUBLESHOOTING CHART

This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshooting.
The questions and check items are used to pinpoint
high probability causes that can be located from the
failure symptoms or simple inspeciton without us-
ing troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
[Questions]
Sections @ + @in the chart on the right corre-
sponds to the items where answers can be ob-
tained from the user. The items in@ are items
that can be obtained from the user, depending
on the user’s level.
[Check items1
The serviceman carries out simple inspection to
narrow down the causes. The items under @ in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information @ that he has obtained from the
user and the results ofothat he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
-
(a) @
t
@ .i (b) 0
I I i I.1 I I
20-202 HD325-6
a
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with 0, and of these, causes that have a high prob-
ability are marked with @.
Check each of the [Questions] and [Check items1 in
turn, and marked the 0 or 0 in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is
the most probable cause, so start troubleshooting
for that item to make final confirmation of the cause.
~1. For [Confirm recent repair history] in the
[Questions] Section, ask the user, and mark
the Cause column with A to use as refer-
ence for locating the cause of the failure.
However, do not use this when making cal-
culations to narrow down the causes.
~2. Use the A in the Cause column as reference
for [Degree of use (Operated for long pe-
riod)] in the [Questions] section as reference.
As a rule, do not use it when calculating the
points for locating the cause, but it can be
included if necessary to determine the order
for troubleshooting.
HD325-6 20-203
0
. Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three
symptoms have causal relationship with this problem: [Exhaust gas slowly became black], [Power
slowly became weaker], and [Air cleaner clogging caution lamp is flashing].
If we look from these three symptoms to find the causes, we find that there is a relationship with
five causes. Let us explain here the method of using this causal relationship to pinpoint the most
probable cause.
s-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
. Insufficient intake of air
. Improper condition of fuel injection
. Excessive injection of fuel
: Possible causes ljudging f

:Mmpzb.able causes (judgi
:Possible causes due to len
I I Engine pickup is poor and combustion is irregular 10
Clanging sound is heard from around cylinder head !$jjJJJJ

:;$$
,..
I IWhen turbocharger is rotated by hand. it is found to be heavy
1 When control rack is pushed, it is found to be heavy or does
20-204 HD3256
0
Five causes
Step 1
Clarify the relationship between the three

symptoms in the [Questions] and [Check items1
section and the five Cause items in the vertical
J
Three symptoms
t ’ ’
Steo 2
Add up the total of Oand Omarks where the 1

horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(I) Clogged air cleaner element: 000
(2) Air leakage between turbocharger
and head: 00
(3) Clogged, seized injection nozzle: 0
(4) Defective contact of valve, valve seat: 0
(5) Worn piston ring, cylinder: 0
Step 3
The calculation in Step 2 show that the closest

relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting area and carry out the
troubleshooting item marked l . The Remedy is
given as [Clean], so carry out cleaning, and the
exhaust gas color should return to normal.
HD325-6 20-205
0
TROUBLESHOOTING S-l
S-l Starting performance is poor

(Starting always takes time)
General causes why exhaust smoke comes !?“a,“,sible causes (judging from Questions and check items)
out but engine takes time to start 0 : Most probable causes (judging from Questions and check items)
A : Possible causes due to length of use (used for a long period)
. Defective electrical system 0 : Items to confirm the cause.
. Insufficient supply of fuel
. Insufficient supply of air
. Improper selection of fuel
(At ambient temperature of 10°C or below, use
ASTM D975 No. 1)
Ir Battery charging rate
90 % 80 % 75 % 70 %
20°C 1.28 1.26 1.24 1.23 1.22
0°C 1.29 1.27 1.25 1.24 1.23
-10°C 1.30 1.28 1.26 1.25 1.24
l The specific gravity should exceed the value for

the charging rate of 70% in the above table.
. In cold areas the specific gravity must exceed
the value for the charging rate of 75% in the
above table.
Confirm recent repair history
Degree of use of machine Operated for long period AA A
Gradually became worse 00000
Ease of starting
Starts when warm 0
Preheating indicator lamp is light up I
/-
Blow-by gas is excessive lol I I I I I

Timing lock on fuel injection pump does not match
Mud is stuck to fuel tank cap
When engine is cranked with starting motor,
1) Little fuel comes out even when injection pump sleeve nut is loosened
2) Little fuel comes out even when fuel filter air bleed plug is loosened 09
Leakaae from fuel oioina
There is hunting from engine (rotation is irregular) I I I I l0101
When compression pressure is measured, it is found to be low

When air cleaner element is inspected directly, it is found to be clogged
When fuel filter, strainer are inspected directly, they are found to be clogged
,E When feed pump strainer is inspected directly, it is found to be clogged
z Electrical intake air heater mount does not become warm
_z
2 Voltage is not 26 - 30V between alternator terminal B and terminal E with
Jx engine at low idling a
z
c Either specific gravity of electrolyte or voltage of battery is low
Soeed does not change when operation of certain cylinders is stopped
I When check is made, injection timing is found to be incorrect
I When control rack is pushed, it is found to be heavy or does not return
When fuel tank cap is inspected directly, it is found to be clogged
I See testing and adjusting
I
I Remedy
20-206 HD325-6
0
TROUBLESHOOTING S-l
t i i i i-i i i
HD3256 20-207
0
TROUBLESHOOTING s-2
S-2 Engine does not start
(1) Engine does not turn

I Causes I
General causes why engine does not turn
. Internal parts of engine seized
Ir If internal parts of the engine are seized, carry

outtroubleshooting for ENGINE STOPS DUR-
ING OPERATIONS.
. Failure in power train

. Failure in electric system
%%ible causes (judging from Questions and check items)

0 : Most probable causes (judging from Questions and check items)
0 : Items to confirm the cause.
1Confirm recent reoair history

Degree of use of machine Operated for long period A A
Condition of horn when Horn does not sound 8 0 0
starting switch is turned
Ah, Volume is low 0
A- I Rotation soeed is slow I IQI I I I I I I I
When starting switch is
Makes grating noise 00
turned to START, pinion
moves out, but Soon disengages again Q
Makes rattling noise and does not turn 0 0 0
I I ._
When starting switch is turned to START, pinion does not
move out IQ/O1
I I
6
I
I I I I I I4
I I I I I ,
When starting switch is turned to ON, there is no clicking B A 65

sound
Battery terminal is loose

Even when starting switch is turned ON, linkage is not actuated
When battery is checked, battery electrolyte is found to be low
Specific gravity of electrolyte, voltage of battery is low

For the following conditions 1) - 4), turn the starting switch
OFF, connect the cord, and carry out troubleshooting
1) When terminal Band terminal C of starting switch are
connected, engine starts ‘p
2) When terminal Band terminal C of starting motor are Y
connected, does engine turn? .5
3) When terminal B and terminal C of safety relay are .g
connected, engine starts z
4) Voltage is not 24V between battery relay terminal M and 2
terminal E =
z
When ring gear is inspected directly, tooth surface is found to b
be chipped %
Does not move even when linkage of fuel cut solenoid is t
disconnected 2
20-208 HD325-6
0
TROUBLESHOOTING s-2
(2) Engine turns but no exhaust smoke comes out

(Fuel is not being injected)
Ir Check that there is no abnormality display for the governor

control system on the monitor panel.
General causes why engine turns but no exhaust smoke comes out
l Supply of fuel impossible

l Supply of fuel is extremely small
. Improper selection of fuel (particularly in winter)
KIND
OF FLUID
Diesel fuel
mixture of No. 2 diesel oil and kerosene can be used.
??epn,d,sible causes (judging from Questions and check items)

Even whenstartinaswitch isturned ON. linkaaeisnotactuated 1 1 1 1 1 l 1 l 1Ql Ql

No fuel comes out even when fuel filter is drained
1 Inspect injection pump directly I.1 I I

When control rack is pushed, it is found to be heavy, or does I l-1 I
p Inspect feed pump directly 0
‘g When fuel filter, strainer are inspected directly, they are found
0
to be clogged
2
!$ When feed pump strainer is inspected directly, it is found
e to be clogged
z When fuel tank cap is inspected directly, it is found to be clogged
Does not move even when linkage of fuel cut solenoid is
disconnected
Does not move even when linkage of engine stop motor is
disconnected
I
HD325-6 20-209
0
TROUBLESHOOTING s-2
(3) Exhaust smoke comes out but engine

does not start (Fuel is being injected)
Causes
General causes why exhaust smoke comes out but

engine not start
. Lack of rotating force due to defective electrical

system
. Improper selection of fuel and oil
%%ible causes (judging from Questions and check items)

0 : yosf probable causes (judging from Questipns and check items)
th of use (used for a long period)
Degree of use of machine Operated for long period AA

Suddenly failed to start 00
When engine is cranked, abnormal noise is heard from
around head Q
Enaine oil must be added more freauentlv 0

Non-specified fuel is being used 0
Replacement of filters has not been carried out according to
Operation Manual 0
Rust are found when fuel tank is drained

Air cleaner clogging monitor caution lamp is flashing
Heater mount does not become warm

Startina motor cranks enaine slowlv
Mud is stuck to fuel tank cap I I I I
When fuel lever is placed at FULL position, it does not contact stopper 1 10 1 1
Electrical intake air heater mount does not become warm I I I I I I I.1 I I I I
Either specific gravih/ of electrolyte or voltage of battery is low
When feed pump is operated, there is no response, or
operation is too heavy
When injection nozzle is tested as individual part, spray condition is
found to be ooor
I When fuel tank cap is inspected directly, it is found to be clogged 0
$ 8 8 Et; :
Remedy 9 S .S 5 C C % @a2 5 g f
gg”a g~aa-,m
aaZaEabbSaaL4
20-210 HD3256
0
TROUBLESHOOTING s-3
S-3 Engine does not pick up smoothly

(Follow-up is poor)
Ir Check that there is no abnormality display for the gov-

ernor control system on the monitor panel.
General causes why engine does not pick up smoothly

. Improper condition of fuel injction
. Improper fuel used
HD325-6 20-211
0
TROUBLESHOOTING s-4
S-4 Engine stops during operations

* Check that there is fuel in the fuel tank.
General causes why engine stops during operations

. Seized parts inside engine
. Overheating
* If there is overheating and the engine stops, carry

out troubleshooting for overheating.
. Failure in power train.
* If the machine stopped because of a failure in

the power train, carry out troubleshooting for the
chassis.
g%.sible causes (judging from Questions and check items)

Condition when engine
When control rack is pushed, it is found to be heavy, or does

not return
20-212 HD325-6
0
TROUBLESHOOTING s-5
S-5 Engine does not rotate smoothly

(Hunting)
General causes why engine does not rotate smoothly
I Causes I
. Air in fuel system

. Defective governor mechanism
. Defective electric governor mechanism (electric
governor type)
* If there is no hunting when the electric gov-

ernor rod is disconnected, carry outtrouble-
shooting for the electrical system.
ggepnodssible causes (judging from Questions and check items)

_ : .Possible causes due to length of use (used for a long penodj
A

Degree of use of machine Operated for long period AA
Occurs at a certain speed range QQQO
Condition of hunting
When feed pump is operated,

11 No resoonse. liaht. return is auick
2) No response, light, return is normal
Engine speed sometimes rises too far QQ
Engine is sometimes difhcult to stop Q 0
~Seal on iniection oumo has come off 0 Q
When governor lever is moved. movement is found to be Door 10 1 10 1 1 1 1 1 I I 1

When injection pump is tested, governor is found to be
improperly adjusted
When control rack is pushed, it is found to be heavy, or
does not return
When fuel cap is inspected directly, it is found to be clogged
When feed pump strainer is inspected directly, it is
found to be clogged
When fuel filter, strainer are inspected directly, they are
found to be clogged
Remedy
HD325-6 20-213
0
TROUBLESHOOTING S-6
S-6 Engine lacks output

(or lacks power) Causes
General causes why engine lacks output

. Improper fuel used
(if non-specified fuel is used, output drops)
. Lack of output due to overtaking
* If there is overheating and lack of output,

carry out troubleshooting for OVERHEATING.
causes (judging from Questions and check items)

Power was lost
I Black QQ
Color of exhaust gas
Blue under light load 0
Noise of interference is heard from around turbocharger Q I
Blow-by gas is excessive Q I I

Enaine oickuo is ooor and combus?ion is irreaular Q 0 00
High idling speed under no load is normal, but speed
QQ 0
suddenly drops when load is applied
When exhaust manifold is touched immediately after starting
engine, temperature of some cylinders is low QO
There is hunting from engine (rotation is irregular)

Clanaina sound is heard from around cvlinder head
20-214 HD325-6
0
TROUBLESHOOTING s-7
S-7 Exhaust smoke is black

(Incomplete combustion) Causes
General causes why exhaust smoke is black

??%sible causes (judging from Questions and check items)

0: Most probable causes (judging from Questions and check items)
Confirm recent repair history I I I I I I I I I I I

Degree of use of machine Operated for long period bblAl I 1 iAl

:
.g
Noise of interference is heard from around turbocharger

I Dust indicator caution is red I 161 I I I I I I I I
E
.%
%
m
6
Exhaust noise is abnormal 0 0 Q
Muffler is crushed 0
Leakage of air between turbocharger and head, loose clamp Q
1
HD325-6 20-215
0
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive

(or exhaust smoke is blue)
* Do not run the engine at idling for more than 20
minutes cqntinuously. (Both low and high idling)
General causes why oil consumption is excessive
. Abnormal combustion of oil

. External leakage of oil
. Wear of lubrication system
“1
II g
‘G
p
When exhaust pipe is removed, inside is found to be dirty with oil
When turbocharaer air SUDDIV oioe is removed, inside is
found to be dir$with oil
I I I I I I I I I
Q
Ihw III
1 lo
6 Oil level rises in clutch or TORQFLOW transmission damper

Q
chamber
Clamps for intake system are loose 0
20-2 16 HD325-6
0
TROUBLESHOOTING s-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly / Causes /
. Entry of exhaust gas due to internal wear

l Clogging of lubrication passage
. Improper fuel
. improper oil used
l Operation under excessive load
uestions and check items)

rom Questions and check items)
use (used for a long period)
Amount of blow-by gas
When compression pressure is measured, it is found to be low

When breather element is insoected directlv, hose is
p broken or is found to be clogged with dirty oil
‘g When oil filter is inspected directly, it is found to be clogged
n
< When oil cooler is inspected directly, it is found to be clogged
2 Turbocharger drain tube is clogged
cS Excessive play of turbocharger shaft
When safety valve is directly inspected, spring is found to
be catching or broken
Remedy
HD3256 20-217
0
TROUBLESHOOTING s-10
S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive
. Leakage of fuel
%%.itAe causes (judging from Questions and check items)

udging from Questions and check items)
6 temperature of some cylinders is low

.r:
2 Match mark on injection pump is misaligned Q
6 There is external leakage of fuel from engine 0
Engine oil level rises and smells of diesel fuel 0 QQ
Enoine low idlina soeed is hioh 0 Q
When injection pump is tested, injection amount is found to be excessive 10 ( ( 1 ( I 1 ( 1

Speed does not change when operation of certain cylinders is stopped 0
When control rack is pushed, it is found to be heavy, or does not return 0
When check is made, injection timing is found to be incorrect 0
Remove head cover and insoect directlv 0
Remove feed wmo and inspect directlv 0
I I When engine speed is measured, low idling speed is found to be high 0
20-218 HD325-6
0
TROUBLESHOOTING S-l 1
11 Oil is in cooling water, or water spurts

back, or water level goes down
General causes why oil is in cooling water
. internal leakage in lubrication system

. Internal leakage in cooling system
uestions and check items)

rom Questions and check items)
use (used for a long period)
HD325-6 20-219
0
S-12 Oil pressure caution lamp lights

up (drop in oil pressure)
General causes why oil pressure caution lamp lights up
. Leakage, clogging, wear of lubricating system

. Defective oil pressure control
. Improper oil used (improper viscosity) %%ible causes (judging from Questions and check items)
. Deterioration of oil due to overheating 0 : Most probable causes (judging from Questions and check items)
* Check that the engine oil level is correct Causes
before starting troubleshooting.
* Standards for enaine oil selection

////llll/
AMBIENT TEMPERATURE
KIND
OF FLUID -:
-::; -Gto -10
14 32
0 50
10 68
20 300 10401
860 40°C
Engine oil
Condition when oil

pressure lamp lights up
When oil filter is inspect’
When oil pressure is measured, it is found to be within

standard value
20-220 HD3256
0
-13 Oil level rises

* If there is oil in the cooling water, carry out trouble-
shooting for “Oil is in cooling water”.
General causes why oil level rises
l Water in oil
. Fuel in oil (diluted, and smells of diesel fuel)
l Oil leaking in from other component
$%&ible causes (judging from Questions and check items)

HD325-6 20-221
0
S-14 Water temperature becomes too

high (Overheating)
Causes
General causes why water temperature becomes too 11/1111111/
high
. Lack of cooling air (deformation, damage of fan)
. Drop in heat dissipation efficiency
. Defective cooling circulation system
. Rise in oil temperature in power train
* Carry out troubleshooting for chassis.
??ep”odssiblecauses (judging from Questions and check items)

I [ Confirm recent repair history

Degree of use of machine 1Operated
Lo E..*..l....l..
1 ,% 1 Condition of overheatino 1~“““G”‘y “vG”‘~a’c
I2I
n\
- 1 Always tends to OVE
Water temperature
Temperature difference between top and bottom radiator tanks .

is excessive
20-222 HD3256
0
S-15 Abnormal noise is made

* Judge if the noise is an internal noise or an Causes
external noise.
General causes why abnormal noise is made
l Abnormality due to defective parts

l Abnormal combustion
l Air sucked in from intake system
: Possible causes (judging from Questions and check items)

udging from Questions and check items)
1Confirm recent repair history I I I I I I I I I I I I I

1 Dnornn
--a---
nf
--
11s:~
-__ of
_. machine
..__....._ 1Ooerated
~_ ~~~ for lona” oeriod
_~ ~~ 1At 1 1 1 1 I I 1 -I
g
.; Condition of abnormal Gradually occurred 0 0
noise Suddenly occurred 00 0
$
Non-specified fuel is being used
Engine oil must be added more frequently
Blue under light load
Black
Metal particles are found in oil filter

Blow-by gas is excessive
Noise of interference is heard from around turbocharger
Engine pickup is poor and combustion is abnormal
When exhaust manifold is touched immediately after starting
engine, temperature of some cylinders is low
Seal on iniection oumo has come off
Abnormal noise is loud when accelerating engine
Clansina sound is heard from around cvlinder head
1 Leakage of air between turbocharger and head, loose clamp
I I Vibratina noise is heard from around muffler I I I I I I I I I I I lal
I When comoression oressure is measured, it is found to be low

I When turbocharaer is rotated bv hand, it is found to be heavv
Remove gear cover and inspect directly
Speed does not change when operation of certain cylinders is
stormed
When control rack is pushed, it is found to be heavy, or does
not return
Injection pump test shows that injection amount is incorrect
Fan is deformed. belt is loose
When valve clearance is checked, it is found to be outside
standard value
Remove cvlinder head cover and insoect directlv
I When muffler is removed, abnormal noise disaooears
Remedy
HD325-6 20-223
0
TROUBLESHOOTING S-16
S-A6 Vibration is excessive

* If there is abnormal noise together with the I Causes I
vibration, carry out troubleshooting also for
“Abnormal noise is made”.
General causes why vibration is excessive
. Defective parts (abnormal wear, breakage)

. Improper alignment
. Abnormal combustion
%‘%sible causes (judging from Questions and check items)

1 1 Confirm recent reoair historv I I I I I I I I I I
suaaeniy mcrea
Condition of vibration
Metal particles are found when oil is drained QQ
Y z
.Z
o)
Y
p
6
Oil pressure is low at low idling
Vibration occurs at mid-range speed
Vibration follows engine speed
Exhaust smoke is black
Seal on injection pump has come off
I
00
I I
0
0
I
01
O/01(
I
(
I
I
QOO
Q
Remove oil pan and inspect directly 1.1 / 1 1 1 I I I

Remove side cover and inspect directly
Inspect directly for loose engine mounting bolts, broken cushion
Inspect inside of output shaft (damper) directly
When face runout and radial runout are inspected, they are
found to be incorrect
Remove front cover and inspect directly
Remove head cover and inspect directly
Injection pump test shows that injection amount is incorrect
Remedy
20-224 HD325-6
0
TROUBLESHOOTING OF TRANSMISSION
CONTROLLER SYSTEM
(A MODE)
Points to remember when carrying out troubleshooting of transmission controller system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-304
Action taken by self-diagnostic device and problems on machine . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-306
Judgment table for transmission controller, transmission related parts . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-326
Electrical circuit diagram for transmission controller system .._..___.._.._._.._............................................................. 20-328
Abnormality in power source

Monitor
Controller
a”fz& display
a) [OFF] Controller self-diagnostic display LED does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-329

A-’ [ v.u 1
b) Drop in voltage of controller power source is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-330

boo’ [::z ::;I
c) Drop in voltage of battery direct power source is displayed . .._.._.._____._._..............20-331

bOdA[~:C=:::~]
d) Drop in voltage of main power source is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-332

bodb [~:,=:::~I
e) Abnormalitay in transmission cut relay power source is displayed . . . . . . . . . . . . . . . . .._.. 20-333

b002 [::,=:::;I
A-2 b003 [ E:Cz ;:;I a) Abnormality in neutral safety system is displayed __............................................... 20-334
Abnormality in controller system
A-3 b005 [ :I,: ;:$ Double engagement for clutch is displayed ................................................................ 20-335
A-4 b006 (E:C z ;:;I Abnormality in transmission [cut relay] system is displayed .................................... 20-336
A-5 b008 [ :I,: ;:;] Abnormality in rear brake solenoid system is displayed ........................................... 20-337
A-6 b009 [ ;:Cz ;:;I Abnormality in exhaust brake solenoid system is displayed.. ................................... 20-338
Abnormality in speed sensor system
A-7 bOl0 [::Cz ;::I or b060 [E:Czz:i]
a) Disconnection in engine speed sensor [Bl system is displayed or failure

in engine speed sensor is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-339
boll [~:Cz:::j orb061 [E:Cz:::j
b) Disconnection in input shaft speed sensor system is displayed or failure

of input shaft speed sensor is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-340
b012 [~:C.i:s] orb062 [E:CzE:z]
c) Disconnection in intermediate shaft speed sensor system is displayed

or failure of intermediate shaft speed sensor is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-341
b013 [ :I,= ::;I or b063 [ E:Cz :::I
d) Disconnection in travel speed sensor (transmission output shaft speed sensor)

system is displayed or failure of output shaft speed sensor is displayed . . . . . . . . . . . 20-342
HD325-6 20-301
0
Speed sensor system, clutch slipping
;$Y;pr Controller
A-8 “,‘z: [ E:rGi::] or b023 [ E:C z $z] a) Input shaft speed sensoror H, L clutchsystem is displayed......... 20-343
b) Travel speed sensor system or speed clutch (1, 2,3,4, R) system is displayed ..... 20-344
Abnormality in model selection system
A-9 b014 [;:Cz ;I:] a) Abnormality in model selection (wiring harness) is displayed . ........ .................. .. 20-345
b) Abnormality in model selection (rotary switch) is displayed ................ ... .... ......... 20-346
Abnormality in shift lever system
A-10 b007 [ ;I,-?+ :I;] a) Short circuit in shift lever assembly power source is displayed.. ......................... 20-347
b015 [;:Cz ;::I b) Shift lever position signal input for 2 or more systems is displayed ................... 20-348
bO16 [;:Cz;:;] c) Shift lever position signal is not input .................................................................... 20-350
A-11 b017 (;:Cu,;:;] A bnormality in accelerator signal is displayed ......................................................... 20-352
A-12 b019 [;:C; ;:“9] A bnormality in transmission oil temperature sensor is displayed ......................... 20-353
Abnormality in pressure Control valve system
A-13 b032 [ $.z :I:] - b038 [ E:C z :I:] a) Fill signal (clutch ON) is displayed regardless of
command ..................... .... ............*....... ............... .............. 20-354
b042 [KS:;]- b048 [E:c=:Zl b) Fill signal is not input and clutch slipping is displayed ...... .. 20-356
b-l) Inspecting fill signal system ............. ............... ............... . 20-356
b-2) Inspecting transmission input shaft speed signal system,

H, L clutch system (inspecting clutch slippage) . ........ ... . 20-357
b-3) Inspecting transmission output shaft speed signal system,

l-4, R clutch system (inspecting clutch slippage).......... 20-357
A-14 b052 (‘,:C; ;:;] - b058 [ ;I,=: ;I;] When fill signal is not input (flow detector valve system) .... 20-358
(” cr7’1] - b078 [=Cz;:;] Short circuit in pressure control valve solenoid

A-‘5 b071 E.Ctt 7.1
system is displayed ._...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-359
b091 [$z;:;] - b098 (&.~;:!j] Disconnection in pressure control valve solenoid

system is displayed ...... .................................... .... ... ......... ... ..... 20-359
20-302 HD325-6
a
Abnormality in sensor system
Monitor
panel Controller
display display
A-16 b0A2  E. ↔ A.2  a) Abnormality in torque converter oil temperature sensor system is displayed ....... 20-361
E.C ↔ A.3 
b043 E. ↔ B.2  b) Abnormality in fuel level sensor system is displayed ........................................... 20-362
E.C ↔ b.2 
b0b2  E. ↔ b.2  c) Abnormality in cooling water temperature sensor system is displayed .............. 20-363
E.C ↔ b.2 
b0b3  E. ↔ b.3  d) Abnormality in air pressure sensor system is displayed ....................................... 20-364
E.C ↔ b.3 
b0b4 E. ↔ b.4  e) Abnormality in retarder brake oil temperature sensor is displayed ..................... 20-365
E.C ↔ b.4 
Warning display
A-17 b0d1 E. ↔ d.1  a) Transmission filter clogged warning is displayed .................................................. 20-366
E.C ↔ d.1 
b0d5 E. ↔ d.5  b) Tilt warning is displayed ........................................................................................... 20-367
E.C ↔ d.5 
b0d6 E. ↔ d.6  c) Drop in radiator water level warning is displayed ................................................. 20-368
E.C ↔ d.6 
b0d7 E. ↔ d.7  d) Battery charge level warning is displayed .............................................................. 20-369
E.C ↔ d.7 
b0E5 E. ↔ E.5  e) Steering oil temperature overheat warning is displayed ...................................... 20-370
E.C ↔ E.5 
b0F5E. ↔ F.5  f) Drop in engine oil pressure warning is displayed .................................................. 20-371
E.C ↔ F.5 
b0F6 E. ↔ F.6  g) Rear brake oil pressure warning is displayed ......................................................... 20-372
E.C ↔ F.6 
A-18 b0b7 E. ↔ b.7  Abnormality in engine oil pressure sensor system is displayed ............................... 20-373
E.C ↔ b.7 
A-19 b0C1 E. ↔ C.1  Abnormality in connector connection is displayed .................................................... 20-374
E.C ↔ C.1 
A-20 b0d2 E. ↔ d.2  a) Torque converter oil temperature overheat warning is displayed ........................ 20-375
E.C ↔ d.2 
b0d3 E. ↔ d.3  b) Engine water temperature overheat warning is displayed ................................... 20-375
E.C ↔ d.3 
b0E9 E. ↔ E.9  c) Air pressure drop warning is displayed .................................................................. 20-375
E.C ↔ E.9 
b0F3 E. ↔ F.3  d) Retarder brake oil temperature overheat warning is displayed ............................ 20-375
E.C ↔ F.3 
b0d8 E. ↔ d.8  e) Engine overrun prevention brake actuated is displayed ....................................... 20-376
E.C ↔ d.8 
b0d9 E. ↔ d.9  f) Engine overshoot actuated is displayed ................................................................. 20-376
E.C ↔ d.9 
fl Re-enacting failures in electrical system
With failures in the electrical system, there are cases where failures, such as defective contact of
wiring harnesses and connectors, occur only under special conditions particularly at the initial stage
of the occurrence of the failure.
(For example, when the engine is running at high speed or the truck is traveling at high speed on
rough road surfaces)
Therefore, investigate the values for the resistance and voltage at the locations indicated by the
abnormal display, Even if no abnormality is found, it is necessary to investigate the conditions under
which the failure occurred, and to try to re-enact the failure condition to carry out troubleshooting.
HD325-6 20-303
8
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLE-

SHOOTING OF TRANSMISSION CONTROLLER SYSTEM
(For details of the monitor panel display, see MONITOR PANEL DISPLAY AND SERVICE CODES in the
Foreword of the Troubleshooting Section.
1. Connection between troubleshooting of electrical system and mechanical system
If the failure display shows 2. , 3. , 4. , 5. , there are some cases where there is a failure in the
electrical system (sensors, wiring harnesses), and other cases where the failure is in the mechanical
or hydraulic system (ECMV or clutch).
Therefore, if troubleshooting is carried out on the electrical circuit and no failure is found, go to
troubleshooting of the mechanical and hydraulic system; on the other hand, if no abnormality is
found during troubleshooting of the mechanical and hydraulic system, go to troubleshooting of the
electrical system.
(For details if the display is 2. * , 3. , 4. , 5. , see Action taken by the self-diagnostic device and
problems on the machine in the section on “Transmission controller system”.)
*: ← 1, 2, 3, 4, 5, 6, 8 = a number from 1 to 8 goes in the box.
2. Saving service code

The transmission controller records failures that have occurred in the past, and can display codes
saved in memory in the monitor panel service mode. (For details of the operation, see Method of
operating monitor panel service mode.) When the starting switch is turned OFF → ON, the transmis-
sion controller displays the recorded codes as shown in Fig. 1.
Therefore, by seeing these recorded service codes, it is possible to obtain information about prob-
lems that have occurred in the past.
• Transmission controller LED display
Fig. 1
20-304 HD325-6
1
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM
Note: When investigating failures, if the starting switch is turned ON/OFF with the connector discon-
nected, the controller may judge that there is an abnormality, and the failure code may be re-
corded.
Therefore, after carrying out troubleshooting, always delete the recorded data and check that the
failure has been deleted.
(For details of the method of deleting the data, see MONITOR PANEL DISPLAY AND SERVICE
CODES in the Foreword of the Troubleshooting Section.)
When disconnecting and connecting the connectors of any other controller or monitor system,
check that the transmission controller has not taken it as a failure.
HD325-6 20-305
1
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE
TROUBLESHOOTING AND PROBLEMS ON MACHINE
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND

PROBLEMS ON MACHINE
Details of abnormality Check the wiring harnesses and equipment
Display Abnormal system given below : Disconnection, short circuit in wiring harness
code fl Judgment conditions
(+): Positive, (–): Negative
  Defective controller power 1. Between (+) battery – (+) circuit breaker

 .  source 2. Between (+) circuit breaker – J07
fl Input voltage: Max. 9V
Min. 37V 3. Between (+) J07 – BT1 fuse No. 10 – TMB (11)
fl Power source voltage 4. Between (+) TMB (11) – ATC1 (9), (17)
inside controller
5. Between (–) ATC1 (8) – TMC (1) – J06 – battery relay terminal E
6. Defective alternator regulator
7. Defective power source circuit inside controller
  Controller box system Defective controller box

 .  fl Watch dog timer actu-
ated
Drop in controller voltage When controller power source has become weak
b001 fl Input voltage when en- 1. Defective generation of electricity by alternator
E. ↔ 0.1  gine speed is 500 rpm or
E.C↔ 0.1  more: Max. 18V and 2. Battery tends to become discharged
direct input 3. Defective charging circuit
voltage max. 18V 1) Between alternator terminal B – emergency steering relay terminal
B – battery 4 (+)
2) Between alternator terminal E – chassis
b0dA Drop in battery direct power When controller power source has become weak
E. ↔ d.A source voltage 1. Defective generation of electricity by alternator
E.C↔ d.A fl Difference in electric po- 2. Battery tends to become discharged
tential between main
power source voltage 3. Defective charging circuit
and battery power 1) Between alternator terminal B – emergency steering relay terminal
source voltage: Min. 5V
B – battery 4 (+)
b0db Drop in main power source When controller power source has become weak
E. ↔ d.b  voltage 1. Defective generation of electricity by alternator
E.C↔ d.b  fl Difference in electric po- 2. Battery tends to become discharged
tential between battery
direct power source 3. Defective charging circuit
voltage and main power 1) Between alternator terminal B – emergency steering relay terminal
source voltage: Min. 5V
B – battery 4 (+)
b002 Drop in solenoid power Defective solenoid power source circuit

E. ↔ 0.2  source voltage 1. Defective transmission cut relay
E.C↔ 0.2  fl Solenoid power source 2. Between ATC2 (1), (12) – TMC (2) – R25 (5), (3) (transmission cut relay)
input voltage when en-
gine speed is 500 rpm or – BT1 fuse No. 10
more and input voltage
is 20V or more: Max. 18V
b003 N safety 1. Defective handling of machine
E. ↔ 0.3  fl With starting switch ON
E.C↔ 0.3  Shift lever at position 2. Defective controller power source system
other than N 1) Looseness of J07, circuit breaker, battery (+)
 There may also be sud-  2) Defective insertion of fuse BT1 fuse (No. 10)
 den cut in power source  3) Defective contact of connectors ATC (9), (17), TMB (11)
contact of control power 
 [when there is defective
4) Looseness of terminal J06, battery relay E
 source and power is mo-  5) Defective contact of connectors ATC1 (8), (16), TMC (1)
 mentarily cut and comes 
 on again] 
fl The top code in the Display code column shows the monitor panel display and the bottom code (in [ ])
shows the transmission controller LED display.
20-306 HD325-6
8
Condition when normal $jj : Check with tester Action of controller %mPtoms that appear in ma-
chine when there isabnormality
when abnormality is Mechatronics abnormality dis-
Voltage IV), current (A), resistance value Q detected play given, warning actuated
1. Between ATCI (9). (17) - (8) (VI 3 : 20 - 30 V Cannot carry out Transmission suddenly
control shifts to Neutral during
2. BetweenTMB(ll)-TMC(l)(V)&:20-30V
1
Transmission is travel and machine
3. Between JO7 - JO6 (V) 6 : 20 - 30 V cannot move off again
I placed in Neutral
4. BTI fuse No. 10 is not blown
Normal controller display: Shows 0.0 or 0.C Cannot carry out Transmission suddenly
control shifts to Neutral during
1
Transmission is travel and machine
cannot move off again
I placed in Neutral
1. Between ATC (9). (17) - (8) (V) 3 : 20 - 30 V Sets to Neutral Transmission suddenly
shifts to Neutral during
2. ATC(7)-(8)(V)&:20-30V
travel and machine
3. BetweenTMB(11)-TMC(1)(V)~:20-30V cannot move off again
4. Between TMC (6) - (I I) (VI $j : 20 - 30 V
5. Between JO7 - JO6 (VI 3 : 20 - 30 V
6. Between JO7 (13) - JO6 (V) $ : 20 - 30 V
7. No looseness of terminals: alternator B, battery relay B, battery (+I
1. Between ATC (7) - (8) (V) & : 20 - 30 V Only gives self-di- There is no problem
2. Between TMB (11) -TMC (6) (V)a: 20-30V agnostic display; with automatic
does not take any gearshifting function
3. Between JO3 (13) - JO6 (VI $ : 20 - 30 V
action
4. No looseness of terminals: alternator B, battery relay B, battery (+I
1. Between ATC (9), (17) - (18) (VI 3 : 20 - 30 V Only gives self-di- There is no problem
agnostic display; with automatic
2. BetweenTMB (II)-TMC(1) (V)&:20-30V
does not take any gearshifting function
3. Between JO7 - JO6 (VI 3 : 20 - 30 V action
4. No looseness of terminals: alternator B, battery relay B, battery (+)
1. Between ATC2 (I), (12) -chassis (VI 3 : 20 - 30 V Actuates transmis- Transmission suddenly
2. Between TMC (2) - chassis (VI $$ : 20 - 30 V sion cut relay and shifts to Neutral during
sets to Neutral travel and machine
3. Between R25 (5) -chassis (VI 3 : 20 - 30 V
4. Between R25 (3) -chassis (V) 3 : 20 - 30 V
1. Starting switch at ON and shift lever at N If there is abnor- 1. When starting switch is
mality when start- turned ON and operation
2. No looseness of terminals: battery, circuit breaker, J07, J06, bat- ing switch is at CN to move machine is car-
tery relay E transmission is ried out, machine does
not move. But if shift le-
3. Connectors TMB, TMC, ATCI securely inserted held at neutral ver is returned to y, ma-
chine can start agaln.
2. There is no mechatro-
nits abnormality dis-
play.
3. Applicable position on
monitor panel shift po-
sition display flashes.
HD325-6 20-307
0

);o$;Y Abnormal system given below 4 : Disconnection, short circuit in wiring harness
Ir Judgment conditions
I+): Positive, (-): Negative
b005 Double engagement of I. Defective controller box

i. -0.5 clutch
!. Defective fill detection switch
i.ctto.5 t With double engage-
ment of clutch, input of 3. Between H SW - TM3 (3) - ATC5A (12) &
fill sensor signal was de- Between L SW - TM3 (6) - ATCSA (10) &
tected
Between R SW - TM3 (9) - ATCSA (13) 4
Double engagement:
Actuated for 2.1-4.7 set Between 1 SW - TM4 (3) - ATC5A (14) 4
Between 2 SW - TM4 (6) - ATCSA (15) &
Between 3 SW - TM4 (9) - ATC5A (I I) .&
Between4SW-TM4(12)-ATC5A(16)&
1. Defective transmission cut relay

~ 2. Between ATCI (15) - TMC (3) - R25 (2). (I) (transmission cut relay) -
..ct,0.6 transmrssrqn cut relay
BTI fuse No. IO &
I l When not actuated:

Max. IIV
b007 Short circuit with ground in 1. Between (+) ATC2 (14) -TMB (I) -SF (I) &
E. HO.7 12V output circuit
2. Defective voltage circuit inside controller
f.cttc.7 1 (Shift lever power source)
* 12V output terminal
voltage, Max. 6V
b008 Disconnection, short circuit, 1. Between (+) ATCI (13) -TMB (16) - RH4 (6) - SL4 (1) 4
1
:. HO.8 short circuit with ground in
E.Ct10.8 rear brake prevention solenoid
+ Rear brake
2.
3.
Between
Between
(-) SL4 (2) - RH4 (5) - GND ER .&
(+I ATCI (5) - TMC (10) - BTI fuse No. 10 &j
When actuated: Min. 1IV
l
4. Defective rear brake solenoid
When not actuated:
l
Max. 1 IV
b009 Disconnection,, short circuit, 1. Between (+) ATCI (14) -TMB (15) - RH4 (4) - SL5 (7) 4@
5. HO.9 short circuit wrth ground in
2. Between (-) SL5 (2) - RH4 (5) - GND ER &
E.CtlO.91 exhaust brake solenoid
* Exhaust brake 3. Between (+I SL5 (I) - RH4 (5) - BTI fuse No. 10 &
When actuated: Min. 1IV
l
4. Defective exhaust brake solenoid
When not actuated:
l
Max. IIV
bOl0 Defective engine speed sen- 1. Engine speed sensor B system

E. HI.0 sor output I) Between El2 (1) - J09M (9) -TMD (13) -ATC3A (13) 4
E.Ct, 1.01 * Engine speed less than
350 rpm and transmission 2) Between El2 (2) - J09M (10) - TMD (74) - ATCBA (74) 4
speed more than 500 rpm 2. Defective engine speed sensor
continues for 10 sec.
boll Disconnection in transmis- 1. Input shaft speed sensor system

E. ~1.1
E.Ctll.l 1 sion input shaft speed sen-
sor
* If disconnection detec-
I) Between Nl (I) -TM2 (I) -ATC3A (2) &
2) Between N2 (2) - TM2 (2) - ATC3A (14) &$
tion is actuated but 2. Defective input shaft speed sensor
there is no sensor signal
b012 Defective transmission in- 1. Intermediate shaft speed sensor system

E. ti 1.2 termediate shaft speed sen-
1) Between N2 (I) -TM2 (3) -ATC3A (12) &
E.Ct11.21 sor output
A- If disconnection detec- 2) Between N2 (2) - TM2 (4) - ATC3A (14) &
tion is actuated but
I The top code in the Display code c 0 Jmn shows the monitor panel display and the bottom code (in 1I)
shows the transmission controller L iD display.
20-308 HD3256
0
Action of controller Symptoms that appear in ma-

Condition when normal 3 : Check with tester when abnormality is
chine when there is abnormality
Mechatronics abnormality dis-
Voltage (V), current (A), resistance value Q detected play given, warning actuated
Display is as shown in the table below when shift lever is at Neutral Q 3 Actuates transmis- Transmission suddenly
sion cut relay and shifts to Neutral during
H SW (male) - chassis TM3 (male) (3) -chassis ATQA (female) (12) -chassis sets to Neutral travel and machine
L SM (male) -chassis TM3 (male) (6) -chassis ATCBA (female) (IO) -chassis Min. 1 cannot move off again
RSW (male) - chassis TM3 (male) (9) -chassis ATC5A (female) (13) -chassis
_ MPor
min. ,
1 SW (male) -chassis TM3 (male) (3) -chassis ATC5A (female) 114) -chassis yen
2 SW (male) -chassis TM3 (male1 (6) -chassis ATCSA (female) (15) -chassis tween
termi-
3 SW (male) -chassis TM3 (male) (9) -chassis ATC5A (female) (11) -chassis ,,slS
4 SW (male) -chassis TM3 (male) (12) -chassis ATC5A (female) (16) -chassis
AT1 TMC R25

Actuates transmis- Transmission suddenly
(V) & a8 sion cut relay and shifts to Neutral during
(15) -chassis (1) -chassis (1) -chassis 20-3OV - sets to Neutral travel and machine
Between cannot move off again
- - relay (I) - (2) - 100 - 5OOQ
1. Between ATCP (14) -chassis (V) 3: 12V 12V output circuit Transmission suddenly
OFF (does not give shifts to Neutral during
2. Between TMB (1) -chassis (V) 3 : 12V
+12V) travel and machine
3. Between SF (1) - (2) (V) 3 : 12V Shifts to Neutral cannot move off again
Q. Each terminal of ATC2 (14), TMB (11, SF (1) -chassis 3 : Min. 1 MQ
1. Between ATC2 (13) -chassisa: 20-60 SL Only gives self-di- Even when engine
agnostic display; speed exceeds 2,600
2. Between SL4 (male) : 20 - 60 Q
(I) - (2) 3
does not take any rpm and engine over-
3. Between ATCI (13) - ATCI (4) (V) 3 : 20 - 30 V action runs, brake to prevent
overrun is not actuated
1. Between ATCI (14) -chassis 3 : 20 - 60 Q Operation of ex- Even when accelerator

haust brake func- pedal is released and
2. Between SL4 (male) (1) - (2) 3 : 20 - 60 n
tion stopped retarder lever is oper-
3. Between ATC (5) - (14) (V) 6 : 20 - 30 V ated, exhaust brake is
not actuated.
1. Engine speed display on monitor panel is normal Speed range used 1. Gearshifting be-
during travel is comes impossible.
2. Between ATC3A (13) - (14) 3 : 500 - 1000 Q, AC 3 : Min. 0.5V
maintained 2. If shift lever is set to
3. Between each terminal ATC3A (13). (14) -chassis&: Min. 1 MQ lf shift lever is at Neutral, it becomes
4. Between El2 (male) (1) - (2) 3 : 500 - 1,000 rR Neutral, transmis- impossible to move
sion is held in Neu- machine off again
tral unless it is stopped.
Speed range used 1. Gearshifting be-

ATC3A (female) TM2 (male) Nl (male) Q& during travel is comes impossible.
Between (2) - (14) 1Between (1) - (2) 1Between (1) - (2) 500 - 1,000 n maintained 2. If shift lever is set to
Each terminal -chassis Min. 1 MQ
If shift lever is at Neutral, it becomes
Neutral, transmis- impossible to move
Speed range used 1. Gearshifting be-

ATC3A (female) TM2 (male) N2 (male) Q% during travel is comes impossible.
Between (14) - (12)1 Between (3) -(4) 1Between (1) -(2) 500 - 1,000 Q maintained 2. If shift lever is set to
Each terminal -chassis Min. 1 MQ If shift lever is at Neutral, it becomes
- Neutral, transmis- impossible to move
HD325-6 20-309
0

b013 Disconnection in transmis- 1. Output shaft speed sensor system
E. ↔ 1.3  sion output shaft speed sen- 1) Between N3 (1) – TM2 (5) – ATC3A (3)
E.C↔ 1.3  sor
fl If disconnection detec- 2) Between N3 (2) – TM2 (6) – ATC3A (14)
tion is actuated but 2. Defective output shaft speed sensor

b014 Defective model selection 1. Between ATC5B (13) – ATC1 (8)  HD325-6 Serial No.: 5680 – 6000 
 HD325-6W Serial No.: 5706 – 6000
E. ↔ 1.4  signal  HD405-6 Serial No.: 1055 – 2000

E.C↔ 1.4  fl After the starting switch 
is turned ON, depending Between ATC5B (11) – ATC1 (8)  HD325-6 Serial No.: 6001 and up
on the wiring harness,  HD325-6W Serial No.: 6001 and up

the model selection sig-  HD405-6 Serial No.: 2001 and up
nal does not match 2. Defective contact of ATC5B, ATC1 connector
b015 Short circuit, short circuit 1. R Between ATC5B (2) – TMB (2) – SF (3)
E. ↔ 1.5  with ground in lever signal N Between ATC5B (3) – TMB (3) – SF (4)
E.C↔ 1.5  system
fl When two or more lever D Between ATC5B (4) – TMB (4) – SF (5)
signals are generated, and 5 Between ATC5B (5) – TMB (5) – SF (6)
this continues for 3 seconds
4 Between ATC5B (6) – TMB (6) – SF (7)
b016 Disconnection in lever sig- 3 Between ATC5B (7) – TMB (7) – SF (8)
E. ↔ 1.6  nal system L Between ATC5B (8) – TMB (8) – SF (9)
E.C↔ 1.6  fl When there is no lever GND Between ATC5A (16) – TMB (9) – SF (2)
signal for 3 seconds
2. Defective shift lever
b017 Accelerator signal system 1. Between ATC3B (11) – TMA (13) – WAS2 (2)
E. ↔ 1.7  Disconnection, defective 2. Defective adjustment of clearance of sensor mount
E.C↔ 1.7  adjustment of mount, link
out of position 3. Damaged accelerator pedal link
fl Voltage between ATC3B 4. Defective acceleration sensor
(11) and chassis
• Min. 4.7 ± 0.1 V 5. Defective engine controller acceleration sensor power source circuit
• Max. 0.6 ± 0.1 V
b019 Short circuit with ground in 1. Between (+) ATC3B (9) – TM4 (13) – C/V.T (1)
E. ↔ 1.9  transmission valve oil tem- Between (–) ATC3A (16) – TM4 (14) – C/V.T (2)
E.C↔ 1.9  perature system
fl When transmission oil 2. Defective transmission valve oil temperature sensor
temperature sensor sig-
nal is more than 150˚C
b022 Clutch slipping or defective 1. Input shaft 1) Between N1 (1) – TM2 (1) – ATC3A (2)
| transmission speed sensor
b028 system Speed sensor 2) Between N1 (2) – TM2 (2) – ATC3A (14)
E. ↔ 2.2  fl When the input shaft 2. Output shaft 1) Between N3 (1) – TM2 (5) – ATC3A (5)
E.C↔ 2.2  speed, intermediate shaft Speed sensor 2) Between N3 (2) – TM2 (6) – ATC3A (14)
 |  speed, output shaft speed
3. One of following clutches worn or damaged: H, L, 1st, 2nd, 3rd, 4th, R
E. ↔ 2.8  are converted and it is
E.C↔ 2.8  found that there is an ab-
normality with either the
HL clutch or speed clutch.
b022 Defective H clutch or input See items for display codes b022 – b028
E. ↔ 2.2  shaft speed sensor system [E. ↔ 2.2, E.C ↔ 2.2, E. ↔ 2.8, E.C ↔ 2.8]
E.C↔ 2.2 
b023 Defective L clutch or input See items for display codes b022 – b028
E. ↔ 2.3  shaft speed sensor system [E. ↔ 2.2, E.C ↔ 2.2, E. ↔ 2.8, E.C ↔ 2.8]
E.C↔ 2.3 
20-310 HD325-6
8

Condition when normal : Check with tester chine when there is abnormality
when abnormality is
Voltage (V), current (A), resistance value Ω detected
play given, warning actuated
ATC3A (female) TM2 (male) N3 (male) Ω Speed range used 1. Speedometer shows
during travel is 0 km/h when travel-
Between (3) – (14) Between (5) – (6) Between (1) – (2) 500 – 1,000 Ω maintained ing, and gearshifting
N3 (1) – TM2 (5) – ATC3A (3) – chassis Min. 1 MΩ If shift lever is at cannot be carried out.
Neutral, transmis- 2. If shift lever is set to
sion is held in Neu- Neutral, it becomes
tral impossible to move
machine off again
unless it is stopped.

1. Between ATC5B (female) (13)  HD325-6 Serial No.: 5680 – 6000  If there is abnor- When starting switch is
 HD325-6W Serial No.: 5706 – 6000 mality when start- turned ON, machine
:0Ω

– ATC1 (female) (8)  HD405-6 Serial No.: 1055 – 2000 ing switch is turned cannot move off even

Between ATC5B (female) (11)  HD325-6 Serial No.: 6001 and up  ON, transmission is when shift lever is op-
 HD325-6W Serial No.: 6001 and up
– ATC1 (female) (8) :0Ω  HD405-6 Serial No.: 2001 and up
 held at Neutral. erated.
2. ATC5B, ATC1 connectors are securely inserted.
Shift lever Set in order of pri- 1. Shifts to same speed

ATC5B TMB SF (V) ority range or higher than
position
R (2) – chassis Between (2) – (9) Between (3) – (2) N>D>5>4>3>L range set by shift le-
If it is together with ver.
N (3) – chassis Between (3) – (9) Between (4) – (2) R, it is taken as N 2. Stays in Neutral and
D (4) – chassis Between (4) – (9) Between (5) – (2) Max. 1.5 V cannot move off.
5 (5) – chassis Between (5) – (9) Between (6) – (2) (1.0 V)
Holds at position 1. Shifts to speed range
4 (6) – chassis Between (6) – (9) Between (7) – (2) before signal higher than range set
3 (7) – chassis Between (7) – (9) Between (8) – (2) stopped by shift lever.
2. Stays in Neutral and
L (8) – chassis Between (8) – (9) Between (9) – (2) cannot move off.
Min. 15V 3. Impossible to shift be-
When lever is not set to above positions Between tween FORWARD and
above terminals (24V) REVERSE
1. Automatic gear- 1. Transmission shock

ATC3B TMA WAS2 Ω shifting is carried becomes large.
(11) – chassis Between (13) – chassis Between (2) – (3) 0.6 – 4.5V out with normal 2. Immediately shifts
mode
2. Control of clutch up when traveling
oil pressure is car- downhill
ried out as for
when accelerator
is fully depressed
ATC3B,3A (female) TM4 (female) C/V.T (male) Ω Clutch oil pressure Transmission shock
control is carried becomes large.
Between (9) – (16) Between (13) – (14) Between (1) – (2) out in mode used
1 KΩ – 100 KΩ before failure oc-
(9) – chassis (13) – chassis (1) – chassis
curred
1 ATC3A (female) Ω Sets to Neutral 1. Transmission sud-

denly shifts to Neu-
Between (2) – (14) tral during travel
Between (12) – (14) 500 – 1,000 Ω and machine cannot
Between (3) – (14) move off again
2. Power is lost when
Each terminal – chassis Min. 1 MΩ traveling, and trans-
2. See TESTING AND ADJUSTING OF TRANSMISSION mission repeatedly
shifts when travel-
3. Transmission oil is not black enough to indicate abnormality ing uphill
1. Between ATC3A (female) (2) – (14) : 500 – 1,000 Ω Sets to Neutral See items for display
codes b022 – b028
2. See TESTING AND ADJUSTING OF TRANSMISSION, H clutch [E. ↔ 2.2, E.C ↔ 2.2,
portion. E. ↔ 2.8, E.C ↔ 2.8]
1. Between ATC3A (female) (2) – (14) : 500 – 1,000 Ω Sets to Neutral See items for display
codes b022 – b028
2. See TESTING AND ADJUSTING OF TRANSMISSION, L clutch [E. ↔ 2.2, E.C ↔ 2.2,
portion. E. ↔ 2.8, E.C ↔ 2.8]
HD325-6 20-311
8

Display Abnormal system given below &, : Disconnection, short circuit in wiring harness
code * Judgment conditions
I+): Positive, (-): Negative
b024 Defective 1st clutch or out- See items for display codes b022 - b028
E. -2.4 put shaft speed sensor sys-
[E. H 2.2, E.C t) 2.2, E. H 2.8, E.C ++ 2.81
[~.~t,2.41 tern
b025 Defective 2nd clutch or out- See items for display codes b022 - b028
E. ~2.5 put shaft speed sensor sys-
[E.Cu 2.5 1 tern [E. w 2.2, E.C @ 2.2, E. e 2.8, E.C H 2.81
b026 Defective 3rd clutch or out- See items for display codes b022 - b028
put shaft speed sensor sys-
[E. w 2.2, E.C e 2.2, E. w 2.8, E.C tf 2.81
tern
b027 Defective 4th clutch or out- See items for display codes b022 - b028
put shaft speed sensor sys-
[E. ++ 2.2, E.C ts 2.2, E. tf 2.8, E.C ti 2.81
b028 Defective R clutch or output See items for display codes b022 - b028
shaft speed sensor system
[E. H 2.2, E.C t3 2.2, E. w 2.8, E.C H 2.81
[::&::I
b032 Defective pressure control 1. Dirt caught in pressure control spool

valve system
2. Short circuit, short circuit with ground in fill detection switch
bd38 Sr When the controller is
‘E. -3.2‘ issuing the command to 1) Between H SW - TM3 (3) - ATCSA (12) &j
E.Ct, 3.2 disengage the clutch, 2) Between L SW - TM3 (6) - ATCSA (10) &
I but the fill detection sig-
3) Between R SW - TM3 (9) - ATC5A (16) &
E. ~3.8 nal is still being issued
E.Ct,3.8 (clutch is engaged) 4) Between 1 SW - TM4 (3) - ATCSA (13) ,&
5) Between 2 SW - TM4 (6) - ATC5A (14) &
6) Between 3 SW - TM4 (9) - ATCSA (15) 4
7) Between4SW-TM4(12)-ATCSA(ll)&j
Defective H clutch pressure 1) Dirt caught in H clutch pressure control spool

control valve system
2) Between HSW - TM3 (3) - ATC5A (12) .&
I I
b033 Defective L clutch pressure 1) Dirt caught in L clutch pressure control spool
[~I,~;:;] control valve system
2) Between LSW -TM3 (6) - ATC5A (IO) &
1) Dirt caught in 1 clutch pressure control spool

2) Between ISW - TM4 (3) - ATCSA (13) &
1) Dirt caught in 2 clutch pressure control spool

2) Between 2SW - TM4 (6) - ATC5A (14) 4
Defective 3rd clutch pres- 1) Dirt caught in 3 clutch pressure control spool
sure control valve system
2) Between 3SW - TM4 (9) - ATC5A (15) .&
Defective 4th clutch pres- 1) Dirt caught in 4 clutch pressure control spool
sure control valve system
2) Between4SW-TM4(12)-ATC5A(ll)&
1) Dirt caught in R clutch pressure control spool

2) Between RSW - TM3 (9) - ATC5A (16) &
* The top code in the Display code c umn shows the monitor panel display and the bottom code (in 1 I)
20-312 HD325-6
0
Action cf ccntrctler Symptoms that appear in ma-

Condition when normal & : Check with tester chine when there isabnormality
when abnormality is
I. Between ATC3A (female) (3) - (14) 3 : 500 - 1,000 S2 Sets to Neutral See items for display
codes b022 - b028
!. See TESTING AND ADJUSTING OF TRANSMISSION, 1st clutch
[E. tf 2.2, EC t) 2.2,
portion. E. ++ 2.8, E.C H 2.81
I. Between ATC3A (female) (3) - (14) 3 : 500 - 1,000 Q Sets to Neutral See items for display
codes b022 - b028
!. See TESTING AND ADJUSTING OF TRANSMISSION, 2nd clutch
[E. tf 2.2, E.C H 2.2,
portion. E. w 2.8, E.C tf 2.81
I. Between ATC3A (female) (3) - (14) & : 500 - 1,000 Q Sets to Neutral See items for display
codes b022 - b028
!. SeeTESTlNGANDADJUSTlNG OFTRANSMISSION, 3rd clutch
[E. t) 2.2, E.C t;r 2.2,
portion. E. t) 2.8, E.C ti 2.81
I. Between ATCBA (female) (3) - (14) 6 : 500 - 1,000 Q Sets to Neutral See items for display
codes b022 - b028
!. See TESTING AND ADJUSTING OF TRANSMISSION, 4th clutch
[E. H 2.2, E.C H 2.2,
portion. E. ts 2.8, E.C H 2.81
I. Between ATC3A (female) (3) - (14) 3 : 500 - 1,000 Q Sets to Neutral See items for display
codes b022 - b028
2. See TESTING AND ADJUSTING OF TRANSMISSION, R clutch
[E. H 2.2, E.C H 2.2,
portion. E. H 2.8, E.C tf 2.81
Sets to Neutral Transmission suddenly

When transmission shift is at N, conditions are as in table below fi 3 shifts to Neutral during
H SW (male) -chassis TM3 (male) (3) -chassis ATC5A(female) (12) -chassis travel and machine
L SM (male) -chassis TM3 (male) (6) -chassis ATC5A (female) 110) -chassis Min. 1
MRor
R SW (male) -chassis TM3 (male) (9) -chassis ATCSA (female) (16) -chassis min. 1
1 SW (male) - chassis TM3 (male) (3) -chassis ATCM (female) (13) -chassis Fe_*
2 SW (male) -chassis TM3 (male) (6) -chassis ATC5A (female) 114) -chassis tween
termi-
3 SW (male) -chassis TM3 (male) (9) -chassis ATC5A (female) (15) -chassis nals
4 SW (male) - chassis TM3 (male) (12) -chassis ATCBA (female) (11) -chassis

H SW (male) TM3 (female) ATC5A (female) Ii:: 1 ! gor shifts to Neutral during
travel and machinecannot
-chassis (3) -chassis (12) -chassis between terminals
move off again

L SW (male) TM3 (female) ATC5A (female) 1::: ; 1 g or shifts to Neutral during
(10) -chassis between terminals travel and machinecannot
-chassis (6) -chassis
move off again

1 SW (male) TM4 (female) ATC5A (female) I$: 1 z E Or shifts to Neutral during
between terminals travel and machinecannot
-chassis (3) -chassis (13) -chassis
move off again

2 SW (male) TM4 (female) ATCSA (female) ,$‘: 1 [ E or shifts to Neutral during
move off again

3 SW (male) TM4 (female) ATC5A (female) Kjz: i i g Or shifts to Neutral during
move off again

4 SW (male) TM4 (female) ATCSA (female) $t: i 1 E Or shifts to Neutral during
-chassis (12) - chassis (11) -chassis between terminals
move off again

R SW (male) TM3 (female) ATC5A (female) 1::: 1 l g or shifts to Neutral during
move off again
HD325-6 20-313
0

Display Abnormal system given below & : Disconnection, short circuit in wiring harness
(+I: Positive, (-): Negative
b042 Defective pressure control Pressure control spool is stuck at clutch disengage position
valve system II
b&6 * When it is tried to en-
‘E. -4.2‘ gage the clutch, the con-
E.Ct14.2 troller issues the com-
I mand, but the fill sensor
E. -4.8 signal is not given, and
E.Ct, 4.8 the clutch is not engaged
b042 Defective H clutch pressure Pressure control spool is stuck at clutch disengage position
(~IC~::;] control valve
Pressure control spool is stuck at clutch disengage position
b045 Defective 2nd clutch pres- Pressure control spool is stuck at clutch disengage position
[=,z::;] sure control valve
Defective 4th clutch pres- Pressure control spool is stuck at clutch disengage position
sure control valve
b046 Defective R clutch pressure Pressure control spool is stuck at clutch disengage position
control valve
[::,::::I
b052 Disconnection in flow detec- 1. Disconnection in fill detection switch system

tion valve system
* When it is tried to en- 1) Between H SW - TM3 (3) - ATC5A (12) &
bd56
‘E. -5.2‘ gage the clutch, the con- 2) Between L SW - TM3 (6) - ATCSA (IO) &j
E.Ctt 5.2 troller issues the com- 3) Between l? SW - TM3 (9) - ATC5A (16) 4
I mand, but the fill sensor
4) Between 1 SW - TM4 (3) - ATC5A (13) ,&
E. -5.8 signal is not given.
EC++5.8 However, the clutch is 5) Between 2 SW - TM4 (6) - ATC5A (14) ,&
engaged. 6) Between 3 SW - TM4 (9) - ATC5A (15) &j
7) Between4SW-TM4(12)-ATCSA(ll)&
2. Defective fill detection switch
b052 Defective H clutch flow con- 1. Between HSW - TM3 (3) - ATC5A (12)
[;:,~ 551 trol valve system 2. Defective H clutch fill detection switch &
b053 Defective L clutch flow con- 1. Between LSW - TM3 (6) - ATCSA (IO)
[hi;:;] trol valve system 2. Defective L clutch fill detection switch &
b054 Defective 1st clutch flow 1. Between 1SW - TM4 (3) - ATC5A (13)
[;:,~;:;j control valve system 2. Defective 1st clutch fill detection switch &
*_ The top code in the Display code column shows the monitor panel display and the bottom code (in [ 1)
20-314 HD3256
0
Action of controller SYmPtoms that appear in ma-

Condition when normal 3 : Check with tester chine when there is abnormality
when abnormality is
Normal controller display: Shows 0.0 or 0.C Sets to Neutral Transmission suddenly
travel and machine
move off again
move off again
travel and machine cannot
move off again
move off again
move off again
move off again
move off again
When each speed range is engaged using the shift checker, the fill Speed range used I. Gearshifting during
sensor signal is given with the combinations shown in Table 1 during travel is travel becomes im-
Table 1 Relationship between speed range and fill sensor signal maintained possible.
lf shift lever is at 2. Ifshiftlever is setto
Neutral, transmis- Neutral, it becomes
sion is held in Neu- impossible to move
tral machine off.
When each speed range is engaged with the shift checker, the fill Seeitemsfordisplay 1. Gearshiftingduri?gtravel
becomes impossrble.
detection signal is issued for the combinations in Table 1 of the codes b052 - b058
items for display codes b052 - b058 [E. ti 5.2, E.C H 5.2 -E. tf 5.8, [E. tf 5.2, E.C t) 5.2 2. ~$i~‘~e~~~e~t~m$~~
E.C t) 5.81 -E. t) 5.8, E.C tf 5.81 sib&o move machine off.
When each speed range is engaged with the shift checker, the fill Seeitemsfordisplay l. ~~~~~~%~~~$Jl~r
items for display codes b052 - b058 IE. tf 5.2, E.C tf 5.2 -E. H 5.8, [E. tf 5.2, EC tf 5.2 2’ $$‘~e~~m~~~m$~:
E.C tf 5.81 -E. H 5.8, E.C -5.81 sib&to move machineoff.
When each speed range is engaged with the shift checker, the fill See itemsfordisplay 1. Gearshiftingdun?g~avel
becomes impossible.
items for display codes b052 - b058 [E. e 5.2, E.C tf 5.2 -E. ++ 5.8, [E. tf 5.2, E.C +-z+5.2 2’ :‘r,s~i~t’~e~o’~e~t~m~~~:
E.C t;r 5.81 -E.t,5.8,E.Ctt5.81 sible’ to move machine off.
HD325-6 20-315
0

Display Abnormal system given below 4 : Disconnection, short circuit in wiring harness
code Ir Judgment conditions
(+I: Positive, (-1: Negative
b055 Defective 2nd clutch flow 1. Between 2SW - TM4 (6) - ATC5A (14)
:. w5.5 :ontrol valve system
2. Defective 2nd clutch fill detection switch &j
E.Ct, 5.5
b056 Defective 3rd clutch flow 1. Between3SW-TM4(9)-ATC5A(15)

E. ~5.6 :ontrol valve system
2. Defective 3rd clutch fill detection switch &j
E.Ctl5.6
b057 Defective 4th clutch flow 1. Between4SW-TM4(12)-ATCSA(11)

E. ~4.4 :ontrol valve system
2. Defective 4th clutch fill detection switch ,&$
E.Ct, 4.4
b058 Defective R clutch flow con- 1. Between RSW - TM3 (9) - ATCSA (16)
E. ~5.8 :rol valve system
2. Defective R clutch fill detection switch &
E.Ctl5.8
b071 Short circuit in pressure 1. 1) Lock-up Between (+I L/U.T (I) -ATCl (1) &$
:ontrol solenoid system Between (-1 L/U-T (2) - ATCI (81, (16) &
bd78 * When it is tried to disen-
2) H clutch Between (+I H.PS (1) -ATC2 (9) &
E. ~7.1 gage the clutch,
E.Ctl7.1 l The pressure control so- Between (-1 H.PS (2) - ATCP (19) &j
I lenoid output is turned 3) L clutch Between (+I L.PS (I I- ATC2 (7) &
E. ~7.8 OFF, but the solenoid
current still flows Between (-1 L.PS (2) - ATC2 (17) 4
E.Ct17.8
or 4) 1st clutch Between (+I l.PS (1) -ATC2 (2) &
l Excessive solenoid cur- Between (-1 l.PS (2) - ATCP (13) &
rent flows
5) 2nd clutch Between (+) 2.PS (1) - ATC2 (4) 4
Between (-)2.PS (2) - ATC2 (15) 4
6) 3rd clutch Between (+I 3.PS (1) - ATCP (3) ,&
Between (-)3.PS (2) - ATC2 (13) ,.&
7) 4th clutch Between (+) 4.PS (I) - ATC2 (8) ,&
Between (-)4.PS (2) - ATC2 (18) &
8) R clutch Between (+I R.PS (1) - ATC2 (5) &
Between (-1 R.PS (2) - ATC2 (15) &
2. Defective pressure control solenoid
b071 Short circuit in lock-up pres- See items for display codes b071 - b078
E. ~7.1 sure control solenoid sys- [E. tf 7.1, E.C tf 7.1 -E. H 7.8, E.C ts 7.81
E.Ctt 7.1 tem
b072 Short circuit in H clutch See items for display codes b071 - b078
E. ~7.2 pressure control solenoid [E.~7.1, E.Ctt7.1 -E.tt7.8, E.Ctt7.81
E.Ctl7.2 system
b073 Short circuit in L clutch pres- See items for display codes b071- b078
E. ~7.3 sure control solenoid sys- [E. tf 7.1, E.C tf 7.1 - E. tf 7.8, E.C G-+7.81
E.Ctl7.3 tem
b074 Short circuit in 1st clutch See items for display codes b071 - b078
‘E. ~7.4 pressure control solenoid [E. ++ 7.1, E.C tf 7.1 -E. tf 7.8, E.C tf 7.81
E.Ctl7.4 system
b075 Short circuit in 2nd clutch See items for display codes b071 - b078
E. ~7.5 pressure control solenoid [E. tf 7.1, E.C tf 7.1 -E. tf 7.8, E.C ++ 7.81
E.Ctt 7.5 system
r The I code in the. Display

. code c umn shows the monitor panel display and the bottom code (in 1I)
. ..
snows tne transmission controller ID display.
20-316 HD3256
0
Action of controller SYmPtoms that appear in ma-

Condition when normal 3 : Check with tester chine when there is abnormality
when abnormality is
Voltage (VI, current (A], resistance value s1 detected play given, warning actuated
/hen each speed range is engaged with the shift checker, the fill Seeitemsfordisplay l. GearshiW?gduri?gtravel
etection signal is issued for the combinations in Table 1 of the codes b052- b058 [E. becomes Impossible.
ems for display codes b052 - b058 [E. tf 5.2, E.C CJ 5.2 -E. H 5.8, tf 5.2, E.C e 5.2 -E. *. $:i~t’~e~~m~~~m$~:
.C ++ 5.81 t) 5.8, E.C t3 5.81 sib&to move machineoff.
/hen each speed range is engaged with the shift checker, the fill See itemsfordisplay I. Gearshiftingduri?gaavel
codesb052-b058[E. becomes impossible.
etection signal is issued for the combinations in Table 1 of the
ems for display codes b052 - b058 [E. t;r 5.2, E.C cf 5.2 - E. t;r 5.8, t) 5.2, E.C H 5.2 -E. *’ ~$rt’~e~~m~~~m~~~:
.C H 5.81 t) 5.8, E.C tf 5.81 sibleto movemachineoff.
/hen each speed range is engaged with the shift checker, the fill Seeitemsfordisplay t. Gearshif%Jduri?gaaver
becomes !m,posslble.
etection signal is issued for the combinations in Table 1 of the codesb052-b058[E.
itIems for display codes b052 - b058 LE. H 5.2, E.C w 5.2 - E. t;r 5.8, H 5.2, E.C ti 5.2 -E. *’ :f$i~t’~e&r~~~~m~~~:
E.C H 5.81 w 5.8, E.C tf 5.81 siblk to move machine off.
-
VIJhen each speed range is engaged with the shift checker, the fill See itemsfordisplay ‘. ~~~~~~~~~~~s~Sl~,avel
dietection signal is issued for the combinations in Table 1 of the codesb052-b058[E.
itiems for display codes b052 - b058 [E. @ 5.2, E.C H 5.2 - E. H 5.8, t) 5.2, E.C ++ 5.2 -E. *. ~$rt’~e~oi~e~$~~:
E .C e 5.81 tf 5.8, E.C tf 5.81 siblk to move machine off.
-
Table 2 Solenoid valve check Actuates transmis- Transmission suddenly
sion cut relay and shifts to Neutral during
ATCI (female) ATC2 (female) Qb sets to Neutral travel and machine
- cannot move off again
Between (1) - (8), (16) 30-8OQ
Between (9) - (19)
Between (7) - (17)
Between (2) - (13)
- Between (4) - (15) 5-25L-Z
Between (3) - (13)
Between (8) - (18)
Between (5) - (15)
Resistance value between each terminal Min. 1 MR
Between each terminal -chassis Min. 1 MC2
c heck with Table 2 for the items for display codes b071 - b078
[E. H 7.1, EC t) 7.1 -E. H 7.8, E.C t) 7.81
Actuates transmis-
sion cut relay and
Transmission suddenly
[E. w 7.1, E.C ti 7.1 -E. ts 7.8, E.C ++ 7.81
Actuates transmis-
sion cut relay and
[E. tf 7.1, E.C tf 7.1 -E. t) 7.8, E.C tf 7.81
Actuates transmis-
sion cut relay and
-
C heck with Table 2 for the items for display codes b071 - b078 Actuates transmis- Transmission suddenly
[E. ti 7.1, E.C t) 7.1 -E. tf 7.8, E.C tf 7.81 sion cut relay and shifts to Neutral during
[E. ti 7.1, E.C tf 7.1 - E. H 7.8, E.C t) 7.81
Actuates transmis-
sion cut relay and
HD3256 20-317
0

lisplay Abnormal system given below &$ : Disconnection, short circuit in wiring harness
(+): Positive, M: Neaative
b076 Short circuit in 3rd clutch See items for display codes b071 - b078
.. ~7.6 xessure control solenoid [E. tf 7.1, E.C .++7.1 -E. H 7.8, E.C tf 7.81
X&7.6 system
b0077 Short circuit in 4th clutch See items for display codes b071 - b078
i. tt7.7 xessure control solenoid [E.~7.1, E.Ctt7.1 -E.~7.8, E.Cw7.81
i.cw 7.7 system
b0078 Short circuit in R clutch pres- See items for display codes b071 - b078
.. ~7.8 ;ure control solenoid sys- [E. t) 7.1, E.C H 7.1 -E. tf 7.8, E.C w 7.81
iSb7.8 :em
b091 Iisconnection in pressure 1. 1) Lock-up Between (+I L/U.T (I) -AK1 (I)&
:ontrol solenoid system Between (-1 L/U.T (2) - ATCI (8). (16) &
bd98 * When it is tried to disen-
2) H clutch Between (+) H.PS (I I- ATC2 (9) ,&
i. -9.1 gage the clutch, the
i.ctt 9.1 pressure control sole- Between (-1 H.PS (2) - ATC2 (19) ,&
I noid output is turned 3) L clutch Between (+) L.PS (1) - ATC2 (7) &
I. tt9.8 ON, but the solenoid
Between (-) L.PS (2) - ATC2 (17) ,&
I.Ctt 9.8 current does not flow
4) 1st clutch Between I+) l.PS (I) - ATCP (2) .&
Between (-1 1.PS (2) - ATC2 (13) &
5) 2nd clutch Between (+) 2.PS (1) -ATC2 (4) ,&
Between (-) 2.PS (2) - ATC2 (15) &
6) 3rd clutch Between (+I 3.PS (1) - ATC2 (3) &
Between f-1 3.PS (2) - ATC2 (13) &
7) 4th clutch Between (+I 4.PS (1) - ATC2 (8) ,&
Between f-1 4.PS (2) - ATC2 (18) 4
8) R clutch Between (+) R.PS (I I- ATCP (5) &
Between (-1 R.PS (2) - ATC2 (15) 4
2. Defective pressure control solenoid
b091 Disconnection in lock-up See items for display codes b091 - b098
E. tt9.1 pressure control solenoid [E. ts 9.1, E.C t) 9.1 -E. H 9.8, E.C tf 9.81
E.Ct19.1 system
b092 Disconnection in H clutch See items for display codes b091 - b098
E. -9.2 pressure control solenoid [E. t) 9.1, E.C t) 9.1 -E. w 9.8, E.C e 9.81
E.Ct19.2 system
b093 Disconnection in L clutch See items for display codes b091 - b098
E. -9.3 pressure control solenoid [E. t) 9.1, E.C tf 9.1 -E. cs 9.8, E.C H 9.81
E.Ctt 9.3 system
b094 Disconnection in 1st clutch See items for display codes b091 - b098
E. tt9.4 pressure control solenoid [E. w 9.1, E.C tf 9.1 -E. H 9.8, E.C ti 9.81
ES& 9.4 system
b095 Disconnection in 2nd clutch See items for display codes b091 - b098
E. t19.5 pressure control solenoid [E. ++ 9.1, E.C t) 9.1 -E. H 9.8, E.C t;r 9.81
E.Ct19.E system
b096 Disconnection in 3rd clutch See items for display codes b091 - b098
E. tt9.E pressure control solenoid [E. H 9.1, E.C ++ 9.1 -E. tf 9.8, E.C w 9.81
E.Ctt9.f system
b097 Disconnection in 4th clutch See items for display codes b091 - b098
E. -9.7 pressure control solenoid [E. ++ 9.1, E.C tf 9.1 -E. ++ 9.8, E.C tf 9.81
E.Ct19.7 system
b098 Disconnection in R clutch See items for display codes b091- b098
E. t19.E pressure control solenoid [E. w 9.1, E.C t) 9.1 -E. tf 9.8, E.C t) 9.81
E.Ct19.E system
* The top code in the Display code c umn shows the monitor panel display and the bottom code (in 1 I)
shows the transmission controller ED display.
20-318 HD325-6
0

when abnormality is
Check with Table 2 for the items for display codes b071 – b078 Actuates transmis- Transmission suddenly
[E. ↔ 7.1, E.C ↔ 7.1 – E. ↔ 7.8, E.C ↔ 7.8] sion cut relay and shifts to Neutral during
sets to Neutral move off again
When each speed range is engaged using the shift checker, the fill When b091 is displayed
sensor signal is given with the combinations shown in Table 1. Turns off lock-up 1. Lock-up does not made
turned on suddenly
Table 2 Solenoid valve check
during travel.
ATC1 (female) ATC2 (female) Ω When b092 – b098 is displayed
Between (1) – (8), (16) — 30 – 80 Ω Sets to Neutral 1. Transmission suddenly
Between (9) – (19) shifts to Neutral during
Between (7) – (17) travel and machine can-
not start again unless
Between (2) – (13) shift lever is set to [N].
— Between (4) – (15) 5 – 25 Ω
Between (3) – (13)
Between (8) – (18)
Between (5) – (15)
Resistance value between each terminal Min. 1 MΩ
Between each terminal – chassis Min. 1 MΩ
Check with Table 2 for the items for display codes b091 – b098 See items for for dis- See items for for display
[E. ↔ 9.1, E.C ↔ 9.1 – E. ↔ 9.8, E.C ↔ 9.8] play codes b091 – b098 codes b091 – b098
[E. ↔ 9.1, E.C ↔ 9.1 – [E. ↔ 9.1, E.C ↔ 9.1 –
E. ↔ 9.8, E.C ↔ 9.8] E. ↔ 9.8, E.C ↔ 9.8]
[E. ↔ 9.1, E.C ↔ 9.1 – [E. ↔ 9.1, E.C ↔ 9.1 –
E. ↔ 9.8, E.C ↔ 9.8] E. ↔ 9.8, E.C ↔ 9.8]
[E. ↔ 9.1, E.C ↔ 9.1 – [E. ↔ 9.1, E.C ↔ 9.1 –
E. ↔ 9.8, E.C ↔ 9.8] E. ↔ 9.8, E.C ↔ 9.8]
[E. ↔ 9.1, E.C ↔ 9.1 – [E. ↔ 9.1, E.C ↔ 9.1 –
E. ↔ 9.8, E.C ↔ 9.8] E. ↔ 9.8, E.C ↔ 9.8]
[E. ↔ 9.1, E.C ↔ 9.1 – [E. ↔ 9.1, E.C ↔ 9.1 –
E. ↔ 9.8, E.C ↔ 9.8] E. ↔ 9.8, E.C ↔ 9.8]
[E. ↔ 9.1, E.C ↔ 9.1 – [E. ↔ 9.1, E.C ↔ 9.1 –
E. ↔ 9.8, E.C ↔ 9.8] E. ↔ 9.8, E.C ↔ 9.8]
[E. ↔ 9.1, E.C ↔ 9.1 – [E. ↔ 9.1, E.C ↔ 9.1 –
E. ↔ 9.8, E.C ↔ 9.8] E. ↔ 9.8, E.C ↔ 9.8]
[E. ↔ 9.1, E.C ↔ 9.1 – [E. ↔ 9.1, E.C ↔ 9.1 –
E. ↔ 9.8, E.C ↔ 9.8] E. ↔ 9.8, E.C ↔ 9.8]
HD325-6 20-319
8

b060 Defective engine speed sen- 1. Engine speed sensor B system
E. ↔ 6.0  sor output 1) Between E12 (1) – J09M (9) – TMD (13) – ATC3A (13)
E.C↔ 6.0  fl Engine speed less than
350 rpm and transmission 2) Between E12 (2) – J09M (10) – TMD (14) – ATC3A (14)
speed more than 500 rpm 2. Defective engine speed sensor
continues for 10 sec.
b061 Defective output of trans- 1. Input shaft speed sensor system

E. ↔ 6.1  mission input shaft speed 1) Between N1 (1) – TM2 (1) – ATC3A (2)
E.C↔ 6.1  sensor
fl When the engine speed, in- 2) Between N2 (2) – TM2 (2) – ATC3A (14)
put shaft speed, and inter- 2. Defective input shaft speed sensor
mediate shaft speed are
converted and it is found
that there is abnormality in
lock-up clutch and HL clutch
b062 Defective output of trans- 1. Intermediate shaft speed sensor system

E. ↔ 6.2  mission intermediate shaft 1) Between N2 (1) – TM2 (3) – ATC3A (12)
E.C↔ 6.2  speed sensor
fl When the input shaft speed, 2) Between N2 (2) – TM2 (4) – ATC3A (14)
intermediate shaft speed, and 2. Defective intermediate shaft speed sensor
output shaft speed are con-
verted and it is found that there
is abnormality in HL clutch and
speed clutch (When disconnec-
tion detection is actuated and
there is no sensor signal)
b063 Defective output of trans- 1. Output shaft speed sensor system

E. ↔ 6.3  mission output shaft speed 1) Between N3 (1) – TM2 (5) – ATC3A (3)
E.C↔ 6.3  sensor
fl When the engine speed, in- 2) Between N3 (2) – TM2 (6) – ATC3A (14)
put shaft speed, intermedi- 2. Defective output shaft speed sensor
ate shaft speed, and output
shaft speed are converted
and it is found that there is
abnormality in relationship
b0A1 Abnormality in model selection 1. Defective controller box

E. ↔ A.1  fl The setting of the rotary 2. Defective setting of rotary switch
E.C↔ A.1  switch is different from
the model in the software.
b0A2 Short circuit with ground in 1. Between (+) ATC3B (7) – TM2 (7) – TC.SE (1)
E. ↔ A.2  torque converter oil tem- Between (–) ATC3A (16) – TMB (9) – TMC (5) – TM2 (8) – TC.SE (2)
E.C↔ A.2  perature system
fl When torque converter oil 2. Defective torque converter oil temperature sensor
temperature sensor signal
is more than 150˚C
b0A3 Disconnection in fuel level 1. Between (+) ATC3B (4) – TMD (7) – J02 (15) – 61 (1)
E. ↔ A.3  sensor system 2. Defective fuel sensor
E.C↔ A.3  fl Input voltage: Min. 4 V
b0b2 Short circuit with ground in 1. Between (+) ATC5B (5) – TMA (15) – J09M (12), (15) – J02 (1) – 26 (1)
E. ↔ b.2  cooling water temperature Between (–) ATC5A (16) – TMB (9) – J09M (13), (16) – J02 (3) – 26 (2)
E.C↔ b.2  sensor system
fl When input resistance 2. Defective coolant water temperature sensor
of cooling water tem-
perature sensor signal is
more than 170 Ω.

 HD325-6 Serial No.: 5680 – 6000 
 HD325-6W Serial No.: 5706 – 6000 
 HD405-6 Serial No.: 1055 – 2000
20-320 HD325-6
8

when abnormality is
1. 1. Engine speed display on monitor panel is normal Speed range used 1. Gearshifting becomes
during travel is main- impossible.
2. Between ATC3A (13) – (14) : 500 – 1,000 Ω, AC : Min. 0.5V tained 2. If shift lever is set to
3. Between each terminal of ATC3A (13), (14) – chassis : Min. 1 MΩ If shift lever is at Neu- Neutral, it becomes
impossible to move
4. Between E12 (male) (1) – (2) : 500 – 1,000 Ω tral, transmission is machine off again un-
held in Neutral less it is stopped.
Speed range used
ATC3A (female) TM2 (male) N1 (male) Ω during travel is main-
1. Gearshifting be-
comes impossible.
Between (2) – (14) Between (1) – (2) Between (1) – (2) 500 – 1,000 Ω tained 2. If shift lever is set to
Each terminal – chassis Min. 1 MΩ If shift lever is at Neu- Neutral, it becomes
tral, transmission is impossible to move
held in Neutral machine off again
ATC3A (female) TM2 (male) N2 (male) Ω Speed range used 1. Gearshifting be-
during travel is main- comes impossible.
Between (14) – (12) Between (3) – (4) Between (1) – (2) 500 – 1,000 Ω tained 2. If shift lever is set to
Each terminal – chassis Min. 1 MΩ If shift lever is at Neu- Neutral, it becomes
tral, transmission is impossible to move
held in Neutral machine off again
ATC3A (female) TM2 (male) N3 (male) Ω Speed range used 1. Speedometer displays
during travel is main- 0 km/h during travel,
Between (3) – (14) Between (5) – (6) Between (1) – (2) 500 – 1,000 Ω tained and gearshifting be-
Between N3 (1) – TM2 (5) – ATC3A (3) – chassis Min. 1 MΩ If shift lever is at Neu- comes impossible.
2. If shift lever is set to
tral, transmission is Neutral, it becomes im-
held in Neutral possible to move ma-
chine off again unless
it is stopped.
2, 3 (*) Holds at neutral When operation to

Set value of rotary switch 1 move machine is car-
4, 5 (**) ried out, machine does
  not move.
(*)  HD325-6 Serial No.: 5680 – 6000  (**)  HD325-6 Serial No.: 6001 and up
 HD325-6W Serial No.: 5706 – 6000

  HD325-6W Serial No.: 6001 and up 
 HD405-6 Serial No.: 1055 – 2000  HD405-6 Serial No.: 2001 and up
ATC3B,3A (female) TM2 (female) TC.SE (male) Ω Only gives self-di- No display at all is given
agnostic display; on torque converter oil
Between (7) – (16) Between (7) – (8) Between (1) – (2) does not take any temperature gauge dis-
1 KΩ – 100 KΩ action play on monitor panel.
(7) – chassis (7) – chassis (1) – chassis
ATC3B TMD J02 61 (V) Only gives self-diag- No display at all is given
nostic display; does on fuel level gauge dis-
(4) – chassis (7) – chassis (15) – chassis (1) – chassis 0.2 – 0.4 V not take any action play on monitor panel.
When engine water temperature is between 25˚C (normal temperature) Only gives self-di- No display at all is
and 100˚C, condition is as shown in table below. agnostic display; given on engine water
ATC3B,3A (male) TMA,TMB (male) J09M J02 61 (V) does not take any temperature gauge dis-
action play on monitor panel.
Between Between Between (12), Between Between 37 Ω
(5) – (16) (15) – (9) (15) – (13),(16) (1) – (3) (1) – (2)
|
(12),(15) (1) – (1) – 4 kΩ
(5) – chassis (15) – chassis – chassis chassis chassis
HD325-6 20-321
8

b0b3 Disconnection in brake air 1. Between (+) ATC3B (2) – TMA (7) – RH4 (1) – SR5 (1)
E. ↔ b.3  pressure sensor Between (–) ATC5A (16) – TMB (9) – RH4 (10) – SR5 (2)
E.C↔ b.3  fl When input resistance of
brake air pressure sensor 2. Defective brake air pressure sensor
signal is more than 3,000 Ω.
b0b4 Short circuit with ground in 1. Between (+) ATC3B (8) – TMD (5) – J02 (10) – 64 (1)
E. ↔ b.4  retarder brake oil tempera- Between (–) ATC3A (16) – TMB (9) – J02 (9) – 64 (2)
E.C↔ b.4  ture sensor system
fl When retarder brake oil 2. Defective retarder brake oil temperature sensor
nal is more than 150˚C
b0b7 Disconnection, short circuit 1. Between ATC3B (12) – TMD (15) – J02 (2) – 27 (3)
E. ↔ b.7  with ground in engine oil Between (+) ATC3A (6) – TMA (16) – J09M (11) – (14) – J01 (11) – 27 (2)
E.C↔ b.7  pressure sensor system 2. Defective voltage circuit inside controller
fl Voltage between ATC3B
(12) – chassis 3. Defective engine oil pressure sensor
• Min. 4.6 ± 0.1 V
• Min. 0.4 ± 0.1 V 
 HD325-6 Serial No.: 5680 – 6000 
 HD325-6W Serial No.: 5706 – 6000 
 HD405-6 Serial No.: 1055 – 2000
b0C1 Mistaken connection of con- 1. Between ATC5A (1) – ATC1 (16)
E. ↔ C1  nector 2. Defective contact of ATC5A connector
E.C↔ C1  fl After the starting switch
is turned ON, depending
on the wiring harness,
the model selection sig-
nal does not match
b0d1 Transmission filter clogging 1. Between (+) ATC5A (6) – TMD (6) – J02 (13) – 52 (1)
E. ↔ d.1  warning Between (–) J03 (8) – 52 (2)
E.C↔ d.1  fl When the transmission 2. Defective transmission filter sensor
oil filter switch is OFF
with the torque con-
verter outlet port oil tem-
perature 50˚C or above.
b0d5 Tilt warning display 1. Between (+) ATC5A (5) – TMD (2) – SR3 (1)
E. ↔ d.5  fl When the machine tilt Between (–) SR3 (2) – GND.ER
E.C↔ d.5  angle switch is OFF.
2. Defective tilt sensor
b0d6 Drop in radiator water level 1. Between (+) ATC5B (15) – TMD (4) – J02 (7) – 01 (9) – 03 (1)
E. ↔ d.6  warning display Between (–) 03 (2) – GND.16
E.C↔ d.6  fl When the machine cooling 2. Defective radiator water level sensor
water level switch is OFF.
b0d7 Battery charge warning dis- 1. Between ATC3B (1) – TMD (1) – J01 (1) – alternator terminal R
E. ↔ d.7  play 2. Defective charging circuit
E.C↔ d.7  fl When battery charge
switch is OFF with en-
gine speed at 500 rpm or
above.

 HD325-6 Serial No.: 5680 – 6000 
 HD325-6W Serial No.: 5706 – 6000 
 HD405-6 Serial No.: 1055 – 2000
b0F5 Engine oil pressure drop 1. Between ATC3B (12) – TMD (15) – J02 (2) – 27 (3)
E. ↔ F.5  warning 2. Defective engine lubricating oil circuit
E.C↔ F.5  fl When an abnormality is 3. Defective engine oil pressure sensor
recognized in the engine oil
pressure with engine speed
at 700 rpm or above.
20-322 HD325-6
8

when abnormality is
ATC3B,3A (male) TMA,TMB (male) RH4,RH1 SR5 Ω Only gives self-di- No display at all is
agnostic display; given on air pressure
Between (2) – (16) Between (7) – (9) Between (1) – (10) Between (1) – (2) does not take any gauge display on moni-
3 – 1,000 Ω
(2) – chassis (7) – chassis (1) – chassis (1) – chassis action tor panel.
ATC3B,3A (male) TMD,TMB (male) J02 64 Ω Only gives self-di- No display at all is
agnostic display; given on retarder oil
2k Ω – 20k Ω
Between (8) – (16) Between (5) – (9) Between (10) – (9) Between (1) – (2) does not take any temperature gauge dis-
(8) – chassis (5) – chassis (10) – chassis (1) – chassis (25˚C – 120˚C) action play on monitor panel.
ATC3B TMD J02 27 (V)

Only gives self-di- Drop in engine oil pres-
agnostic display; sure cannot be de-
(12) – chassis (15) – chassis (2) – chassis (3) – chassis does not take any tected.
0.4 – 4.6 V action
Between (2) – (3)
1. Between ATC5A (1) – ATC1 (16) :0Ω If there is abnor- When starting switch is
mality when start- turned ON, machine
2. ATC5A, ATC1 connectors are securely inserted. cannot move off even
ing switch is turned
ON, transmission is when shift lever is op-
held at Neutral. erated.
Only gives self-di- 1. If operations are con-

When transmission filter is normal, condition is as shown in table below. tinued, dirt will circu-
agnostic display; late in transmission cir-
ATC5A TMD J02 52 does not take any cuit.
(6) – chassis (6) – chassis (13) – chassis (1) – chassis action 2. Mechatronics abnor-
No continuity mality display is not
Between (1) – (2)
given.
3. Buzzer does not sound.
1. If operations are contin-
When machine tilt angle is ± 15˚, condition is as shown in table below. Only gives self-di-
ued, machine may roll
agnostic display; over.
ATC5A TMD SR3 does not take any 2. Mechatronics abnormal-
(5) – chassis (2) – chassis (1) – chassis, (1) – (2) Continuity action ity display is not given.
When radiator water level is normal, condition is as shown in table below. 1. If operations are contin-
Only gives self-di- ued, there will be over-
ATC5B TMD J02 01 03 agnostic display; heating.
(15) – chassis (4) – chassis (7) – chassis (8) – chassis (1) – chassis, (1) – (2) Continuity
does not take any 2. Mechatronics abnormal-
action ity display is not given.
1. Travel is possible until
When engine is running (1/2 throttle or above), condition Only gives self-di- controller power source
is as shown in table below. agnostic display; voltage drops. If opera-
ATC3B TMD J01 (V) does not take any tions are continued, bat-
action tery life will be reduced.
(1) – chassis (1) – chassis (1) – chassis 27.5 – 29.5 V 2. Mechatronics abnormal-
ity display is not given
3. Buzzer does not sound.
ATC3B TMD J02 27 (V) Only gives self-di- 1. Loses power during op-
erations.
1,000 (12) – (15) – (2) – Between 1.3 – agnostic display; 2. Engine acceleration be-
Engine rpm chassis chassis chassis (1) – (3) 5.0 V does not take any comes poor.
speed 1,800 (12) – (15) – (2) – Between 2.1 – action 3. Mechatronics abnormal-
rpm chassis chassis chassis (1) – (3) 5.0 V ity display is not given
HD325-6 20-323
8

b0E5 Steering oil temperature 1. Between ATC3A (11) – TMA (8) – J01 (6) – 21 (1)
E. ↔ E.5  overheat warning 2. Defective steering oil temperature sensor
E.C↔ E.5  fl When steering oil tem-
perature switch is ON.
b0F6 Rear brake oil pressure 1. Between (+) ATC5A (8) – TMC (12) – J03 (2) – BLSL (1)
E. ↔ F.6  warning display Between BLSL (2) – BLSR (1)
E.C↔ F.6  fl When brake stroke Between (–) BLSR (2) – GND.67
switch is ON for 2 sec-
onds. 2. Defective brake stroke sensor
b0d3 Engine water temperature Abnormal rise in engine water temperature.

E. ↔ d.3  overheat warning
E.C↔d.3  fl When engine water
nal is above 102˚C.

 HD325-6 Serial No.: 5680 – 6000 
 HD325-6W Serial No.: 5706 – 6000 
 HD405-6 Serial No.: 1055 – 2000
b0d2 Torque converter oil tem- Abnormal rise in torque converter oil temperature
E. ↔ d.2  perature overheat warning
E.C↔ d.2  fl According to network
data from monitor sys-
tem.
b0E9 Air pressure drop warning Abnormal drop in air pressure inside air tank
E. ↔ E.9  fl According to network
E.C↔ E.9  data from monitor sys-
tem.
b0F3 Retarder oil temperature Abnormal rise in retarder oil temperature

E. ↔ F.3  overheat warning
E.C↔ F.3  fl According to network
data from monitor sys-
tem.
b0d8 Engine overrun prevention Engine overrun prevention brake actuated display
E. ↔ d.8  brake actuated display
E.C↔ d.8  fl Overrun prevention brake
actuated with transmission
input shaft speed more than
2,600 rpm.
b0d9 Engine overshoot display Engine overshoot display (sudden spurt)
E. ↔ d.9  fl When d.8 does not de-
E.C↔ d.9  tect engine overshoot
display with engine
speed at 2,600 rpm or
above
20-324 HD325-6
C

when abnormality is
When steering oil temperature is 25˚C (normal temperature), condition is as shown in table below. Only gives self-di- 1. If operations are contin-
agnostic display; ued, oil may leak.
ATC3A TMA J01 21 does not take any 2. Mechatronics abnormal-
ity display is not given.
(11) – chassis (8) – chassis (6) – chassis (1) – chassis No continuity action
When brake stroke is normal, condition is as shown in table below. Only gives self-di- 1. If operations are contin-
agnostic display; ued, braking effect will
ATC5A TMD J03 BLSL become poor.
does not take any
(8) – chassis (12) – chassis (2) – chassis (1) – chassis action 2. Mechatronics abnormal-
Continuity ity display is not given.
— — — (1) – (2), (2) – chassis
Only gives self-di- 1. Lacks power during op-

agnostic display; eration.
does not take any 2. Engine acceleration be-
action comes poor.
————— 3. Mechatronics abnor-
mality display is not
given

agnostic display; tinued, oil may leak.
————— does not take any 2. Mechatronics abnor-
action mality display is not
given

agnostic display; tinued, braking effect
————— does not take any will become poor.
action 2. Mechatronics abnor-
given
agnostic display; tinued, braking effect
————— does not take any will become poor.
given
agnostic display; tinued, engine may
————— does not take any be damaged.
given
agnostic display; tinued, engine may
————— does not take any be damaged.
given
HD325-6 20-325
8
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER,
TESTING AND ADJUSTING TRANSMISSION RELATED PARTS

TRANSMISSION RELATED PARTS
Self-diagnostic display (abnormal display)
Power Neu- Con- Trans- Rear Ex- Speed Clutch Model
source tral troller mis- brake haust sen- slip selec-
sys- safety box sion sole- brake sor speed tor
Check item
tem sys- cut noid sole- sys- sensor signal
tem relay sys- noid tem sys- sys-
system tem system tem tem
. 0.3 0.5 0.6 0.8 0.9 1.0 2. 1.4

0.1 C.1 1.2 ↑
0.2 1.3 2–8
d.A
No. Category Failure mode d.b
1 Engine does
not start (1) Engine does not start b b
(1)
Does not start in any speed range b b b b b b
2 Machine (2)
Cannot start in R or D – L
does not start
After stopping and placing in N, it is impos-
(3) sible to start again b
(1) Travels forward even when lever is at N
Movement of (2) Travel forward when lever is in R
3 machine
abnormal
is
(3) Starting shock is abnormally large
when starting Starts in F3 or above
(4) (starting when machine is stopped) b
(1) Enters R, F1, F2, but does not enter F3 b
(2) Suddenly shifts down b
(3) Repeatedly shifts between certain speed ranges b
Will not shift from a certain speed range when
(4) traveling b
Movement of
(5) Engine stalls b
4 machine is
abnormal (6) Transmission shock is abnormally large
during travel
(7) Brake is applied when traveling b b
Shift limit switch is ON, but shifts up to F7 in
(8) D range and to F2 in L range
(9) Abnormal display given when overrun speed is reached b
Retarder is being operated, but transmission
(10) immediately shifts up
Transmission shifts to neutral when traveling, but it is
Suddenly (1) possible to start again with transmission shift lever at N b
returns to
5 neutral when Shifts to neutral when traveling, but impossible
(2) to start again b b b b
traveling
(3) Shifts to N when about to lock up
(1) Shift up speed is too high
6 Long time taken
to shift up (2) Long time taken to lock up
(1) Lack of power at all speed ranges
7 No power (2) Lack of power at certain speed range b
(3) Does not lock up
(1) Time lag is excessive when starting
Excessive
8 time lag (2) Takes time to shift gear
(3) Takes time to shift from FORWARD to REVERSE b
(1) Gearshifting is normal, but E display is given
9 Defective shift
indicator display (2) Gearshifting is normal, but display is wrong
Defective (1) Exhaust brake does not work b
10 actuation of Operation of exhaust brake and movement of
exhaust brake (2) machine do not match
Torque converter oil
11 temperature is high (1) Torque converter oil temperature is high
Defective monitor
12 panel gauge display (1) Gauge does not give present level display
13 Pilot lamp lights up
14 Pilot lamp lights up, defective
15 Warning display (1) Operation
Troubleshooting code when abnormal display is given A-1 A-2 A-3 A-4 A-5 A-6 A-7 A-8 A-9
ª In the case of [monitor panel display] (controller display) – [monitor panel display]
(controller display) display, for the display of A-13 b) only, measure the oil pressure of
the clutch first, and if the oil pressure is normal, carry out troubleshooting of the
electrical system. (The probability of the clutch slipping is high)
20-326 HD325-6
1
TESTING AND ADJUSTING TRANSMISSION RELATED PARTS
Self-diagnostic display (abnormal display) Monitor panel display Pilot lamps

Shift Ac- Trans- Pres- Flow Pres- Tem- Sensor Other Mis- Warn-
lever cel- mission sure de- sure pera- sys- sen- taken ing
sys- erator valve con- tector control ture tem sor con- dis-
oil (mecha- nec-
tem signal tem- trol valve sole- sen- tronics sys- tion of play Trouble-
sys- pera- valve sys- noid sor ma- tems con- shooting
tem ture system sys- sys- chine nec- Mode Shift Shift Shift Brake Body Ex- code when
system tem tem tem only) tors selec- indi- posi- lim- FLOAT haust no abnormal
tion cator tion iter brake display is
0.7 1.7 1.9 3. 5.
7. A.2 1.7 d.1 C.1 d.2 given
d.5 d.3
1.5 4. ↑ 9. A.3 d.6 d.8
1.6 ↑ 2–8 ↑ b.2 d.7 d.9
b.3 E.5 E.9
1–8 1–8 F.5 F.3
b.4 F.6
b b c c S-2
b b c
b bª b c c H-1
b
b c
—
b c
b b b H-4
—
c c —
c —
b b c H-2
b c —
c H-3
b b b H-4
c
—
b bª b —
b
c
H-5
b
H-6
b
b H-5
b
b b H-7
c
—
c
c H-18
b c c —
b H-8
b —
b —
b —
b —
A-10 A-11 A-12 A-13 A-14 A-15 A-16 A-17 A-18 A-19 A-20 P-6 P-13 P-8 P-9 F-1 F-2 F-3
fl Failure codes [b2], [F5], and [d3] is applied to HD325-6 Serial No. 5680 – 6000, HD325-6W Serial No. 5706 – 6000, HD405-6
Serial No. 1055 – 2000.
HD325-6 20-327
8
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION
TESTING AND ADJUSTING CONTROLLER SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION

CONTROLLER SYSTEM
* For details of this page, see Section 90.
20-328 HD3256
0
TESTING AND ADJUSTING A-l
A-l Abnormality in power source system

Controller
display
a) [OFF] Controller self-diagnostic display LED does not light up

0
LEB!
TWH00224
When fuse BTI (No. IO) is normal.

If it is blown, check for a short circuit with the ground in the wiring harness between the fuse and
controller.
When the battery is normal.
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on to the next step.
Cause I Remedy
2 YES
Is voltage be-
YES tween ACT1 (9).
1 (17) - (8). (16) Defective contact or
- normal? disconnection in wiring Repair or
harness between fuse BTl replace wiring
Does horn *20-30V NO (No.lO)-TMB(ll)-ACT1 harness
sound? * Turn starting (female) (9).(17)
switch ON. Defective contact or
l Turn starting harness between battery replace wiring
switch ON. NO relay M - circuit breaker harness
JO7 - BTl (19)
A-l a) Related electrical circuit diagram
cry
Y
Fuse box
. 1
(ST11 JO7
I_ Circuit breaker
I
TMC (S 12) PW fPAl ,
Overrun solenoid
Power source
Exhaustbrake solenoid
mer suurce J-l-
II
I I
GND
Power source
Transmission
cut relay
GND
I I
I I Power source 1 F
II
-
I
R25
TWH00225
HD325-6 20-329
0
Monitor Panel Controller

display display
b) pjygg$j) Drop in voltage of controller power source is displayed
TWH00226
When fuses BTI (IO) (19 - 20) and BT2 (8) (15 - 16) are normal.
If it is blown, check for a short circuit with the ground inside the controller and in the wiring harness
between the fuse and controller.
Cause Remedy
1
YES
I
1
Defective contact or dixon-
Is voltage between nection in wiring harness
ATCl (female) (8) - between ATCl Ifemale) (8). (17). Repair or
YES
TMC (female) (l), between ATCl replace wiring
(9). (16) - (17). and 2 (female) (9),(16)- TMB (female)
(7) - (17) normal? - harness
_ Is voltage between (11). or between ATCl (female)
(7) - TMC (female) (6)
*20-30V TMC (female) (1) -
L (6) and TMB (fe- - Defective contact or Repair or
. Connect 3 YES disconnection in wiring
NO male) (11) - TMC (fe- replace wiring
T-adapter to harness between ThK (male)
male) (1) normal? Is voltage between harness
ATCl . (1) - JO6 - battery relay
TMC (male) (6) -
. Start engine. *20-30V Defectivecontactor disconnection
NO chassis and TMB (11)
*Turn starting in wiring harnessbetweenTMC Repair or
-chassis normal?
switch ON. imale) (6) - ET2 (No. 6) - JO3 (13) -
replace wiring
battery relay terminal 6 or between
NO NB (male) (11) - BTl (No. 10)- harness
JO7 - battery relay terminal M
A-l b) Related electrical circuit diagram
Circuit breaker
20-330 HD325-6
0
Monitor panel Controller

display display
Drop in voltage of battery direct power source is displayed
TWH00228
When fuse BT2 (8) (15 - 16) is normal.

Cause Remedy
2 YES
System is reset
Isdifference in elec- 1 1
YES tric potential bet-
- ween ATCl (female) - Defective contact or I
1 (8)- (9)and (16) - (17) disconnection in wiring
Repair c’
Is voltage between
and (7) - (17) normal? harness between ATCl I __ ,.
replace wiring
(female) (7) - TMC (6) - BT2
ATCl (female) (8) - _ *o-5v NO
(9) and (16) - (17)
(No. 8) - JO3 (13) -3OA - I harness
* Connect T-adapter to ATCI. battery relay terminal B
normal?
*20-30V
I*Turn starting switch ON.

* Connect NO
T-adapter to
ATCI.
*Turn starting
switch ON.
A-l c) Related electrical circuit diagram
I nl
I”1
I I Fuse box I r,,,
16) ,_fBT’) , JO7 Circuit breaker
HD325-6 20-331
0

display display
d) ~(~I$$ Drop in voltage of main power source is displayed
TWH00229
When fuse BTI (IO) (19 - 20) is normal.

Cause Remedy
2 YES -
System is reset
Is difference in elec-
YES tric potential be-
- tween ATCl (female) - Defective contact or
1 (7) - (17) and (8) - (9) disconnection in wiring Repair or
and (7) - (17) normal? harness between ATCI
Is voltage be- replace wiring
*NO (female) (91117)- TMB
tween ATCI (fe- lo-5v harness
(female1 Ill) -fuse t-(10) -
male) (7) - (17) l Connect T-adapter to ATCl.
JO7 - battery relay terminal M
normal? *Turn starting switch ON.
*20-30V Replace
* Defective controller
* Connect NO
T-adapter to
ATCI.
* Turn starting
switch ON.
A-l d) Related electrical circuit diagram
FUW
Transmission controller TMC(S12) - . -
I ruse DOXU
ATCl (MIC17) (BT2) Jo*) FU
Battery Battery -
--I+
*
I I
1 I&ND I I
JO/ Circuit breaker BRLJM
Al -. on. .
I v I L3”““Ll
TWH00227
20:332 HD325-6
0

display display
el Abnormality in transmission cut relay power source is displayed

@$j)
TWH00230
* When battery and charging voltage are normal

* When fuse FBI (No. 10) is normal
+ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
YES
SeeA-4 -
1 I I
IsE.-O.6dis-
Replace
played? 2 YES Defective transmission cut
transmission
relay
Does condition be cut relay
* Turn starting come normal when
ND transmission cut re- Defective contact or
switch ON.
lay is replaced?
harness between ATCZ replace wiring
* After replacing NO (female) (11X12) - TMC (2) harness
relay, turn starting - R25 (female) (5)
switch ON.
A-l e) Related electrical circuit diagram

R25
Transmission controller Fuse box I

I
ATCl (MIC17) TMB (S16)
ATC2 (MIC21) TMC (S12)
source 1
Solenoid Power 1
source 2
TWH00231
HD325-6 20-333
0
TESTING AND ADJUSTING A-2

display display
Abnormality in neutral safety system is

A-2
displayed
TWH00232
* When the starting switch is turned to ON with the shift lever at a position other than N, or when the
power source is momentarily cut when traveling.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Ir Always connect any disconnected connectors before going on to the next step.
1
*
1 YES Mistaken operation Set shift lever
%See Operation Manual
Was startingkey 11 I toN
turnedto START
when leverwas at po- Defective contact or
sitionotherthan N? disconnection in wiring Repair or
harness between battery replace wiring
NO relay terminal M - circuit harness
breaker - JO7 - fuse 1410)
A-2 Related electrical circuit diagram
ATCl (MICi7) TMC (S12) JO6

,..,.T
llNlJ
Controller t Battery
Power source relay
GND
Controller Fuse box I
Power source
Circuit breaker
a-““=
1 TWH00233
20-334 HD325-6
0

display display
A-3 Double engagement for clutch is displayed
TWH002.34
Cause Remedy
See A-13 a) -
b032 - b038 [E.++32,
E.Co32 - E.e38, -
EL&+38 displayed
at same time? Failure of controller fqeplace
. Turn starting NO
switch ON.
HD325-6 20-335
0

display display
Abnormality in transmission [cut relay]

A-4
system displayed
TWH00.235
Ir Displays disconnection, short circuit, or short circuit with chassis ground in transmission cut relay
system.
Ir Before carrying out troubleshooting, check that all the related connectors are properly inserted.
1
YES
Defective relay
I Replace
Is E.0.6 displayed
when relay is re- -
2 YES
placed? k Defective controller Replace
~. Is resistance be-
* Replace relay R25. tween ATCl (fe- Defective contact or
*Turn starting NO male) (15) - disconnection in wiring
switch ON. (9)(17) normal?
~100-500a NO
harness between ATCl
(female) (15) - TMC (3) -
I Repair or
replace wiring
harness
l Turn starting R25 (2) or ATCl (female)
switch OFF. (9)(17) - TMB (11) - R25 (1)
* Disconnect
ATCl.

R25
I
I!ATClO (
Controller Fuse box I
(~~11 JO7 Circuit breaker
Power source x
I
I TWH00236
20-336 HD325-6
0
Monitor Controller
Panel display display
Abnormality in rear brake solenoid system is

A-5
TWH00237
Sr Always connect any disconnected connectors before going on to the next step.
Cause Remedy
3 YES Defective controller Replace
::jzH- Defective contact or

Repair or
disconnection in wiring
replace wiring
harness between ATCI
YES between ATCl *20-30V NO
(female) (4) and TMC (10) harness
- (13) (female) and - * Turn starting
1 Defectivecontactor discon-
- chassis normal? switch ON. nection in wiring harness be
Is resistance between SL4 (ll- RH4 (6) - TMS (161 Repair or
tween SL4 (male) *20-6OQ - ATCl (13, or defective contact replace wiring
- * Turn starting NO or disconnection in wiring harness
(1) and (2) nor-
switch OFF. harness between SL4 (2) - RH4 (5)
mal? - chassis ground
.20-60&-J
I Defective solenoid
*Turn starting
NO
switch OFF.
* Disconnect SL4.
Fuse box I (13~1)

TMC (S12)
-a
_ Overrun
prevention
Engine overrun
Power source
I I
77% TWH00238
HD325-6 20-337
0
Monitor Control ler

Abnormality in exhaust brake solenoid

system is displayed
TWH00239
Cause Remedy
3 YES R:eplace
Defective controller
Is voltage
be-
YES tween ATCl (5)
c and ACT1 (14)
2 Defective contact or Ii lepair or
_ normal? disconnection in wiring
Is resistance n splace wiring
*20-30V harness between ATCl (5)
YES between ATCI NO h arness
and TMC (9)
- (14) and chassis - * Turn starting
1 switch ON. Defectivecontactor discon-
P normal?
nectionin wirin harnessbe- Ftepair or
Is resistance be- P tween SL5 (1) - wH4 (4) - TMB
*20-6052 (15) - ATCl (14), or defective r’eplace wiring
tween SL5 (1) - NO
*Turn starting contactor disconnectionin t.larness
and (2) normal? wiring harnessbetween SL5 (2)
switch OFF.
and chassisground
l20-6OQ
l Turn starting Defective solenoid Fleplace
NO
switch OFF.
l Disconnect SL5.
Fuse box (13~1)

TMC (S12)
-3
Exhaust
brake
ATCl (MICi7) RH4 68) SL5 (x2) solenoid
I \ I
Exhaust brake 3
Power source
Exhaust brake 3
solenoid output
I
7sx TWH00240
20-338 HD325-6
0
A-7 Abnormality in speed sensor system

Monitor Controller
Disconnection in engine speed sensor [Bl system is displayed or
TWH00241
Monitor Controller
Failure of engine speed sensor is displayed
TWH00.242
* Before carrying out troubleshooting, check that all the related

Cause Remedy
connectors are properly inserted.
* Always connect any disconnected connectors before going on
to the next step.
Defective adjustment of
-
speedsensorB
YE is
Short circuit with chassis
ground in wiring harness
between ATCBA (female) Repair or replac
(2) - E6 (female) (l).(2) -
1 ATC3A (female) (14)
Is resistancebe-
tween ATC3A (fe-
male) (13) and (14) Defective soeed sensor B Replace
. Turn starting NO
1
as shown in Table l?
switch OFF.
l Turn starting * Disconnect E6. Defective contact or dis-
5 YES connection in wiring
switch OFF.
harness between ATC3A Repair or replac
* Disconnect Is resistance
(female) (13) - E6 (female)
ATCSA. between E6 (male)
D).(2) - ATCBA (female) (14:
NO (1) and (2) as
shown in Table l?
Defective speed sensor B Replace
* Turn starting NO
switch OFF.
* Disconnect E6:
Table 1
ATC3A (female) E6 (male) Resistance

Between (13) - (14) 1 Between (1) - (2) 1 500 a- 1006 a
Between (13) - chassis Between (1) - chassis Min. 1 MD
A-7 a) Related electrical circuit diagram
Speed
ATC3At04020) TMD(S16) J09MtS16) E6 (x2) sensor B
D @ 3
$iJ @ 3
I TWH00243
HD325-6 20-339
0
Monitor Controller
Disconnection in input shaft speed sensor system is displayed or
TWH00244
Monitor Controller
Failure of input shaft speed sensor is displayed
TWH00245
Check that the mounting bolts of the input shaft speed sensor are not loose.
Cause Remedy
2 YES Return to Item 1 and start -

troubleshooting again
YES Is 11.11 displayed _
when traveling?
System is reset
-
* Delete abnormality NO
display memory.
*Turn starting switch OFF +*ON.
* Start engine and drive machine.
disconnection in wiring qepair or
*Turn starting harness between Nl .eplace wiring
switch OFF. (female) (1). (2) - TM2 (1). G larness
* Disconnect - ATCBA (female) (2). (14)
Defective input shaft

leplace
speed sensor
*Turn starting NO
switch OFF.
*Disconnect Nl.
Table 1
ATC3A (female) Nl (male) Resistance

Between (2) - (14) Between (1) - (2) 500 n - 1000 n
Between (2) - chassis Between (1) - chassis Min. 1 MQ
A-7 b) Related electrical circuit diagram
Transmission controller Transmission

input shaft
speed sensor
ATC3At040iO) TM2 (SWP14) Nl (X2)
Input shaft
a 3 3
speed sensor (+I
Input shaft
(Lj 3 3
speed sensor (-1
TWH00246
20-340 HD325-6
0
Monitor Controller
Panel disulav display
Disconnection in intermediate shaft speed sensor system is

displayed or
TWH00247
Monitor Controller
Failure of intermediate shaft speed sensor is displayed
TWH00248
* Check that the mounting bolts of the intermediate shaft speed sensor are not loose.
Cause Remedy
2 YES Iieturn to Item 1 and start -

1:roubleshooting again
-I system is reset -
display memory.
wee” ATC3Affe- * Turn starting switch OFF- ON.
male) (12) - (14). and qepair or
* Start engine and drive machine.
between (12) - chas- Defective contact or peplace wiring
disconnection in wiring narness
3 YES harness between N2
II
* Turn starting
slstance be-- (female) (1). (2) - TM2 (3),
switch OFF. ?n N2 (male) (I) (4) - ATC3A (female) (12).
H
* Disconnect (14)
ATC3A. N
Defective input shaft
Replace
*Turn starting speed sensor
switch OFF.
* Disconnect N2.
Table 1
ATC3A (female) N2 (male) Resistance
Between (12) - (14) 1 Between (I) - (2) 1 500 Q- 1000 Q
1 Between (12) -chassis 1 Between (1) -chassis 1 Min. 1 MD I
A-7 c) Related electrical circuit diagram

I I intermediate
I TWH00.249
HD325-6 20-341
0
Monitor Controller
Disconnection in travel speed sensor (transmission output shaft

speed sensor) system is displayed or
TWH00250
Monitor Controller
~gfg$g) Failure of output shaft speed sensor is displayed
TWH00251
* Check that the mounting bolts of the travel speed sensor are not loose.
connectors are properly inserted. Cause
to the next step.
2 YES Return to Item 1 and start -
troubleshooting again
YEiS Is [1.31 displayed _
when traveling?
System is reset -
Delete abnormality NO
Is resistance bet- display memory.
ween ATC3A (fe- *Turn starting switch OFF + +ON.
male) (31- (14). and
bermen 13) -chassis * Start engine and drive machine.
as shown in Table 17 Defective contact or
Turn starting 3 YES
l
harness between N3 replace wiring
switch OFF. (female) (1). (2) - TM2 (5). (61 harness
l Disconnect -II) - ATCM (female) (31, (14)
- (2). and between
ATC3A.
shown in Table I? Defective travel speed
NO sensor
* Turn starting
switch OFF.
* Disconnect N3.
Table 1
Between (3) - (14)
Between (1) - (2) 500 n - 1000 Q
Between (3) -chassis
- Between (1) -chassis Min. 1 MQ
Card tv~e Payload meter

A-7 d) Related electrical circuit diagram
PM4 (S6)
Transmission
OutPut (+I
Transmission
OutPut (-1
Suscension controller
TMA (Sl6) SU3 LS16)

Transmission
3 @
3 @
I I

r I output shaft
speed sensor
ATC3A (04020) TM2 LSWP14) N3 (X2)
---a 3
Transmission ----a 3
I. TWH00252
20-342 HD325-6
0
A-8 Speed sensor system, clutch slipping

Monitor Controller
panel di.sPlav display
or
TWH00253
Monitor Controller
Input shaft speed sensor or H, L clutch system is displayed
TWH00254
* Check that the mounting bolts of the speed sensor are not loose.
Cause Remedy
See H-6, c)
(Oil pressure of H, L clutch1
YES * If the oil pressure is
normal, return to Item 1 -
1 and start troubleshooting
Is resistancebe- again.
tween ATCBAffe- Defective contact or
male) (2) - (14). be - disconnection in wiring Repair or
tween 12)- chassisas 2 YES
harness between ATCBA replace wiring
shown in Table 17 Is resistance be- (female) (2),(14) - TM2 harness
tween Nl (male) (1) (l),(2) - Nl (female) (1). (2)
* Turn starting - - (2), between 11)- -
switch OFF. NO chassis as shown in
* Disconnect Table l? Defective transmission
Replace
ATCBA. *Turn starting NO input shaft speed sensor
switch OFF.
* Disconnect Nl.
Table 1
ATC3A Nl Resistance
Between (2) - (14) Befween (1) - (2) 500 -1oooa
Between (2) - chassis Between (1) - chassis Min. 1 MD

input shaft
speed sensor
TM2tSWP14)
Input shaft
3
speed sensor (+I
input shaft
3
speed sensor (-1
I I TWH00246
HD325-6 20-343
0
Monitor Controller Monitor Controller

Panel display display Panel display display
Travel speed sensor system or

b1 speed clutch (I, 2,3,4, RI system
is displayed
TWH00255 TWH00256
* Check that the mounting bolts of the travel speed sensor are not loose.
Cause Remedy
See H-6, c)
(Oil pressure of speed
YES clutch 1, 2,3,4, R) -
I * If the oil pressure is normal,
return to Item 1 and start
1 I troubleshooting again.
Isresistance be- Disconnection or short circuit
tween ATCSA (fe- with chassisground in wiring
male) (3) - (14). be-- - harness between N3 (female)
tween (3) -chassis as [l),(2) - TM2 (5),(6) - ATCBA lepair or
YES [female) (3),l14),or short circuit
shown in Table l? eplace wiring
21 with chassisground in wiring
*Turn starting harnessbetween TM2 (female)(5 harness
switch OFF.
Is resistance be- TMA (1) - SU3 (2) - SSPZB
tween N3 Imale) (1) (female)(2) or betweenTMA
* Disconnect - - (2). between (I) - . (male) (1) and PMCPA(3) (female
ATC3A. NO chassis as shown in
Table l?
*Turn starting I Defective travel speed
switch OFF. N0 sensor
* Disconnect N3. _-- I I
Table 1
Between (3) - (14)
Between (1) - (2) 5oon-1000a
Between (3) -chassis
- Between (I) -chassis Min. 1 M!2
A-8 b) Related electrical circuit diagram Card tvPe Payload meter

r
PM4 LS6) PM5 (MIC13)

I output shaft
TM2 (SWP 14) speed sensor
ATCSA (04020) N3 (X2)
8 3
OutPut (+I
Transmission
8 3
TWH00252
20-344 HD325-6
0
A-9 Abnormality in model selection (wiring harness) is displayed
a) Abnormality in model selection (wiring harness) is displayed
fl When the controller power source is normal.

fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on to the next step.
Cause Remedy
2 YES Defective transmission

controller Replace
Under same condi-
YES tions as when
measuring Item 1,
1 is [1.4] displayed?
Is voltage between System is reset —
• Delete abnormality NO
ATC5B (10) (11) (12)
display memory.
(13) and ATC1 (8) as
shown in Table 1?
• Turn starting switch OFF → ON
and start engine.
• Turn starting • Wait for 20 seconds.
switch ON. harness between ATC5B
(female) and ATC1 replace wiring
NO (female) - TMC (12) - harness
chassis ground
Table 1
HD325-6 Serial N0.: 5680 – 6000 HD325-6 Serial N0.: 6001 and up
HD325-6W Serial N0.: 5706 – 6000 HD325-6W Serial N0.: 6001 and up
HD405-6 Serial N0.: 1055 – 2000 HD405-6 Serial N0.: 2001 and up
ATC5B ATC1 Voltage
(10) – (8) Min. 15 V Min. 15 V
(11) – (8) Min. 15 V Max. 1 V
(12) – (8) Min. 15 V Min. 15 V
(13) – (8) Max. 1 V Min. 15 V
HD325-6 20-345
8
Monitor Controller
b) m@t==-&j) Abnormality in model selection (rotary switch) is displayed
TWH00259
Sr When the controller power source is normal.

Sr Before carrying out troubleshooting, check that all the related connectors are properly inserted.
t Always connect any disconnected connectors before going on to the next step.
Cause Remedy
I YES Defective transmission

Replace
controller
Is model selection
switch (rotary
switch 1) as
shown in Table I? Set to ap-
Defective setting plicable number
* Turn starting NO
switch OFF.
- Remove cover of
switch 1.
- Remove cover
Switch 2 Switch 1
Rotary switch (switch 1, 2) combinations

(Switch 1 setting) - (Switch 2 setting)
TWH00763
20-346 HD3256
8
A-10 Abnormality in shift lever system

Monitor Controller
al Short circuit in shift lever assembly power source is displayed
TWH00261
* When the controller power source is normal.

Cause Remedy
2 YES
Defective controller leolace
When connector
YE is returned to
original position,
is IO.71 displayed?
System is reset -
1
display memory.
between ATCP * Turn startina switch
(female) (14) and OFF +t ON:
II YES Defective shift lever
Xeplace
If resistancevalue in I assembly
*Min. 1 MCZ
* Turn starting Item 1 is abnormal,
keep same rneaaure-
switch OFF.
ment conditions,and
* Disconnect N It; disconnect SF. Does
ATC2. resistance value be- tepair or
come normal?
I between ATC2 (female) eplace wiring
* Min. 1 MQ (14)-TMB(l)-SF rarness
. Turn starting (female) (1)
switch OFF.
* Disconnect SF.
ransmission controller
ATCZ(MIC21)
ATMA(04020)
Transmission
Shift lever N Yer
Shift lever D
Shift lever 6
Shift lever 4
Shift lever 3
Shift lever L
TWH00262
HD3256 20-347
0
Monitor Controller
b) Eq (k/-&j) Shift lever position signal input for 2 or more systems is displayed
TWH00263
-k Before carrying out troubleshooting, check that all the related connectors are properly inserted.
F
Remedy
tepair or
Abnormality in
system (D,5,4,3,L) >/$i;g;$$t’t$; eplace wiring
rarness
Defective transmission
neutral relay (internal teplace
short circuit)
YE ; :s::::y
~~~~~ Defective payload meter
relay (internal short
circuit)
Short circuitwith chassis
seplace
ground in wiring harness be-

tween transmission neutral lepair or
relay R02 (female) (2) -SF eplace wiring
. Turn starting NC (female) (4) - TMB (3) - ATCBB rarness
switch ON. (female) (3) or between pay-
1 . Lever position: D load meter relay and SF
(female) (4) (*See Table 1)
Does existing 3 YES Defective backup alarm ?eplace
lever position relay
Abnormality K_j%%&%$HP
1exist? system WI)
%Order of operation between SF (female) (3) - lepair or
*Turn starting backup alarm relay R05 eplace wiring
-Turn starting NO (female) (2) or between SI iarness
switch ON.
switch ON. (female) (3) - TMB (2) -
* Operate lever N-+i
* Lever position: D ATC5B (female) (2)
+D+5+4-+3+L,
and check signal Defective shift lever
qeplace
input. assembly
*The system where
the lever position is
restored is abnormal.
%For details of the
abnormal system and
the related wiring
harnesses, see Table 1.
20-348 HD325-6
0
Table 1
1 Abnormal system 1 Svstem with failed wirina harness
I N SF (4) - ATC5B (3) -transmission neutral relay

R02 (2) - oavload meter relav Rll (6)
R SF (3) -ATC5B (2) - backup alarm relay R06 (2)
D SF (5) - ATC5B (4)
5 SF (6) - ATC5B (5)
4 SF (7) - ATC5B (6)
3 SF (8) - ATC5B (7)
L SF (9) - ATC5B (8)
Transmission
neutral relay Backup alarm relar Parload meter relay
R02 ROS Rll
Fuse box I
(ET11
T ransmissioncontroller J
,
ATCP(MICi1) I I I
I I
1
m-
ATC3A(040iO) /I
I
Shift lever R
Shift lever N
Shift lever D
Shift lever 5
Shift lever 4
Shift lever 3
Shift lever L
L I TWH007.64
HD3256 20-349
0
Monitor Controller
Shift lever position signal is not input
TWH00265
Cause Remedy
See E-10 a) (12V system) -
3 YES
lefective controller (eplace
IsIO.71display-
ed? YE
pijiGij[-
System is reset -
- Delete abnormality NO
display memory.
*Turn starting switch OFF-ON.
* Operate transmission shift lever in
order shown in Table 1.
disconnection in wiring lepair or
4 YES
l Turn starting harness between problem eplace wiring
switch ON. ATCBB (female) and SF rarness
* Operate lever pi?$5$+- (female)
N+R +D+5 +4 N
+3+Landcheck Defective shift lever
sssemblv ieplace
signal input. - Turn starting NO
See Table 1 to switch ON.
judge. * Set lever to position where failure
Re-enaction test occurred, and measure +12V power
source and signal from position of
failure. See Table 1 to judge.
Table 1
Shift lever SF
20-350 HD325-6
0
A-10 c1 Related electrical circuit diagram
Transflission controller
Transmission
Shift lever N
Shift lever D
Shift lever 5
6
3 7
6
8
I I TWHD0262
HD325-6 20-351
0
TESTING AND ADJUSTING A-II
Monitor Controller
A-II Abnormality in accelerator signal is displayed
TWH00266
Cause Remedy
2 YES
I I I Defective controller
With hem 1 nor-
YE
mal, is Il.71 dis- -
played?
System is reset -
display memory.
tween ATCSB (I I) *Turn starting switch
OFF-ON. Repair or
and ATC3A (16)
replace wiring
Defective contact or discon-
harness
* l.O-4.ov 3 YES section in wiring harness
* Turn starting
I I I aetween ATC3B (female) Ill)
Is voltage bet- ‘TMA (13) - AS2 (female) (2)
switch ON. ween ATC3A (6) -
* Accelerator NO and (16) normal? Defective contact or
pedal: disconnection in wiring Repair or
Slowtk Full iarness between ATCSA replace wiring
-4.6 - 5.4 V NO :female) (6) - TMA (16) - harness
* Turn starting AS2 (female) (3)
switch ON.
A-l 1 Related electrical circuit diagram
I Accelerator
ATC3At04020) TMB (Sl6) WAS2 (X3) sensor
-3
3
ATC3Bt04016) T”m) 3
I \,1 I
ID\ +
1 I TWH00267
20-352 HD3256
0
Monitor Controller
(EHj) Abnormality
sensor
in transmission
is displayed
oil temperature
TWH00268
Cause Remedy
2 YES -
-C refective controller
With Item 1 nor-
YEiS
mal, is 11.91 dis- -
played?
s;ystem is reset -
1 . Delete abnormality NO
display memory.
tween ATC3A (16) *Turn starting switch
OFF f-f ON. Cjefective contact,
dlisconnection, or short
C ircuit with chassis
sepair or
*Turn starting 3 YES
Iround in wiring harness ‘eplace wiring
switch OFF. I I I iarness
Is resistance be- Eletween CTV (female)
al-5ookQ l),(2) -TM4 (13),(14) -
- tween CTV (male) -
* Disconnect : \TC3A (16) - ATC3B (9)
NO (1) - (2) normal?
ATC3A and 38. _I: jefective transmission oil
ttemperature sensor
<eplace
.I-500kQ NO
* Disconnect CTV
Transmission controller CYT (~2) Transmission oi I

I TM4 (SWP14) . temperature sensor
ATC3At04020) @ 3
Sensor GND @ 3
I
ATC3B(04016)
Transmission oil
&-
temperature sensor
TWH00269
HD325-6 20-353
0
A-13 Abnormality in pressure control valve system

a) (E/q) Fill signal (clutch ON) is displayed

regardless of command
TWH00270 TWH00271
Cause
See H-6, c).

YES * If the hydraulic pres-
sure is normal, return -
to item 1 and start
troubleshooting again.
chassisand wiringbar-~ Wiring harness in
nessbetweenATCBA problem circuit short Repair or
2 YES
(female)and SW as circuiting with ground replace wiring
Are voltage and re- harness
shownin Table l? (See Table 1)
sistancevalue be-
* When measuring - tween q SW (male) -
voltage, turn NO and chassisas Defective fill switch in
startingswitch 0~. shown inTable l?
problem circuit (See Replace
l When measuring * The measurement NO Table 1)
resistance, turn conditions are the
starting switch same as for Item 1.
OFF. * 0 indicates H, L,
* Disconnect ATC5A. 1, 2, 3.4, or R.
Table 1
r 1Connection of connector and fill switch 1 Fill switch 1

When connected When open
er connector kill Switch
Binnumber Voltage Resistance Voltage Resistance
I
b032[E.c+3.2,
H clutch ATCM (12) -H. SW Max. 1 V Max. 1 !G? 15-25V Min. 1 MQ
E.C*3.21
b033IE.ct3.3,
L clutch ATC5A (10) - L. SW Max. 1 V Max. 1 Q 15-25V Min. 1 MQ
E.Ce3.31
b034[E.*3.4, Min. 1 MQ
1 clutch ATCBA (13) - 1. SW Max. 1 V Max. 1 Q 15-25V
E.C*3.41
b035IE.++3.5,
2 clutch ATC5A (14) - 2. SW Max. 1 V Max. 1 S2 15-25V Min. 1 MQ
E.Cw3.51
b036[E.*3.6, 15-25V Min. 1 MQ
3 clutch ATC5A (15) - 3. SW Max. 1 V Max. 1 G
E.C++3.61
;pc”“y&3.7, Max. 1 V Max. 1 Q 15-25V Min. 1 MR
4 clutch ATC5A (11) -4. SW
*
b038[E.*3.8,
R clutch ATC5A (16) -R. SW Max. 1 V Max. 1 Q 15-25V Min. 1 MO
E.Cct3.81
20-354 HD3256
0
TMC 612) JO6 HSW(Xl)
Fill
Fill
Fill
Fill
Fill
ATC6At04020)
switch
switch
switch
switch
switch
L
1
2
_I
r d
TM3 (SWP14)
r
_
3
6
#
TM4UWP141
.
i
Fill switch 3
Fill switch R
r
TWH00272
HD325-6 20-355
0

Fill signal is not input and clutch

(b$$) slipping is displayed
TWH00.273 TWH00274
* Measure the clutch oil pressure of the system where the abnormality is displayed. If the oil pressure
is normal, carry out the troubleshooting below.
b-l) Inspecting fill signal system
I Cause Remedy
YES See H-6~). -

1 (Clutch oil pressure)
Is resistance and
voltage between
ATCBA (female) - Applicable switch (fill
and chassis as 2 YES Replace
switch) defective, see
shown in Table l? - Is voltage between Table 1
* Disconnect q SW (fill switch)
ATC5A. NO (female) and chassis
as shown in Table I? Applicable circuit wiring Repair or
harness defective, see replace wiring
*Turn starting NO Table 1 harness
switch ON.
* Disconnect 0 SW.
* 0 indicates H, L, 1,
2,3,4. or R.
Table 1
20-356 HD3256
0
b-2) Inspecting transmission input shaft speed signal system, H, L clutch system (check clutch slip)
TWH00273 TWH00275
j, Before carrying out troubleshooting, check that all the related connectors are properly inserted.
I
b-3) Inspecting transmission output shaft speed signal system, 1-4, R clutch system
(check clutch slip)
(E/q ) is displayed
TWH00276 TWH00.274
Gototroubleshooting
of A-7 a).
TMC (S 12) JO6
GND _a
IGND >q TM3 (SWP14)
ATC6A (04O:O)
Fill switch L
Fil I switch 4
Fill witch H
Fill switch I
Fill switch 2
F
TWH00272
HD325-6 20-357
0

TWH00278 TWH00278
Carry out troubleshooting of A-13 b-l) Fill

signal system. Respond to the display as
follows.
5.2 e* 4.2
5.3 tf 4.3
5.4 u 4.4
5.5 t* 4.5
5.6 t--* 4.6
5.7 u 4.7
5.8 u 4.6
TWH00272
20-358 HD3256
0

A-15 m (f$-q) -
TWH00280 TWH00281
TWH00282 TWH00283
Remedy
2 YES Return to Item 1 and start

When connector is troubleshooting again
YES returned to original _
position, is 07.09,
1 displayed? NO
System is reset -
Is resistance of * Delete abnormality display memory.
ARC1 or ATC2 (fe- _ *Turn starting switch OFF-ON.
male) as shown in * Put 1 - 8 inside 0. disconnection in wiring ?epair or
Tables 1 and 2? 3 YES harness between problem .eplace wiring
.XMeasure at pin Is resistance be- ATCI or ATC2 - TM3 or
tween 0 PS or larness
no. where ab- TM4-[IPSorLCT
- LCT (male) (1) and - (female)
norma’ disp’aY NO (2) as shown in Ta- 3eplace
is given. Applicable solenoid is
bles 1 and 2? .4~&-.,.C.,~
*Turn starting spplicable
* Turn starting See Table 1 solenoid
switch OFF.
l Disconnect ATCl switch OFF
Disconnect III PS
l
or ATCZ.
or LCT.
Cl indicates H, L,
l
1,2,3,4, or R.
Table 1 Table 2
1 ‘““‘““i It locatior
Measurement Measurement
item IVormal value )isPtaY Trouble- Trouble- item Normal value
1
shooting shooting 2
Resistance Resistance
Between 5-25.Q 30-80R
7.2 Between t between (I) - (2) letween (1) - (2:
ATCl HPS
9.2
(9) - (19) (1) -(2)
7.3 Between Between Between Between

7.1
ATC2 LPS ATCl LCT
9.3 9.1 Resistance
(7) - (17) (l)-(2) (l)-(8)tlf (1) - (2)
between (2) - Min. 1 MD
7.4 Between Between chassis ground
ATCP 1 PS
9.4
(2) - (13) (1) -(2)
Resistance
7.5 Between Between Min. 1 MR
between (21-
ATC2 2 PS
9.5 chassis ground
(4) - (15) (l)-(2)
7.6 Between Between * b0 [E., E.C] is omitted from the Display column.
ATC2 3 PS
9.6
(3) - (13) (1) - (2)
7.7 Between Between
9.7 ATC2 4 PS
(8) - (18) (11- (2)
7.8 Bep;n Between

RPS
9.8
(5) - (15) (l)-(2) -
HD3256 20-359
0
HPS (X2)
-3
3
TM3 (SWP14)
?I-
I I I I
Solenoid 1.3 (-)
Solenoid 2.R (-)
Solenoid L C-1
m TWH00284
20-360 HD325-6
0
A-16 Abnormality in sensor system

Monitor Controller
a) Abnormality in torque converter oil temperature sensor system is

displayed
TWH00285
* When the controller power source is normal.

Cause Remedy
Contact of chassis ground

and wiring harness After inspec-
YES
between ATC3B (female) tion, repair or
(7) - TM2 (7) - TC.SE replace
(female) (I)
Defective torque
YES
converter oil temperature Replace
chassis ground? Does display area sensor
* Turn starting
verter oil temper-
switch OFF.
* Disconnect
TC.SE, ATCBA,
and ATC3B. Defective transmission
Replace
*Turn starting NO controller
switch OFF.
. Disconnect TCSE.
* Turn starting
switch ON.
TM2
Transmission controller LSWP 14) TC, SE Torque converter
oil temperature
sensor
ATC3B (04016)
oil temperature
TWH00286
HD325-6 20-361
0
Monitor Controller
Abnormality in fuel level sensor system is displayed
TWH00287
(It takes 30 seconds for the fuel gauge to change 1 level. Take this into account when carrying out
troubleshooting.)
Cause Remedy
YES
Defective fuel sensor Replace
1 I
, .. i
Does fuel gauge
display FULL? YES
* Turn starting
switch OFF.
disconnection in wiring After inspec-
. Disconnect
harness between ATC3B tion, clean or
CN-61. .4-loon NO (female) (4) - TMD (7) - replace
* Connect CN-61 * Turn starting JO2 (15) - CN-61 (female)
(female) to chassis switch OFF.
ground. . Disconnect PO9.
*Turn starting
switch ON.
ATC3B (04Oi6) TMD (S16) JO2 (S16) CN-61 (Xl) ~~~kaUge

Fuel level .a 3
TWH00288
20-362 HD3256
0
Abnormality in cooling water temperature sensor system is

c)
displayed
HD325-6 Serial No.: 5680 – 6000

HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
Cause Remedy
YES Defective engine water Replace

1 temperature sensor
Does water tem-
perature gauge and wiring harness between After inspec-
show lowest level? 2 YES
ATC3B (female) (5) - TMA tion, clean or
Is there continuity (15) - J09M (12) - (15) - J09 replace
• Turn starting between P09 (fe- (1) - CN-26 (female) (1)
switch OFF. NO male) (4) and
• Disconnect CN-26. chassis ground?
• Turn starting Defective controller Replace
• Turn starting NO
switch ON. switch OFF.
• Disconnect CN-26
and P09.
A-16 c) Related electrical circuit diagram
HD325-6 20-363
8

display display
d) Abnormality in air pressure sensor system is displayed
TWH00291
YES Defective air pressure

Replace
sensor
1
Does air pressure

* YES
gauge show Defective controller
FULL?
Is there continuity
*Turn starting between ATCSB Defective contact or
3 YES
. ;E;;;z;:SR5, NO $%ek%~: P harness between ATC3B tion, clean or
Is there continuity (female) (2) - TMA (7) - RH4 redace
ATC3A. and - between SR5 (fe- (1) SR5 (female) (I)
ATC3B. •,“,sn~~~h~” NO male) (2) and Defective contact or
* Connect short chassis ground? disconnection in wiring After inspec-
connector to SR5 SR5 (female). harness between ATC3A tion, clean or
(female). * Turn starting NO (female) (16) - TMB (9) - RHl replace
* Turn starting switch OFF. (10) - SRS (female) (2)
switch ON. - Disconnect SR5.
Air Pressure
sensor
Transmission
controller
I S,R5 !X21)
I
ATC3At04020) TMB (S16) RHl (SlO) -3
Sensor GND 3 @ 3
I
ATC3B (04016) TMA (S/6) RH4 (S8)
1 Air Pressure sensor/d b( 1 b( 1
TWH00292
20-364 HD325-6
0

display display
‘) m (Fig) Abnormality
displayed
in retarder brake oil temperature sensor system is
TWH00293
Remedy
YES Defective retarder oil

Replace
1 temperature sensor
Does retarder oil
temperature Contact of chassis ground
and wiring harness After inspec-
gauge show low- 2 YES
f between ATC3B (female) tion, repair or
est level? Is there continuity (8) - TMD (5) - JO2 (10) - replace
* Disconnect between ATCSB CN-84 (female) (1)
CN-84. NO (female) (8) and
* Turn starting chassis ground?
switch ON. Defective controrra’ Replace
* Turn starting NO
switch OFF.
* Disconnect CN84, ATC3A.
and ATC3B.
A-16 e) Related electrical circuit diagram
Transmission J09MtS16)
:ontrol ler
Retarder oi
ATC3B (04Oi6) TMD (Sl6)

Retarder brake
oil temperature
TWH00294
HD325-6 20-365
0
A-17 Warning display

Monitor panel Controller
display display
a’ ~#g-$j) Transmission filter clogged warning is displayed
TWH00.295
* Before carrying out troubleshooting, check that the transmission oil filter is not clogged.
f Always connect any disconnected connectors before going on to the next step.
Cause Remedy
3 YES
Defective controller qeplace
Is there continuity
YES between ATC5A
(6) and chassis Defective contact or dis-
2 connection in wiring Repair or
F ground?
Is there continuity p P harness between ATC5A replace wiring
YES between 52 (fe- *Turn starting NO (female) (6) - TMD (6) - JO2 harness
male) (2) and - switch OFF. (13) - CN-52 (female) (1)
1 * Disconnect
~ chassis ground? Defective contact or
Is there continuity ~ ATC5A. disconnection in wiring Repair or
between 52 * Turn starting harness between CN-52 replace wiring
(male) (I) and - switch OFF. NO (female) (2) and JO3 harness
.~.
121) * Disconnect (female) (8)
’ 1 CN-52.
*Turn starting
I Defective transmission oil
switch OFF. 3eplace
NO filter sensor
- Disconnect
CN-52.
Transmission
controller
I CN-52 Transmission
ATC5A(04020) TMD (S16) JO2 (S16) (x2) oil filter sensor
Transmission
a 3 3
oil filter
3
Battery relay
onitor Panel
I CN-30
DP05 (04012) JO3 (Sl6)
E-Y
@d - M
111 ck \/
I I TWH00.296
20-366 HD325-6
0

display display
b) Eq ( FDg) rlt warning is displayed
TWH00297
+ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Cause Remedy
Vormal -
1 4 YES
Replace
Is there continuity
to RAISE and is YES between ATC5A
body tilting to side 3 (female) (5) and Defective contact or dis-
more than +18? chassis ground? connection in wiring Repair or
Is there continuity _-[ harness between ATC5A replace wiring
YI between RH2 _ * Turn starting NO (female) (5) - TMD (2) - SR: harness
(male) (7) and switch OFF. (female) (1)
(817 l Disconnect ATCM.
. Turn starting Defective body RAISE
switch OFF. NO switch
* Disconnect
RH2.
* Turn starting
switch OFF. Defective tilt sensor
* Disconnect D
SR3.
Transmission
controller
I
ATC5At04020) TMD (S16)
3
Ti It
sensor
RH2 (S12)
.a
.a
Body RAISE
switch
TWH007.98
HD325-6 20-367
0

display display
Drop in radiator water level warning is displayed
TWH00299
* Before carrying out troubleshooting, check that the cooling water level is not low.
Cause Remedy
YES
Drop in water level dd water
1
Is radiator water
3 YES
level outside speci- Defective controller eplace
1 Is there continuity1 7
11
fied range (below
1
LOW level)? Defective contact or dis-
connection in wiring epair or
harness between ATC5B ?place wiring
i
(female) (15) - TMD (4) -
arness
;2;);le) (1) and 1 syitch OFF.- JO2 (7) - CN-01 - CN-03
NO (female) (I)
- Disconnect ATC5B.
L
-Turn starting I Defective radiator water eplace

switch OFF. NO level sensor
- Disconnect
CN-03.
A-l 7 c) Related electrical circuit diagram
Transmission
controller Radiator
water level
ATCSB (04016) TMD 61 6) JO2 6516) LSWP14) . ..-. sensor
Coolant level 3
1
I f-3
TWH00300
20-368 HD325-6
0

display display
Battery charge warning is displayed
TWH00301
Remedy
Mr
YES
Defective contact or dis-

connection in wiring Repair or
2 YES
harness between ATC3B replace wiring
.a hdh.,san (female) (1) -TMD (1) - JO1 harness
*20-3ov alternator terminal (1) -alternator terminal R
* Start engine. NC R and chassis
* Connect T-adapter ground normal?
Defective alternator Replace
to ATC3B. *20-30V NO
* Start engine.
Transmission
controller Radiator
1
ctq-0 w-03 water level
ATC5Bt04016) TMD (S16) JO2 (S16) (SWP14) (X2) sensor
Coolant level 1 4
i PC ’ - r-D\
7iv” - TWH00300
HD3256 20-369
0

display display
1: 1:
t. C.-l
e) Steering oil temperature overheat warning is displayed
1: I- 1: 1:
EE3L.L I_._’
TWH00302
* Before carrying out troubleshooting, check if the steering oil temperature is high.
Cause Remedy
:0110w
nstructions in
2 YES Abnormality in steering
Operation and
I I I oil temperature
wl;l;;;ance
YE Is E51 displayed
when sensor is -
replaced?
1 Defective steering oil
leplace
NO temperature sensor
. Replace sensor.
between CN-21 . Turn starting switch
ON. Defective contact or dis-
connection in wiring ?epair or
3 YES harness between ATC3A ,eplace wiring
l Turn starting Is there continuity (female) (11) - TMA (8) - larness
switch OFF. between ATC3A JO1 (6) - CN-21 (female) (I)
l Disconnect B I (female) (11) and
CN-21. chassis ground?
System is reset -
. Turn starting NO
switch OFF.
* Disconnect
ATCJA.
A-17 e) Related electrical circuit diagram
Transmission
controller
I CN-21 Steering oil
temperature
ATC3At04020) TMA (S16) JO1 (S16) (Xl) sensor
temperature
TWH00303
20-370 HD325-6
0
f) Drop in engine oil pressure warning is displayed
HD325-6 Serial No.: 5680 – 6000

HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
fl Before carrying out troubleshooting, check if the engine oil pressure is low.
Cause Remedy
YES
1
Is voltage be-
tween ATC3B (12) Carry out
and ATC3A (16) 2 YES Drop in engine lubricating maintenance of
normal? oil pressure engine
Is [E.5] displayed lubricating oil
• 0 – 2.1 V when sensor is
• Start engine. NO replaced?
• Raise engine Defective engine oil
speed to more temperature sensor Replace
• Replace sensor. NO
than 1800 rpm. • Start engine.
A-17 f) Related electrical circuit diagram
HD325-6 20-371
8
g) Rear brake oil pressure warning is displayed
fl Before carrying out troubleshooting, check if the rear brake chamber has reached the end of its
stroke.
Cause Remedy
3 YES
Is there continuity
YES between ATC5A
(8) and chassis
2
ground?
Is there continuity To A
YES between BLSL • Turn starting NO
(male) (1) and switch OFF.
1 • Disconnect ATC5A.
(2)?
Is there continuity Defective brake stroke
between BLSR • Turn starting Replace
switch OFF. NO sensor (rear left)
(male) (1) and
(2)? • Disconnect
BNSR.
• Turn starting Defective brake stroke
switch OFF. Replace
NO sensor (rear right)
• Disconnect
BLSL. Defective contact or dis-
connection in wiring Repair or
YES
harness between ATC5A replace wiring
4 (female) (8) - TMC (12) - harness
Is there continuity J03 (2) - BLSL (female) (1)
From A between BLSL Defective contact or dis-
(female) (2) and 5 YES connection in wiring Repair or
chassis ground? harness between BLSL replace wiring
Is there continuity (female) (2) and BLSR harness
• Turn starting between BLSR (female) (1)
switch OFF. NO (female) (2) and Defective contact or Repair or
• Disconnect chassis ground? disconnection in wiring
BLSL. replace wiring
• Turn starting NO harness between BLSR
(female) (2) and 67 harness
switch OFF.
• Disconnect BLSR.
A-17 g) Related electrical circuit diagram
20-372 HD325-6
1
A-18 Abnormality in engine oil pressure sensor

system is displayed
HD325-6 Serial No.: 5680 – 6000

HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
Cause Remedy
2 YES
YES
Is [b.7] displayed?
1 NO
System is reset —
Is voltage • Delete abnormality
between ATC3B display memory.
(12) and ATC3A • Start engine. Defective contact or dis-
(16) normal? 3 YES connection in wiring Repair or
harness between ATC3B replace wiring
• 0.45 - 4.5 V (female) (12) - TMD (15) - harness
Is voltage be- J02 (2) - CN-27 (female) (1)
• Turn starting
tween ATC3A (6)
switch ON. NO and (16) normal? Defective contact or
harness between ATC3A replace wiring
• 4.6 - 5.4 V NO (female) (6) - TMA (16) - harness
• Turn starting J09M (11) - J09M (14) - J01
(11) - CN-27 (female) (2)
switch ON.
HD325-6 20-373
8
A-19 Abnormality in connector connection is dis-

played
Cause Remedy
YES Defective wiring harness Repair or

(Disconnect wiring replace wiring
harness of ATC3A (1)) harness
1
Is wiring harness 3 YES
connected to After checking Item
ATC3A (1)? YES 2, return connector
to original position.
2
• Turn starting Is [C.1] displayed?
switch OFF. Is there continuity System is reset —
between ATC5A • Delete abnormality NO
• Disconnect
NO (female) (1) and display memory. Defective contact or
ATC3A.
chassis ground? • Turn starting switch ON. disconnection in wiring Repair or
• Turn starting harness between ATC5A replace wiring
NO (female) (1) - ATC1
switch OFF. harness
(female) (16) - TMC (1) -
• Disconnect J06 - chassis ground
ATC5A.
20-374 HD325-6
1
A-20
a) Torque converter oil temperature overheat warning is displayed
fl This shows that there has been an abnormal rise in the torque converter oil temperature.
fl If the rise in the torque converter oil temperature is abnormal, carry out troubleshooting H-8.
b) Engine water temperature overheat warning is displayed
HD325-6 Serial No.: 5680 – 6000

HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
fl This shows that there has been an abnormal rise in the engine water temperature.
fl If the rise in the engine water temperature is abnormal, see the engine Shop Manual.
c) Air pressure drop warning is displayed
fl This shows that there has been an abnormal drop in the air pressure.
fl If the drop in the air pressure is abnormal, carry out troubleshooting H-18.
d) Retarder brake oil temperature overheat warning is displayed
fl This shows that there has been an abnormal rise in the retarder brake oil temperature.
fl If the rise in the retarder brake oil temperature is abnormal, see the Operation and Maintenance
Manual.
HD325-6 20-375
8
e) Engine overrun prevention brake actuated is displayed
fl This shows that the engine overrun prevention brake has been actuated to protect the transmission.
Cause Remedy
1 YES
Normal —
Has machine been
traveling with
transmission input
shaft speed of more
than 2600 rpm?
• Use the machine NO
data monitor in the
background mode
of the machine
monitor system to
check the transmis-
sion input shaft
speed.
For details, see
USER MODE AND
SERVICE FUNC-
TION of the
monitor panel.
f) Engine overshoot actuated is displayed
fl This shows that there has been engine overshoot (sudden spurt).
Cause Remedy
1 YES Abnormality in engine

Repair
Has accelerator fuel injection system
been depressed to
raise engine speed
to more than 2600
rpm?
• Use the machine NO
data monitor in the
background mode
of the machine
monitor system to
check the engine
speed.
For details, see
USER MODE AND
SERVICE FUNCTION
of the monitor panel.
20-376 HD325-6
C
TROUBLESHOOTING OF SUSPENSION
CONTROLLER SYSTEM
(SP MODE)
Judgment table for suspension controller, suspension related parts ................................................ 20-402
Action taken by self-diagnostic device and problems on machine .................................................... 20-404
Electrical circuit diagram for transmission controller system ............................................................. 20-408
Monitor
panel
display Controller display
SP-1 d001 [All OFF or E.↔01] Abnormality in power source is displayed ........................... 20-410
SP-2 d011 [E.↔11 is displayed] Abnormality in pressure sensor [right] system is displayed ...... 20-411
SP-3 d012 [E.↔12 is displayed] Abnormality in pressure sensor [left] system is displayed ..... 20-411-2
SP-4 d015 [E.↔15 is displayed] Abnormality in travel speed sensor system is displayed ........ 20-413
SP-5 d016 [E.↔16 is displayed] Abnormality in steering sensor system is displayed .......... 20-414
SP-6 d0C2 [E.↔C2 is displayed] Defective model selection data is displayed ........................ 20-415
SP-7 d021 [E.↔21 is displayed] Abnormality in solenoid [1] system is displayed ................. 20-416
SP-10 d0C1 [E.↔C1 is displayed] Disconnection in network is displayed ................................. 20-419
SP-11 d0C3 [E.↔C3 is displayed] Defective travel speed compensation data is displayed ........ 20-420

HD325-6 20-401
8
JUDGMENT TABLE FOR SUSPENSION CONTROLLER,
TROUBLESHOOTING SUSPENSION RELATED PARTS
JUDGMENT TABLE FOR SUSPENSION CONTROLLER, SUSPEN-

SION RELATED PARTS
Self-diagnostic display (abnormal display)
Check item
Power Pressure Pressure Travel Steering
source sensor sensor speed sensor
system (right) (left) sensor system
system system system
[All OFF]
or d011 d012 d015 d016
No. Failure mode d001 [E. ↔ 11] [E. ↔ 12] [E. ↔ 15] [E. ↔ 16]
[E. ↔ 01]
1 Abnormal noise comes from suspension
2 Suspension mode switches extremely frequently ● ● ● ●
(1) Stays in medium mode when ● ● ● ● ●

Suspension traveling loaded
mode no longer
switches (2) Stays in medium mode when
● ● ● ● ●
fl Operator traveling unloaded
3 judges that
(3) Stays in hard mode ●
condition is
abnormal (4) Stays in soft mode ●
from monitor
panel mode (5) Does not give mode display
(all OFF) ●
display
(6) Abnormal display (all ON)
Chassis has started

to roll excessively (1) Always rolls excessively
fl Operator judges
4 that condition is
normal from (2) Sometimes rolls excessively
monitor panel ● ●
mode display
Riding comfort has
become poor (1) Riding comfort is always poor
fl Operator judges
5 that condition is
normal from
monitor panel (2) Riding comfort is sometimes poor ● ●
mode display
Machine has started to bounce
6 fl Operator judges that condition is normal from monitor
panel mode display
Actuation of anti-nosedive function is
defective
Operation of (When service brake is applied, does
(1) not change as follows
machine and Empty machine S → M
7 suspension Loaded machine M → H)
mode do not
Actuation of anti-lift function is
match
(2) defective
(Does not switch to hard mode when
body is at position other than FLOAT)
Troubleshooting code when abnormality is displayed SP-1 SP-2 SP-3 SP-4 SP-5
fl The self-diagnostic display d0 is the monitor panel display; [ ] shows the controller LED display.
20-402 HD325-6
1
JUDGMENT TABLE FOR SUSPENSION CONTROLLER,
TROUBLESHOOTING SUSPENSION RELATED PARTS
Self-diagnostic display (abnormal display) Pilot display

Model Solenoid Solenoid Solenoid Network Machine
selection 1 2 3 system speed Monitor Troubleshooting
data compensa- panel code when no
tion data mode Body abnormality is
display Brake FLOAT displayed
d0C2 d021 d022 d023 d0C1 d0C3
[E. ↔ C2] [E. ↔ 21] [E. ↔ 22] [E. ↔ 23] [E. ↔ C1] [E. ↔ C3]
See TESTING AND

ADJUSTING
SUSPENSION
c c —
See TESTING AND
● ADJUSTING
SUSPENSION
See TESTING AND
● ADJUSTING
SUSPENSION
● —
● —
● ● ● ● c —
c —
See TESTING AND
ADJUSTING
SUSPENSION
See TESTING AND
ADJUSTING
SUSPENSION
See TESTING AND
● ● ADJUSTING
SUSPENSION
See TESTING AND
ADJUSTING
SUSPENSION
See TESTING AND
● ● ADJUSTING
SUSPENSION
c —
See TESTING AND

c ADJUSTING
SUSPENSION
Carry out
troubleshooting
for ap-plicable F-1 F-2
monitor panel
SP-6 SP-7 SP-8 SP-9 SP-10 SP-11 item
Troubleshooting code when lamp
does not light up when appli-
cable operation is carried out
HD325-6 20-403
1
TROUBLESHOOTING PROBLEMS ON MACHINE
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS

ON MACHINE
Details of abnormality
Display Abnormal system Check the wiring harnesses and equipment given below
code fl Judgment conditions : Disconnection, short circuit in wiring harness
(+) : Positive, (–) : Negative
Defective controller power 1. Between (+) battery relay terminal M – circuit breaker – junction
source system block – fuse II-(13) – SU3 (1) – SSP1 (8)
[All OFF] fl Input voltage: Less than 2. Between (–) SSP1 (9) – SU3 (16) – J06 - terminal ER
or 17V 3. (–) SSP1 (9) – SL1 (2), SL2 (2), SL3 (2)
d001
[E. ↔ 01]
Defective pressure sensor 1. [In the case of ✩]

(right) system (When payload meter is installed)
If suspension pressure Between (+) PM1 (10) – J04 (1) ~ J04 (1) ~ CN-63 connector (1)
fl • Is abnormally high (When payload meter is not installed) Between
Between (+) SSP1 (13) – RH2 (6) PM3 (3) ~ ~ CN-62 connector (1)
• Has escaped [In the case of ✩✩]
fl Disconnection, short (+) Payload meter 
circuit in sensor system Printer type: PM1A (10) – PM1 (6)
 ~ J04 (1) ~ CN-63 connector (1)
d011 Card type: PM6 (2) – PM1 (6)
[E. ↔ 11]

When payload meter is not installed 
 (+) SSP1 (13) ~ ~ Between CN-62 connector (1)
2. [In the case of ✩]
Between SSP2B (9) – SU3 (7) – SCFR (1) – J04 (5) – CN-62 connector (3)
[In the case of ✩✩]
3. Defective sensor
4. When sensor is installed to suspension, if it is not tightened
sufficiently, pressure cannot be detected.
Defective pressure sensor 1. [In the case of ✩]

(left) system (When payload meter is installed)
fl If suspension pressure is Between (+) PM1 (10) – J04 (1) ~ J04 (1) ~ CN-63 connector (1)
• Is abnormally high (When payload meter is not installed) Between
Between (+) SSP1 (13) – RH2 (6) PM3 (3) ~ ~ CN-62 connector (1)
• Has escaped [In the case of ✩✩]
fl Disconnection, short (+) Payload meter 
circuit in sensor system Printer type: PM1A (10) – PM1 (6)
 ~ J04 (1) ~ CN-63 connector (1)
d012 Card type: PM6 (2) – PM1 (6)
[E. ↔ 12]

When payload meter is not installed 
 (+) SSP1 (13) ~ ~ Between CN-62 connector (1)
2. [In the case of ✩]
[In the case of ✩✩]
3. Defective sensor
4. When sensor is installed to suspension, if it is not tightened
sufficiently, pressure cannot be detected.
Defective travel speed 1. Between (–) N3 (1) – TM2 (5) – TMA (1) – SU3 (2) – SSP2B (5)
sensor system 2. Between (–) N3 (2) – TM2 (6) – TMA (2) – SU3 (3) – SSP2B (2)
fl Detects disconnection in 3. Disconnection in transmission output shaft speed sensor
d015 sensor system
[E. ↔ 15]
Defective steering sensor 1. Between (+) SR2 (1) – SU3 (4) – SSP1 (13)
system 2. Between (–) SR2 (3) – SU3 (6) – SSP2B (12)
fl • When traveling at 10 3. Between SR2 (2) – SU3 (5) – SSP2B (4)
km/h or more and there 4. Damaged, defective steering sensor
d016 is no sensor signal for 5. Deformation, looseness of steering sensor mount
[E. ↔ 16] more than 10 minutes
6. When traveling for a long time on a straight road for a long
or
• When abnormal steer- distance and not operating steering at all
ing angle is detected.
fl The top code in the Display code column shows the monitor panel display and the bottom code (in [ ]) shows
the transmission controller LED display.
20-404 HD325-6
8
Action of
Condition when normal : Check with tester controller Symptoms that appear in machine
when
Voltage (V), current (A), resistance value Ω abnormality
when there is abnormality
is detected
1. Between SSP1 (8) – SSP1 (9) : 20 – 30 V Cannot 1. Suspension mode display

2. Between SSP1 (8) – chassis : 20 – 30 V carry out stays at condition before
3. Between SSP1 (9) – chassis :0Ω control abnormality was detected or
4. Fuse II-(13) is not blown all lamps go out.
2. Monitor panel detects A016.
3. Machine sometimes rolls
excessively.
4. Ride is uncomfortable.
Measure when machine is stopped unloaded (voltage between Fixes in 1. Does not switch mode.
SSP2B(1) – chassis ground) medium • Remains in medium mode.
1. When sensor is installed (V) : 1.3 – 2.4 V mode 2. Sometimes ride is uncomfort-
able.
2. When sensor is removed (V) : Max. 0.1 V • It takes a long time to judge,
so if there is defective contact,
it may not switch mode.
excessively.
4. Other mechatronics caution
lamp on monitor panel flashes.
Measure when machine is stopped unloaded (voltage be- Fixes in 1. Does not switch mode.
tween SSP2B(9) - chassis ground) medium • Remains in medium mode.
1. When sensor is installed (V) : 1.3 – 2.4 V mode 2. Sometimes ride is uncomfortable.
• It takes a long time to judge, so
2. When sensor is removed (V) : Max. 0.1 V if there is defective contact, it
may not switch mode.
excessively.
4. Other mechatronics caution lamp
on monitor panel flashes.
TM2 TMA SU3 SU2 Fixes in 1. Does not switch mode.

N3 male male female male female Ω medium • Remains in medium mode.
Between Between Between Between Between 500 – mode 2. Machine sometimes rolls
excessively.
(2) – (3) (5) – (6) (1) – (2) (2) – (3) (1) – (8) 1 kΩ
3. Ride is uncomfortable.
Between each terminal - chassis 4. Other mechatronics caution
lamp on monitor panel
flashes.
Suspension Operate Fixes in 1. Does not switch mode.

SR2 SU3 controller (V) steering (V) medium • Remains in medium mode.
Between Between Between SSP1 mode 2. Machine sometimes rolls
18 V — excessively.
(1) – (3) (4) – (6) (21) – (9)
Indicator of 3. Ride is uncomfortable.
Between Between Between SSP2B tester fluctu- 4. Other mechatronics caution
(2) – (3) (5) – (6) (4) – (12) —
ates between lamp on monitor panel
0V and 5V flashes.
No looseness or play at steering sensor mount
HD325-6 20-405
8
Details of abnormality
Display Abnormal system Check the wiring harnesses and equipment given below
code fl Judgment conditions : Disconnection, short circuit in wiring harness
(+) : Positive, (–) : Negative
Defective model selection 1. Between SSP1 (12) – SU3 (13) – TMD (12) – ATC4 (12), DP05 (4)
data 2. Between SSP1 (1) – SU3 (9) – TMD (10) – ATC4 (6), DP05 (3)
fl Cannot receive model 3. Between SSP2A (9) – SU3 (12) – TMD (9) – ATC4 (10), DP05 (5)
d0C2 selection data from 4. Between SSP2A (9) – SU3 (14) – TMD (11) – ATC4 (10), DP05 (5)
[E. ↔ C2] transmission controller 5. Improper setting of model selection in transmission controller
fl Receives model selection
that is not set.
Solenoid 1 system defective 1. Between (+) SL1 (1) – SSP1 (21)

fl Disconnection, short 2. Between (–) SL1 (2) – SSP1 (9)
circuit in solenoid 1 3. Defective solenoid
system detected 4. Damaged diode
d021 (Solenoid 1 switches air
[E. ↔ 21] cylinder port B ON/OFF.)


Disconnection in network 1. Between SSP1 (12) – SU3 (13) – TMD (2) – ATC (12), DPO5 (4)
fl Disconnection in network 2. Between SSP1 (1) – SU3 (9) – TMD (10) – ATC (6), DPO5 (3)
communications 3. Between SSP1 (9) – SU3 (12) – TMD (9) – ATC (10), DPO5 (5)
d0C1 4. Between SSP2A (9) – SU3 (14) – TMD (11) – ATC (10), DPO5 (5)
[E. ↔ C1] 5. Defective monitor panel
Defective machine compen- 1. Between SSP1 (12) – SU3 (13) – TMD (2) – ATC (12), DPO5 (4)
sation data 2. Between SSP1 (1) – SU3 (9) – TMD (10) – ATC (6), DPO5 (3)
fl Machine compensation 3. Between SSP1 (9) – SU3 (12) – TMD (9) – ATC (10), DPO5 (5)
data cannot be received 4. Between SSP2A (9) – SU3 (14) – TMD (11) – ATC (10), DPO5 (5)
d0C3 from monitor panel 5. Defective monitor panel
[E. ↔ C3]
fl The top code in the Display code column shows the monitor panel display and the bottom code (in [ ]) shows
the transmission controller LED display.
20-406 HD325-6
8
Action of
Condition when normal : Check with tester controller Symptoms that appear in machine
when
Voltage (V), current (A), resistance value Ω abnormality
when there is abnormality
is detected
1. Between SSP1 (female) (12) – ATC4 (female) (12), DP05 Cannot 1. All lamps on mode display go
(female) (4) :0Ω carry out out.
2. Between SSP1 (female) (1) – ATC4 (female) (6), DP05 control 2. Machine sometimes rolls
(female) (3) :0Ω excessively.
3. Between SSP2A (female) (9) – ATC4 (female) (10), DP05 3. Ride is uncomfortable.
(female) (5) :0Ω
4. Model selection setting for transmission controller must be
correct.
Cannot 1. All lamps on mode display go

SL1 SU3 Ω (V)
carry out out.
Between male Between (female)
(1) – (2) (16) – SSP1 (21) 20 – 100 Ω control 2. Machine sometimes rolls
excessively.
Between female 3. Ride is uncomfortable.
(1) – chassis — Min. 1 MΩ
Between female — — lamp on monitor panel flashes.
(1) – chassis 20 – 30 V
Between SL1
female (2) – chassis
— 0Ω —

SL2 SU3 Ω (V)
carry out out.
excessively.
(1) – chassis 20 – 30 V
Between SL2
— 0Ω —

SL3 SU3 Ω (V)
carry out out.
excessively.
(1) – chassis 20 – 30 V
Between SL3
— 0Ω —
1. Between SSP1 (female) (12) – ATC4 (female) (12), DPO5 Continues 1. Suspension mode display
(female) (4) :0Ω control stays at condition before
2. Between SSP1 (female) (1) – ATC4 (female) (6), DPO5 normally abnormality was detected, but
(female) (3) :0Ω all lamps may go out.
3. Between SSP2A (female) (9) – ATC4 (female) (10), DPO5
(female) (5) :0Ω
4. Model selection setting for transmission must be correct.
1. Between SSP1 (female) (12) – ATC4 (female) (12), DPO5 Fixes in 1. Suspension mode display
(female) (4) :0Ω medium stays at condition before
2. Between SSP1 (female) (1) – ATC4 (female) (6), DPO5 mode abnormality was detected, but
(female) (3) :0Ω all lamps may go out.
3. Between SSP2A (female) (9) – ATC4 (female) (10), DPO5 2. Machine sometimes rolls
(female) (5) :0Ω excessively.
4. Model selection setting for transmission must be correct. 3. Ride is uncomfortable.
lamp on monitor panel
flashes.
HD325-6 20-407
8
ELECTRICAL CIRCUIT DIAGRAM OF
TROUBLESHOOTING SUSPENSION CONTROLLER SYSTEM
ELECTRICAL CIRCUIT DIAGRAM OF SUSPENSION

CONTROLLER SYSTEM
HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
20-408 HD325-6
8
HD325-6 20-409
8

20-409-1 HD325-6
8
HD325-6 20-409-2
8
TROUBLESHOOTING SP-1
Monitor cane1 Controller

display display
SP-1 All OFF or (FHg )

Abnormality
displayed
in power source is
TWH00319
When fuse 11413) is normal.

When only the suspension mode is OFF.
Cause Remedy
2 YES Defective suspension

Leplace
In condition used controller
for measuring
YES Item 1, do both
- controller LEDs -
1 B;zO;pr is do01
Is voltage displayed?
System is reset -
between SSPl _
* Turn starting NO
(8) and (9) Defective contact or
normal? switch ON.
harness between SSPl
l20-30V [female) (8) - SU3 tepair or
- Turn starting (female) (1) or SSPI eplace
switch ON. (female) (9) - SU3
(female) (16)
disconnection in wiring lepair or
l20-30V NO harness between fuse II eplace
lTurn starting 413) - SU3 (male) (l), or
between SUS (male)
switch ON. (16) - JO6 - chassis
ground (ER)
SP-1 Related electrical circuit diagram
Fuse boxa
(BT2) 1 ,_,JO7
4.3 Circuit breaker
20-410 HD325-6
0
SP-2 Abnormality in pressure sensor [right]

system is displayed
HD325-6 Serial No.: 5680 – 6000

HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
fl Before carrying out troubleshooting, check that all the related Cause Remedy
fl Always connect any disconnected connectors before going on
to the next step.
controller Replace
Is d001 [E.↔11]
YES displayed when
power is switched
ON again?
System is reset —
switch ON.
1
5 YES
Is voltage Defective sensor Replace
Is voltage
between SSP2B Short circuit in wiring
YES between SSP2B
(1) and SSP2A harness between CN63
4 (1) and SSP2A (7)
(9) normal? (female) (3) - J04 (5) -
as shown below? SCFR (1) - SU3 (7) -
Is resistance Repair or
•1–4V YES between CN63 • Max. 1 V NO SSP2B (female) (1) - PM1 replace
• Turn starting (female) (3) and • Disconnect CN63. (female) (12)
switch ON. 3 chassis normal? • Turn starting Disconnection, defective
switch OFF. contact, or short circuit with
Is voltage • 300 - 600 KΩ ground in wiring harness
• Disconnect CN63 NO Repair or
between CN63 between CN63 (female) (3) -
NO (2) and chassis and PM1. J04 (5) - SCFR (1) - SU3 (7) - replace
• Turn starting switch OFF. SS2B (female) (1) - PM1
normal? (female) (12)
See
• 16 – 19 V When there is payload meter troubleshooting
—
• Turn starting NO of payload
switch ON. Defective contact or meter
When there is no payload meter disconnection in wiring
6 YES harness between CN63 Repair or
(female) (2) - J04 (1) -
Is voltage SU6 (1) - SU3 (15) - SSP1 replace
between SSP1 (female) (13).PM6 (1) -
(13) and SSP2A PM1 (male) (10)
(9) normal? Replace
Defective suspension
• 16 – 19 V NO controller
• Turn starting
switch ON.
HD325-6 20-411
8

fl Before carrying out troubleshooting, check that all the related
fl Always connect any disconnected connectors before going on Cause Remedy
to the next step.

controller Replace
Is d001 [E.↔11]
YES displayed when
power is switched
ON again?
System is reset —
switch ON.
1
5 YES
Is voltage
YES between SSP2B
4 (1) and SSP2A (7)
(9) normal? (female) (3) - J04 (5) -
as shown below? SCFR (1) - SU3 (7) -
Is resistance Repair or
•1–4V YES between CN63 • Max. 1 V NO SSP2B (female) (1) - PM1 replace
switch OFF. contact, or short circuit with
Is voltage • 300 - 600 KΩ ground in wiring harness
• Disconnect CN63 NO Repair or
between CN63 between CN63 (female) (3) -
NO (2) and chassis and PM1. J04 (5) - SCFR (1) - SU3 (7) - replace
• Turn starting switch OFF. SS2B (female) (1) - PM1
normal? (female) (12)
See
—
switch ON. Defective contact or meter
(female) (2) - J04 (1) -
Is voltage SU6 (1) - SU3 (15) - SSP1 replace
(9) normal? Replace
Defective suspension
• Turn starting
switch ON.
20-411-1 HD325-6
8
SP-3 Abnormality in pressure sensor [left]

system is displayed
HD325-6 Serial No.: 5680 – 6000

HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
fl Before carrying out troubleshooting, check that all the related Cause Remedy
to the next step.
controller Replace
Is d012 [E.↔12]
YES displayed when
power is switched
ON again?
System is reset —
switch ON.
1
5 YES
Is voltage
YES between SSP2B
4 (9) and SSP2P (female) (3) - J04 (4) -
(9) normal?
(9) as below? SCFR (2) - SU3 (8) - Repair or
Is resistance
•1–4V YES between CN62 NO SSP2B (female) (9) - PM1 replace
• Max. 1 V
• 300 - 600 KΩ switch OFF. contact, or short circuit with Repair or
Is voltage ground in wiring harness replace
between CN62 • Disconnect CN62 NO between CN63 (female) (3) -
NO (2) and chassis and PM1. J04 (5) - SCFR (2) - SU3 (8) -
normal? • Turn starting switch OFF. SS2B (female) (4) - PM1
(female) (13) See
switch ON. meter
(female) (2) - J04 (1) - replace
Is voltage SU6 (1) - SU3 (15) - SSP1
(9) normal?
Defective suspension Replace
• Turn starting
switch ON.
HD325-6 20-411-2
8

fl Always connect any disconnected connectors before going on Cause Remedy
to the next step.

controller Replace
Is d012 [E.↔12]
YES displayed when
power is switched
ON again?
System is reset —
switch ON.
1
5 YES
Is voltage
YES between SSP2B
4 (9) and SSP2P (female) (3) - J04 (4) -
(9) normal?
(9) as below? SCFR (2) - SU3 (8) - Repair or
Is resistance
•1–4V YES between CN62 NO SSP2B (female) (9) - PM1 replace
• Max. 1 V
• 300 - 600 KΩ switch OFF. contact, or short circuit with Repair or
Is voltage ground in wiring harness replace
between CN62 • Disconnect CN62 NO between CN63 (female) (3) -
NO (2) and chassis and PM1. J04 (5) - SCFR (2) - SU3 (8) -
normal? • Turn starting switch OFF. SS2B (female) (4) - PM1
(female) (13) See
switch ON. meter
(female) (2) - J04 (1) - replace
Is voltage SU6 (1) - SU3 (15) - SSP1
(9) normal?
Defective suspension Replace
• Turn starting
switch ON.
20-412 HD325-6
8
SP-4 Abnormality in travel speed sensor system

is displayed

Cause Remedy
to the next step.
1 YES See troubleshooting of
transmission controller —
Is there any
display showing
abnormality in
transmission
output speed on 2 YES Defective controller Replace
transmission Is resistance
controller? between SSP2B
NO (female) (5) and disconnection in wiring Repair or
(12) normal?
harness between SSP2B replace
• 500 – 1000 Ω NO (female) (5), (12) - TM2
• Turn starting (5), (6)
switch OFF.
• Disconnect SU2.

HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000

HD325-6 20-413
8
SP-5 Abnormality in steering sensor system is

displayed
Cause Remedy

When power is
turned ON again
YES and steering wheel
is turned slowly,
does display stay
at d016 [E.↔16]? —
System is reset
2 • Turn starting NO
Is voltage bet- switch ON.
YES ween SSP2B (4) Defective contact or
• Turn steering
and (12) as 5 YES disconnection in wiring Repair or
shown in Table wheel slowly. harness between SR2
Is voltage bet- (2) (female) - SU3 (5) - replace
1? YES ween SR2 (2) SSP2B (female) (4)
• Turn starting and (3) as
4 shown in Table
switch ON. Defective steering Replace
Is voltage bet- 1?
1 • Turn steering ween SR2 (1) • Turn starting NO sensor
Is voltage bet- wheel slowly.
NO and (3) nor- switch ON. Defective contact or
ween SSP1 (13) mal? • Turn steering disconnection in wiring
and (9) nor- wheel slowly. harness between SSP1
mal? • 16 – 19 V (female) (13) - SU3 (4) - Repair or
• Turn starting NO SR2 (female) (1), (3) - replace
• 16 – 19 V SU3 (6) - SSP2B
switch ON.
• Turn starting (female) (12)
switch ON. 6 YES Defective steering Replace
Does voltage sensor
become normal Short circuit with
NO when SR2 is dis- chassis ground in
connected in wiring harness between
test in Item 1? Repair or
SSP1 (female) (13) - replace
• 16 – 19 V NO SU3 (4) - SR2 (female)
• Turn starting (1), (3) - SU3 (6) - SSP2B
switch ON. (female) (12)
20-414 HD325-6
1
SP-6 Defective model selection data is displayed

connectors are properly inserted. Cause Remedy
to the next step.
controller Replace
Is there continuity
YES between ATC4 -
3 Defective contact or dis-
DP05 of network connection in wiring har-
Is there continuity line shown in ness between DP05 and
Table 1? TMD of network wiring Repair or
YES between SSP1, • Disconnect ATC4 NO harness where continuity replace
SSP2A - ATC4 of
network line and DP05. check shows abnormality
shown in Table 1? • Turn starting Defective contact or dis-
2
switch OFF. connection in wiring har- Repair or
Does monitor • Disconnect SSP1, NO ness between SU3 and replace
YES panel detect SSP2A, and ATC4. ATC4 of network wiring
[A013], [A018]? • Turn starting harness where continuity
check shows abnormality
switch OFF. 4 YES
• Press bulb check Defective suspension Replace
1 switch. Is there continuity controller
between SSP1,
Is model selection • Turn starting Defective contact or dis-
SSP2A - ATC4 of
on transmission switch ON. connection in wiring har-
NO network line ness between SSP1,
controller
shown in Table 1? SSP2 and TMD of net-
correct? Repair or
work wiring harness replace
• Check • Disconnect SSP1, NO where continuity check
transmission SSP2A, and ATC4. shows abnormality
controller rotary • Turn starting switch OFF. Adjustment of
switches 1 and 2. Defective model selec- transmission
For details, see NO tion of transmission con- controller
TESTING AND troller rotary switch
ADJUSTING, SETTING ROTARY SWITCH (MODEL DATA, NETWORK
DATA) WHEN REPLACING TRANSMISSION CONTROLLER.
Table 1
Network wiring
harness (1) SSP1 (12) SU3 (13) TMD (12) ATC4 (12) DP05 (4)
Network wiring
harness (2) SSP1 (1) SU3 (9) TMD (10) ATC4 (6) DP05 (3)
Network wiring
harness (3) SSP2A (9) SU3 (12) TMD (9) ATC4 (10) DP05 (5)
Network wiring
harness (4) SSP2A (9) SU3 (14) TMD (11) ATC4 (10) DP05 (5)
HD325-6 20-415
1
SP-7 Abnormality in solenoid [1] system is

displayed
fl When carrying out repairs or troubleshooting, check the direction of the solenoid diode.
Cause Remedy
Short circuit in wiring

YES harness between SSP1 Repair or
3 (female) (21) and SL1 replace
Is voltage (1)
YES between SSP1
(female) (9) and 4 YES
2 (21) normal? Is voltage
between SSP1 Defective contact or dis-
Is resistance • 20 – 30 V connection in wiring
YES between SSP1 NO (17) and (9) harness between SSP1
2 • Turn starting normal?
(female) (9) and (female) (17) and SU3 Repair or
switch ON. replace
1 (21) normal? • 20 – 30 V NO (1)
• Turn starting switch Defective contact, dis-
Is resistance of • 20 – 50 Ω connection, short cir-
each pin of SL1 ON.
• Turn starting cuit with ground in wir- Repair or
as shown in switch OFF. ing harness between replace
NO
Table 1? • Disconnect SSP1. SL1 (female) (2) - SSP1
(female) (9), (21) - SL1
switch OFF. Defective solenoid Replace
• Disconnect SL1. NO
Table 1
No. Measurement location Normal value
(1) SL1 (male) (1) – (2) 20 – 50 Ω
(2) SL1 (male) (1) – chassis Min. 1 MΩ
20-416 HD325-6
8

displayed
Cause Remedy

YES harness between SSP1
(female) (20) and SL2 Repair or
3 replace
(1)
Is voltage
YES between SSP1
• Turn starting normal?
(female) (9) and (female) (17) and SU3 Repair or
switch ON. replace
1 (20) normal? • 20 – 30 V NO (female) (1)
each pin of SL2 ON.
• Turn starting cuit with ground in wir- Repair or
NO
(female) (9), (21) - SL2
switch OFF. Replace
Defective solenoid
Table 1
(1) SL2 (male) (1) – (2) 20 – 50 Ω
HD325-6 20-417
8

displayed
Cause Remedy

YES harness between SSP1
(female) (20) and SL3 Repair or
3 replace
(1)
Is voltage
YES between SSP1
(female) (9) and 4 YES Defective controller
Replace
2 • Turn starting normal? Repair or
(female) (9) and (female) (17) and SU3
switch ON. replace
1 (11) normal? • 20 – 30 V NO (1)
ON.
each pin of SL3 • Turn starting cuit with ground in wir- Repair or
NO
(female) (9), (11) - SL3
switch OFF. Defective solenoid Replace
Table 1
(1) SL3 (male) (1) – (2) 20 – 50 Ω
20-418 HD325-6
8

display display
w-10 Eq (Ft-jEj)Disconnection in network is displayed
TWH00337
Remedy
* Always connect any disconnected connectors before aoina on
YES - - 5ee troubleshooting of
to the next step. - Imonitor panel system
31
/ Does monitor iI
YE
IDefective suspension
,controller
Defective
contact or dis-
,connection
in wiring
harness between DP05
YE in Table I? IL and SSPI, SSPPA of Repair or
replace
network wiring harness
l Disconnect DP05. NC1
where continuity check
l Turn starting switch shows abnormality
* Press bulb check OFF. -
switch. 4 YES Defective suspension Replace
BTurn starting controller
switch ON.
~~~
l Check System is reset

transmission l Press bulb check ND
controller rotan/ switch. (Only
switches 1 and 2. when A016 is detected.) Adjustment 01
l Turn starting switch ON. Defective model selec- transmission
tion of transmission controller
10 controller rotary switch
For details, see TESTING AND ADJUSTING, SETTING ROTARY SWswlTCH (MODEL
DATA, NETWORK DATA) WHEN REPLACING TRANSMISSION CONTROLLER.
Table 1
SP-IO Related electrical circuit diagram

Suspension Transmission
controller controller
I I I I
SSPl (MIC21) su3 (Sl61 TMD (S16) ATC4 (040 12)
S-NET (+) c 3
xx.
S-NET (+) @T +I
T_
SSPPA (04020) xx
*+
I 1
Monitor Panel
TWH00330
HD3256 20-419
0

display display
Defective travel speed compensation data is

SP-11
displayed
TWH00338

Cause Remedy
to the next step.
YES See troubleshooting of
nonitor panel system
3
Does monitor
YI panel detect
other abnormal- - 5 YES Iefective suspension
:ontroller Replace
ities in network Is there continu-
system? ity between Defective contact or dis-
SSPI , SSPZA - :onnection in wiring
YE
d NG DP05 of net-
work line shown
in Table I?
larness between DP05
3nd SSPl, SSPPA of
letwork wiring harness Repair or
1L
panel detect
IA0161? I
I
l
l
Disconnect DP05. NO
Turn startina switch
where continuity check
;hows abnormality
replace
* Press bulb check OFF. -

switch. Defective suspension
1 4 YES Replace
l Turn starting controller
switch ON.
tion on trans-
n
troller correct? System is reset
* Check
transmission Adjustment of
NO Defective model selec-
controller rotary tion of transmission transmission
switches 1 and 2. 1 controller controller
NO rotary switch
For details, see TESTING AND ADJUSTING, SETTING

ROTARY SWITCH (MODEL DATA, NETWORK DATA)
WHEN REPLACING TRANSMISSION CONTROLLER.
Table 1
Network wiring
harness (1) SSPI (12) SU3 (13) TMD (12) ATC4 (12) DP05 (4)
Network wiring
harness (2) SSPI (I) SU3 19) ThdD (IO) ATC4(6) DP05 13)
Network wiring
harness (3) SSPPA (9) SU3 (12) TMD (9) ATC4 (10) DP05 (5)
Newark wiring
harness (4) SSPSA (9) SU3 (14) TMD (11) ATC4 (IO) DP05 (5)

Suspension Transmission
C:ontrol ler controller
I I
SSPl (MIC21) SU3 (S16) TMD (Sl6) ATC4 (040 12)
x x_
SSPZA (040201
Monitor Panel
1 I
TWH00330
20-420 HD3256
0
TROUBLESHOOTING OF PAYLOAD METER
(PRINTER TYPE) SYSTEM
(LP MODE)
HD325-6 Serial No.: 5680 – 6000

HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
Service codes and self-diagnosis of payload meter (printer type) ..................................................... 20-502
Electrical circuit diagram for payload meter (printer type) system .................................................... 20-504
LP-1 No display appears when starting switch is turned ON ......................................................... 20-506
LP-2 Calibration demand (CAL flashes) is shown continuously after starting
switch is turned ON .................................................................................................................... 20-507
LP-3 Calibration cannot be carried out ............................................................................................. 20-508
LP-4 After starting switch is turned ON, all external display lamps do not light up ..................... 20-511
LP-5 Condition does not exist for lamps to light up, but external display lamps light up ........... 20-513
LP-6 Level of lighting up of external display lamps is not correct ................................................. 20-514
LP-7 Abnormality in display logic ..................................................................................................... 20-516
LP-8 E01 – E04 is displayed ................................................................................................................ 20-521
LP-10 E21 – E28 is displayed by sensor check .................................................................................... 20-523
LP-11 E31 is displayed .......................................................................................................................... 20-524
LP-12 E32 is displayed .......................................................................................................................... 20-526
LP-13 E41 is displayed .......................................................................................................................... 20-528
LP-14 E42 is displayed .......................................................................................................................... 20-529
LP-15 Printer does not print anything (blank paper comes out) ....................................................... 20-530
LP-16 Printer prints only “NO DATA” .................................................................................................. 20-530
LP-17 Printer does not print out when PRT switch is pressed .......................................................... 20-530
LP-18 “PAPE” flashes ........................................................................................................................... 20-531
LP-19 Time is wrong ............................................................................................................................. 20-531
LP-20 E33 is displayed .......................................................................................................................... 20-531
fl As to Serial No. 6001 and up (HD325-6, HD325-6W), 2001 and up (HD405-6), see pages from 20-551 to
20-581.

HD325-6 20-501
8
SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER
TROUBLESHOOTING (PRINTER TYPE)

(PRINTER TYPE)
Order of
orioritv Display Content
1 --- 8 Internal CPU stopped (CPU is reset) (Controller power source etc. normal)
E-31 Abnormal sensor power source (18V)
2 E-32 Short circuit in relay
E-33 Drop in back-up battery voltage

7 I
l Disconnection in pressure sensor signal wire
l Signal wire in contact with chassis
l Defect inside sensor
l Pressure sensor signal wire in contact with power source line
l When sensor check is carried out, abnormality in sensor system

’ 1-1 is detected.
Note 1: Once an error is displayed, the error contin-

ues to be displayed in display portion (2) until
CAL switch (1) is pressed.
Note 2: If the controller detects the abnormalities in
the above table, all the display lamps light
up-
20-502 HD325-6
0
ELECTRICAL CIRCUIT DIAGRAM FOR PAYLOAD METER
TROUBLESHOOTING (PRINTER TYPE) SYSTEM

Shift lever Ipayload
!_!_ meter brir
Starting switch
PM 1
(M IC21)
RUPt RUP-
PreSS”re
Suspension SI?“SO~ FR
Pressure sensor I iiii I IllIll J IIIII
connector for
each suspension
pressure sensor
Model L--Ll IJq R16 RI7 R18

n. c R19 R20 R02 Rll
BFl
selection Tilt External External External External External Transmission PaYlba’d
connector sensor Bodv FLOAT
display lame ;;;;;a; lamp ;;;;;a; lamp disolau lamp d$;ia; Iamu neutral relay meter relay
relay 4
coti:r’Fkan FLOAT) lelaY ’ TWH00339
20-504 HD325-6
0
aI
_. 2,. r------
_________~
External displ ay
SNR/CN-39 (X3)
lamps (r isht)
1. 2, 3:Green
4 :Yel low
5 :Red
I inder (r isht)
CN_40 ___-.___:
I
CN-30 (SWP6)
JO3 (S161
1.25
CN_s3r_________.‘____
Suspension
Pressure
sensor
L_______________ J
Rear suspension
CYI inder (right)
----_-__-_____
1
Suspensionl
Pressure
sensor
I
L_-____________A
Rear suspension
CYI inder (left)
I External display
Suspensionl
lamps (left)
Pressure
1, 2, 3:Green
sensor :
4 :Yel low
--------I Front suspension CYI inder (left)
ITransmission controller/ TWH00340
HD325-6 20-505
0
TROUBLESHOOTING LP-1
LP-1 No display appears when starting switch is turned ON

* Before carrying out troubleshooting, check that ail the related connectors are properly inserted.
Cause Remedy
f
Defective PLM controller Replace
1 I Short circuit of wiring
Is voltage be- After inspec-

tween PM1 (16) - tion, repair
and (17) normal? YES
2
.20-30v
l Turn starting Replace
Is controller fuse
switch ON.
NO blown?
1 Disconnection in wiring
After inspec-
tion, repair
LP-1 Related electrical circuit diagram
Payload meter
TWH00341
20-506 HD325-6
0
LP-2 Calibration demand (CAL flashes) is shown continuously after

starting switch is turned ON
Cause Remedy
4 YES
Does problem
YES appear even after
3 calibration is
carried out? -
YES Is voltage be- Normal
NC
- tween PM1 (11) -
2 and (17) normal?
YES Is voltage be- * 4-6V ground in wiring harness After inspec-
tween PM1 (5) - * Turn starting NO between PM1 (11) and tion, repair
1 and (17) normal? switch ON. RH2 (3)
ground in wiring harness After inspec-
between PM1 (5) and RH2 tion, repair
(2)
. 4-6V Short circuit with chassis

* Turn starting ground in wiring harness Replace
switch ON. NO between PM1 (I) and RH2
(1)
Payload meter
(Printer tyPeI
I
PM1 (MI&) RH2 (S12)
Model selection 1 ,D
Model selection 2 8 Model select ion
connector
Model selection 3 3 (not connected)
GND $g
I
TWH00342
HD3256 20-507
0
LP-3 Calibration cannot be carried out

3 YES
Drive machine
with CAL still
YES flashing. Does
2r CAL display light
up if CAL switch is
pressed?
sion lever is at N,
YI fS
does CAL display NO
flash if CAL switch
NO
s fuse for
YE
ransmission N
shown in Table 1 ,elay blown?
when transmission
lever is operated? 8 YES
* Turn starting When transmission

switch ON. YES lever is at N, is
N voltage between SF4
(4) and (2) normal?
7 * Max. 1.5 V NO
* Turn starting * Turn starting
When transmission
switch ON. switch ON.
lever is at position
other than N, is
4
voltage between SF
4
When transmission (4) and (2) normal? YES
lever is at N, is volt-
age between PM1 *20-27V
No (20) and (17) normal * Turn starting
Is there continuity
switch ON.
mMax.1.5V between SF (4)
* Turn starting
‘L
I
switch ON.
. Remove transmis-
sion N relay. NO
YES
11
When transmission ,
lever is operated 11
between N and YES
i position other than
NO N, is there sound of YE
Table 1 transmission N 12
Is voltage between chassis ground?
SF (4) and (2)
-1
normal both when * Remove transmis- NO
1
*Turn starting
switch ON. NI transmission lever sion N relay.
is at N and oosition t
other than i? I
. Max. 1.5V
I
NO
- Turn starting
switch ON.
20-508 HD325-6
0
w Cause Remedy
laplace
7eplace
Wer inspec-
:ion, repair
kplace
I/ seplace
z!yCtive transmission

Is voltage be- relay
_ tween PO2 (2) and _
chassis ground
normal? Disconnection in wiring
Uter inspec-
harness between R02 (1)
*20-27V NO and fuse l-(6)
tion, repair
* Remove transmission
N relay.
Disconnection in wiring
After inspec-
harness between SF4 (4)
tion, repair
and R02 (2)
harness between PM1 (20 After inspec-
- R02 (6) or R02 (3) - tion, repair
chassis ground

After inspec-
tion, repair
between R02 (2) and SF (’
tI ieplace
E;;tive transmission
r;;iy trrnsmission Xeplace
HD325-6 20-509
0

Shift lever
D 5 4 3 L
Payload
(Printer
meter
type)
I
SF
(S12) OO(
TT I
PM1 (MIC21)
Neutral sianal
I
I
Fuse box I
Battery relay
Cir;uit bretker JO7 (BTl)
.n. -A aoAA I-I
I r\ I
m
I”1 Transmission
neutral relay
R02
TWH00343
20-510 HD3256
0
LP-4 After starting switch is turned ON, all external display lamps do
not light up
Cause Remedy
Ishort circuit with chassis

YES !ground in wiring harness .fter inspection
1 -1 ,etween lamp fuse and rpair
cjisplay lamp
Is external <short circuit between
display lamp YES
fuse blown?
,:hassis ground and wirin ,fter inspection
2 Ilarness where there is ?pair
Is there continuiw ,:ontinuity
between each lamp
Nt-, relay (2) and
chassis ground? 3 YES
GotoA
- Is resistance be-
tween each lamp
NO relay (6) and chassis IDisconnection in wiring
ground normal? Iharness between each
,fter inspection
Ilamp relay (6) and each
. Max. 20 0 NO Ppair or replace
display lamp, or blown
lamp
YES
Defective lamp relay leplace
4
Is voltage between Disconnection in wiring
From A each lamp relay (3) harness between Rll (2). Lfter inspection
and chassis (4) and each lamp relay epair
ground normal? When transmission (3), or between fuse II-U!
lever is operated and RI1 (3). (1)
l20-27V between N and
* Remove lamp _ position ofher than _
NO N, is there sound of 6 YE S
relay. Defective payload relay
payload relay being ieplace
* Turn starting When transmis-
actuated?
switch ON. sion lever is at N, is
*Turn starting NO voltage between SF
switch ON. (4) and (2) normal?
leplace
*Max. 1.5V N( ) lever
HD325-6 20-511
0

CN-14 CN-40
Left (SWPG) (SWPG) Right
External display External display External display

lamp relay I lamp relay 2 lamp relay 3
RI1 R16 RI7

Payload External display External display
meter relay lamp relay 5 lamp relay 4
TWH00344
20-512 HD325-6
0
LP-5 Condition does not exist for lamps to light up, but external display
lamps light up
Cause Remedy 1
Contact of +24V with wiring
harness between Rll (2). (4) After inspec_
YES
- each lamp relay (3), or
tion, repair
between each lamp relay (6)
-display lamp
stay lighted up
even when Rll 2 YES
When transmission Defective payload relay Replace
is removed?
* Turn starting - other than N, is
switch ON. NO voltage between SF
(4) and (2) normal? ~ Defective transmission
Replace
p NO lever
*20-27V
* Turn starting
switch ON.
I I
CN-14 ~-40 __._
Left (SWPG) (SWPG) nlgnt
External display External display External display

lamp relay I lamp relay 2 lamp relay 3
Payload meter
(printer type)
tuse box U
L 1
Shift 1
lever
n
Rll R16 R17

TWH00344
HD325-6 20-5 13
0
LP-6 Level of lighting up of external display lamps is not correct

Cause Remedy
YES -
Normal
1 After replacing,
3 YES
Is relationshipbe- Defective controller carry out
tween lighted level of calibration
displaylamp and ton - YE
z!zzJ~~
displayas shown in
Table l? 1 Disconnection in After inspec-
wiring harness?
. Turn starting spplicable wiring harness tion, repair
2 NO
switch ON.
Does display
lamp light up After replacing,
5 YE6
NO when display is 0 Defective controller carry out
ton? calibration
l Turn starting
switch ON.
* Transmission Normal -
lever: N
After inspec-
I I
Defective wiring harness tion, repair,
*Turn starting I
NO of PM1 (1). (51, (11) carry out

switch ON.
calibration
Table 1
Model 1 HD325-6 I HD405-6 I
Display lamp I 2 3 4 5 1 2 3 4 5
Color Green Green Green Yellow Red Green Green Green Yellow Red
Tondisplay 10 14 29 35 38 12 18 36 40 42
Table 2
Display lamp 1 2 3 4 5
RI7
Display lamp relay 72’; 9:; Ft:; (2) 7:;
PLM connector PM1 (2) (3) (4) (8) (9)
Table 3
1 Detected terminals 1 Voltaae 1

I (I) - (17) I 4-6V I
1 (5)-(17) 1 4-6V -1
I (II)-(17) I 4-6V I
20-514 HD325-6
0

CN-14 CN-40
Left (SWPG) (SWPG) Ri aht
External display
lamp relay 3
RI8
I
I Powor
R
_...
Shift I
lever N k
r-M-- 0 L
Rl 1 R16 R17
@
TWH00345
HD325-6 20-515
0
LP-7 Abnormality in display logic

a) Even when dump body is operated, display does not show 0 ton
Cause Remedy
YES
I Defective controller Replace
Defective wiring harness

between body float switch After inspec-
PM2 (female) (9) and PM1 tion, repair
(female) (19)
Defective body float

detection pressure switch Replace
light up when dump
body is operated to N(jj and chassis n
. Pull out bodv Disconnection in wiring
float switch wiring ground?
IL harness between PM1
(male) (7) and chassis
After inspec-
harness. NC tion, repair
* Operate dump body. ground
3efective air pressure After inspec-

system tion, repair
Table 1 Table 2
20-516 HD325-6
0
b) Display stays at 0 ton and does not change
Cause Remedy

2
Is voltagebeweenPM1
YE (19)and117)asshown
I
Defective wiring harness After inspec-
in Table1 whendump 3 YES
between PM1 (female) (19 tion, repair
body is operated? t and body float switch
1 . Turn starting
switch ON.
L_t
Does FLOAT lamp
light up when dump
body is operated to
Defective body float
FLOAT? Replace
detection pressure switch
. Pull out body float NO
switch wiring harness.
* Operate dump body.
Defective air pressure After inspec-
system tion, repair
Table 1 Table 2
LP-7 a), b) Related electrical circuit diagram
Payload meter Body FLOAT switch

(other than FLOAT)
(printer type)
RH2 612)
I. PM1 (MI&l)
I
II Body FLOAT
(other than FLOAT)
I
N. c
TWH00346
HD325-6 20-517
0
c) When transmission is at N, weight display is not given (stays at time display)
I
transmission N
isvoltage between
PM1 (20) and (17) When transmis-
as shown in Table 1 6 YES
sion lever is opa-
when transmission rated between N When transmission
and position other YE lever is at N, is
* Turn starting
switch ON.
NO
than N, is there
sound of transmis-
1
1 sion N relav beina
1
I1
voltage between SF4
(4) and (2) normal?
H
1actuated? . - 11 Max. 1.5 V NO
l Turn starting Turn starting
r
YES
.20-27V
other than N, is volt-
* Turn starting
switch ON. Is there continuity
(20) and (17) normal?
between SF (4)
*Max. 1.5V
* Turn starting
switch ON. . Remove transmis-
sion N relay. NO
YES
9
When transmission
lever is operated 1
between N and 11 YES
position other than
N, is there sound of Is there continuity
NO transmission N YE% between R02 (2) _
10
relay being p and chassis
When transmission
actuated? ground?
_ lever is at both N and _ p
Table 1 * Turn starting _ positionother than _ . 6emove transmis- NO
switch ON. NO N, is voltage sion N relay.
between SF (4) and
(2) lessthan 1.5V?
I
1 Other than N 1 Max. 1.5 V 1 * Turn starting
NO
switch ON.
20-518 HD325-6
0
Cause Remedy
Blown fuse Replace
Replace
neutral relay
Replace
lever
Replace
Replace
sion N relay. Disconnection in wiring

harness between SF After inspec-
(female) (4) and R02 tion, repair
(female) (2)
harness between PM1
After inspec-
(female) (20) - R02
tion, repair
(female) (6) or R02 (3) -
chassis ground
between R02 (female) (2) tion, repair
and SF (female) (4)
Replace
lever
Replace
neutral relay
HD325-6 20-519
0
d) When transmission lever is at position other than N, display does not change to time display
Cause Remedy
YES
PM1 (20) and (171 harness between RMI After inspec-
as shown in Table 1 ‘ES (female) (20) and R02 tion, repair
when transmission 2 (female) (6)
When transmission
I H
lever is operated I harness between R02 After inspec-
switch ON. between N and NO (female) (3) and chassis tion, repair
position other than ground
NO
N, is there sound of
transmission N relay
being actuated? transmission
Defective
- Replace
* I urn startrng bJO relay
switch ON.
Table 1
1 Other than N 1 Max. 1.5 V 1
LP-7 c), d) Related electrical circuit diagram

Shift lever
Ai%
Payload meter
Circuit breaker
&
I L
T
I
Transmission
neutral relay
R02
TWH00343
20-520 HD3256
0
LP-IO E2 1 - E28 is displayed by sensor check
Cause
Carry out
Calibration weight offset calibration
again
CN-63(x3)
HN
rlm,,llM
s"s,sntion
P,B**",B
.m"SD,
TWH00347
HD3256 20-523
0
LP-11 E31 is displayed

-k Always connect any disconnected connectors before going on to the next step.
3 YES
Is there continuity
YEc between PM1 _
(female) (10) and
chassis ground?
NO
o lRemove J04.
1When Jo4 is dis_ 1 1 * Disconnect PMl.
connected and
YE 5 YES
rWhen CN-62 is
then power source
._H
is reset, is same l-l II
replaced and CN-63
disconnected, and
then power source is
reset, is same
.__ errcr
When CN-02 is
disconnected and
then power scurce is * Remove 62. I
* Turn starting NO
reset, is same error
switch ON.
* Remove 02. 7 YES

* Turn starting When CN-13 is
switch ON.
(
1When CN-02 is
replaced and CN-13
disconnected, and
* Remove 39. NO
then power scurce is
* Turn starting
reset, is same errcr
switch ON.
* Remove 13.
* Turn starting
switch ON.
CR-1 3 (X3)
CN-63 (X3)
HN
Ralr ristl,
susPension
Pr***Yr*
ssn,or
TWH00347
20-524 HD325-6
0
Cause Remedy
between PM1 (IO) and JO4 “‘“’ repa’r

between JO4 (1) and each tion, repair
sensor connector (1)
Defective RR sensor Replace
Defective RL sensor Replace

tion, repair
Defective FR sensor Replace
Defective FL sensor Replace
HD325-6 20-525
0

f Always connect any disconnected connectors before going on to the next step.
Remedy
After inspec-
YES Is resistance tion, repair
1 I between PM2
-
H
NO11 Defective controller Replace
then power source is Max. 1 Q
Measure resist-
message displayed? ance of relay coil
. Pull out R16 - 20. according to
Defective relay Table 1 and re
* Turn starting NO
place defective
switch ON.
part
Table 1
Relay terminal Resistance Applicable relay

(l)-(2) 1 200-350&X 1 1
(1) - (2) 200 - 350 n 2
(l)-(2) 200 - 350 n 3
(1) - (2) 200 - 350 a 4
I (l)-(2) 1 200-350Q 1 5 1
20-526 HD325-6
0

CN-14 CN-40
Left (SWPG) (SWPG) Risht
External d ispl ay External disDlav External diselav

lamp relay 1 IamP relay 2 lamp relay 3
R20 Rl9 R16
I- ll- I
P wload meter
brinter type)
,
PM1 (WIC21) RH2 (S12) PM2 (M4)
1 ,
kKl
I=
I
2 6 i /
3 -b\ l---/j
4 I
i-use box u
I
ihift I t=A=
w
0
6
4
3
Rll R16 R17
L Payload External display External display
,~ meter relay lamp relay 5 lamp relay 4
TWH00345
HD325-6 20-527
0

Cause Remedy
YES
Normal —
1
Is machine travel- YES
ing on or parked Defective controller Replace
on uphill slope of
more than 10°? 2
Is voltage 4 YES with wiring harness After inspec-
between PM1 (18) Is resistance be- between PM1 (18) and tion, repair
NO and (17) normal? YES tween PM3 (fe- PM3 (2)
male) (2) and (1)
• Max. 1.6 V 3 normal? After checking
• Turn starting Is voltage be- Defective clinometer
• Max. 1 Ω NO mount, replace
switch ON. tween clinometer
• Disconnect PM3.
NO (3) and (1) nor-
mal?
• 18±1 V
• Turn starting
NO harness between PM1 tion, repair
switch ON.
(10) and PM3 (3)
20-528 HD325-6
8

Cause Remedy
YES
Normal —
1
Is machine travel-
ing on or parked
on downhill slope YES
2 Defective controller Replace
of more than 10°?
Is voltage be-
tween PLM1 (18) Defective wiring harness
NO and (17) normal? 3 YES After inspec-
between PM1 (18) and tion, repair
When PM3 is dis-
connected and then PM3 (2)
• Max. 3.6 V
power source is
• Turn starting NO reset, is same error
switch ON. message displayed?
Defective clinometer Replace
NO
HD325-6 20-529
8
TROUBLESHOOTING LP-15.16.17
LP-15 Printer does not print anything (blank paper comes out)
Cause Remedy
Defective setting of Set printer

printer paper paper correctly
Is printer paper
inserted uoside-
1 I I
NO
LP-16 Printer prints only “NO DATA”

Cause I Remedy
1 YES
When dump body
is raised, does
weight display
show 0 ton?
-
See LP-7 a)
NO
LP-17 Printer does not print out when PRT switch is pressed
Cause Remedy
20-530 HD325-6
0
TROUBLESHOOTING LP-18,19,20
LP-18 “PAPE” flashes

Cause Remedy
1 YES
‘aper jam Iear paper jam
When error dis-
play is canceled,
does PAPE light up -
again immediately?
Vormal
- Press CAL switch NO
and cancel error
display.
LP-19 Time is wrong
Cause Remedy
1 YES
Does clock gain
or lose more than
10 minutes a
month?
Normal Reset time
NO
Cause Remedy
Drop in backup battery

voltage (battery built into Replace battery
controller)
HD325-6 20-53 1
0
TROUBLESHOOTING OF PAYLOAD METER
(LP MODE)

Service codes and self-diagnosis of payload meter (printer type) ..................................................... 20-552
Electrical circuit diagram for payload meter (printer type) system .................................................... 20-554
LP-1 No display appears when starting switch is turned ON ......................................................... 20-556
LP-2 Calibration demand (CAL flashes) is shown continuously after starting
switch is turned ON .................................................................................................................... 20-557
LP-3 Calibration cannot be carried out ............................................................................................. 20-558
LP-4 After starting switch is turned ON, all external display lamps do not light up ..................... 20-561
LP-5 Condition does not exist for lamps to light up, but external display lamps light up ........... 20-563
LP-6 Level of lighting up of external display lamps is not correct ................................................. 20-564
LP-7 Abnormality in display logic ..................................................................................................... 20-566
a) Even when dump body is operated, display does not show 0 ton ................................... 20-566
b) Display stays at 0 ton and does not change ....................................................................... 20-567
c) When transmission is at N, weight display is not given (stays at time display) ............. 20-568
d) When transmission lever is at position other than N,
display does not change to time display ............................................................................ 20-570
LP-10 E21 – E28 is displayed by sensor check .................................................................................... 20-573
LP-11 E31 is displayed .......................................................................................................................... 20-574
LP-12 E32 is displayed .......................................................................................................................... 20-576
LP-13 E41 is displayed .......................................................................................................................... 20-578
LP-14 E42 is displayed .......................................................................................................................... 20-579
LP-15 Printer does not print anything (blank paper comes out) ....................................................... 20-580
LP-16 Printer prints only “NO DATA” .................................................................................................. 20-580
LP-17 Printer does not print out when PRT switch is pressed .......................................................... 20-580
LP-18 “PAPE” flashes ........................................................................................................................... 20-581
LP-19 Time is wrong ............................................................................................................................. 20-581
LP-20 E33 is displayed .......................................................................................................................... 20-581
fl As to Serial No.: 5680 – 6000 (HD325-6), 5706 – 6000 (HD325-6W), 1055 – 2000 (HD405-6), see pages
from 20-501 to 20-531.

HD325-6 20-551
8
TROUBLESHOOTING (PRINTER TYPE)

(PRINTER TYPE)
Order of
priority Display Content
1 _ _ _ 8 Internal CPU stopped (CPU is reset) (Controller power source etc. normal)
E – 3 1 Abnormal sensor power source (18V)
2 E – 3 2 Short circuit in relay
E – 3 3 Drop in back-up battery voltage
E – 0 1 Rear right wheel

• Disconnection in pressure sensor signal wire
E – 0 2 Rear left wheel
3 • Signal wire in contact with chassis
E – 0 3 Front right wheel
• Defect inside sensor
E – 0 4 Front left wheel
E – 1 2 Rear left wheel

4 • Pressure sensor signal wire in contact with power source line
E – 4 1 Disconnection in clinometer signal wire or contact with chassis

5
E – 4 2 Clinometer signal wire in contact with power source line
6 PAPE Printer REDY signal not given (paper jam)
7 FUL L Data saved in memory has reached 200 cycles (overflow)
8 CAL _ Calibration needed
E – 2 2 Rear left wheel • When sensor check is carried out, abnormality in sensor system
9 is detected.
Note 1: Once an error is displayed, the error contin-

ues to be displayed in display portion (2) until
CAL switch (1) is pressed.
Note 2: If the controller detects the abnormalities in
the above table, all the display lamps light
up.
20-552 HD325-6
8

20-554 HD325-6
8
HD325-6 20-555
8
LP-1 No display appears when starting switch is turned ON

Cause Remedy
YES
Defective PLM controller Replace
1 Short circuit of wiring

harness between con-
Is voltage be- 3 YES troller fuse and PM1A at After inspec-
tween PM1A (16) Is there continuity be- (16) - (17) or contact be- tion, repair
and (17) normal? YES tween PM1 A(16) and tween (16) and chassis
2 (17), or between (16) ground
• 20 – 30 V and chassis ground?
• Turn starting Defective PLM controller Replace
Is controller fuse NO
switch ON.
NO blown?
harness between fuse II-
After inspec-
(8) and PM1 A(16), or
NO tion, repair
between PM1A (17) and
battery relay (E)
20-556 HD325-6
8
LP-2 Calibration demand (CAL flashes) is shown continuously after

starting switch is turned ON
Cause Remedy
1 YES
The voltage
between PM1A
(1), (5), (11) – (17)
normal? Short circuit with chassis Checking and
ground in PM1A (1), (5), repairing
•4–6V NO
(11) harness
• Turn starting
switch to ON.
HD325-6 20-557
8
LP-3 Calibration cannot be carried out

3 YES
Drive machine
with CAL still
YES flashing. Does
2 CAL display light
When transmis- up if CAL switch is
sion lever is at N, pressed?
YES
does CAL display NO
flash if CAL switch
is pressed?
NO
YES
1 5
Is voltage between YES
PM1A (20) and (17) YES Is fuse for
transmission N
as shown in Table 1 relay blown?
when transmis-sion 6
lever is operated? 8 YES
When transmission
• Turn starting lever is operated When transmission
switch ON. between N and YES lever is at N, is
position other than
NO voltage between SF4
N, is there sound of
(4) and (2) normal?
being actuated? 7 • Max. 1.5 V NO
• Turn starting • Turn starting
When transmission
4 NO other than N, is
voltage between SF
When transmission (4) and (2) normal? YES
lever is at N, is volt-
age between PM1A • 20 – 27 V 9
NO (20) and (17) normal? • Turn starting
Is there continuity
switch ON.
• Max. 1.5 V between SF (4)
NO and R02 (2)?
• Turn starting
switch ON.
• Remove transmis-
sion N relay. NO
YES
11
When transmission
lever is operated
position other than
Is there con-
NO N, is there sound of YES tinuity between
Table 1 transmission N 12
relay being R02 (2) and
Position Voltage Is voltage between
actuated? chassis ground?
N 15 – 25 V SF (4) and (2)
• Turn starting normal both when • Remove transmis- NO
Other than N Max. 1.5 V switch ON. transmission lever sion N relay.
NO is at N and position
other than N?
• Max. 1.5 V
NO
• Turn starting
switch ON.
20-558 HD325-6
8
Cause Remedy
Normal —
Blown fuse Replace

After inspec-
tion, repair
between PM1A (20) and R02
(6)
neutral relay Replace
Replace
lever

Replace
tween P02 (2) and
chassis ground
After inspec-
harness between R02 (1)
NO tion, repair
• 20 – 27 V and fuse I-(6)
• Remove transmission
N relay.
After inspec-
harness between SF4 (4)
tion, repair
and R02 (2)
harness between PM1A After inspec-
(20) - R02 (6) or R02 (3) - tion, repair
chassis ground

After inspec-
tion, repair
between R02 (2) and SF (4)
Replace
lever
Replace
neutral relay
HD325-6 20-559
8
20-560 HD325-6
8
LP-4 After starting switch is turned ON, all external display lamps do
not light up
Cause Remedy

YES ground in wiring harness After inspection,
1 between lamp fuse and repair
display lamp
Is external
Short circuit between
display lamp YES chassis ground and wiring After inspection,
fuse blown? repair
2 harness where there is
Is there continuity continuity
between each lamp
relay (2) and
NO 3 YES
chassis ground?
Go to A
Is resistance be-
tween each lamp
NO relay (6) and chassis
ground normal? harness between each
After inspection,
lamp relay (6) and each
• Max. 20 Ω NO repair or replace
display lamp, or blown
lamp
YES
Defective lamp relay Replace
4
Is voltage between
From A each lamp relay (3) harness between R11 (2), After inspection,
5 YES (4) and each lamp relay
and chassis repair
ground normal? When transmission (3), or between fuse II-(15)
lever is operated and R11 (3), (1)
• 20 – 27 V between N and
• Remove lamp position other than
relay. NO N, is there sound of 6 YES
payload relay being Defective payload relay Replace
• Turn starting When transmis-
actuated?
switch ON. sion lever is at N, is
• Turn starting NO voltage between SF
switch ON. (4) and (2) normal?
Replace
• Max. 1.5 V NO lever
HD325-6 20-561
8
20-562 HD325-6
8
LP-5 Condition does not exist for lamps to light up, but external display
lamps light up
Cause Remedy
Contact of +24V with wiring

harness between R11 (2), (4) After inspec-
YES
- each lamp relay (3), or tion, repair
1 between each lamp relay (6)
Does display - display lamp
stay lighted up
even when R11 2 YES
When transmission Defective payload relay Replace
is removed?
• Turn starting other than N, is
switch ON. NO voltage between SF
(4) and (2) normal? Defective transmission
Replace
NO lever
• 20 – 27 V
• Turn starting
switch ON.
HD325-6 20-563
8
LP-6 Level of lighting up of external display lamps is not correct

Cause Remedy
YES
Normal —
1 After replacing,
3 YES
Is relationship be- Defective controller carry out
Use Table 2 to
tween lighted level calibration
of display lamp and YES check lamp that
lighted up in Item 2.
ton display as shown
Is there continuity
in Table 1? Disconnection in After inspec-
in wiring harness?
• Turn starting NO applicable wiring harness tion, repair
2
switch ON.
Does display
lamp light up After replacing,
5 YES
NO when display is 0 Defective controller carry out
ton? Does problem calibration
YES appear even
• Turn starting
4 after calibration
switch ON.
• Transmission Is voltage between is carried out?
Normal —
lever: N PM1A (1), (5), (11) - NO
NO (17) as shown in
Table 3? After inspec-
• Turn starting Defective wiring harness tion, repair,
switch ON. NO of PM1 (1), (5), (11) carry out
calibration
Table 1
Model HD325-6 HD405-6
Display lamp 1 2 3 4 5 1 2 3 4 5
Color Green Green Green Yellow Red Green Green Green Yellow Red
Ton display 10 14 29 35 38 12 18 36 40 42
Table 2
Display lamp 1 2 3 4 5
R20 R19 R18 R17 R16
Display lamp relay (2) (2) (2) (2) (2)
PLM connector PM1 (2) (3) (4) (8) (9)
Table 3
Detected terminals Voltage
(1) – (17) 4–6V
(5) – (17) 4–6V
(11) – (17) 4–6V
20-564 HD325-6
8
HD325-6 20-565
8
LP-7 Abnormality in display logic

a) Even when dump body is operated, display does not show 0 ton
Cause Remedy
YES
2
Is voltage between
YES PM1A (19) and (17) as Defective wiring harness
shown in Table 1 3 YES between body float switch After inspec-
when dump body is RH2 (female) (9) and tion, repair
operated? Is resistance be-
tween body float
PM1A (female) (19)
• Turn starting switch and chassis
1 switch ON. NO ground as shown in 4 YES Defective body float
Does FLOAT lamp Table 2 when dump detection pressure switch Replace
Is there continuity
light up when dump body is operated?
between RH2 (7)
body is operated to
FLOAT? • Pull out body NO and chassis Disconnection in wiring
float switch wiring ground? harness between PM1A After inspec-
harness. NO (male) (7) and chassis tion, repair
• Operate dump body. ground

NO system tion, repair
Table 1 Table 2
Position Voltage Position Resistance
FLOAT 15 – 25 V FLOAT Min. 1 MΩ
Other than FLOAT Max. 1 V Other than FLOAT Max. 1 Ω
20-566 HD325-6
8
b) Display stays at 0 ton and does not change
Cause Remedy
YES
2
Is voltage between
YES PM1A (19) and (17) as Defective wiring harness
3 YES After inspec-
shown in Table 1 when between PM1A (female)
dump body is operated?
tion, repair
Is resistance be- (19) and body float switch
tween body float
1 • Turn starting switch and chassis
Does FLOAT lamp switch ON. ground as shown in
light up when dump Table 2 when dump
body is operated to body is operated?
FLOAT? NO Defective body float
Replace
• Pull out body float NO detection pressure switch
switch wiring harness.
• Operate dump body.
NO system tion, repair
Table 1 Table 2
Position Voltage Position Resistance
Other than FLOAT Max. 1 V Other than FLOAT Max. 1 Ω
LP-7 a), b) Related electrical circuit diagram
HD325-6 20-567
8
c) When transmission is at N, weight display is not given (stays at time display)
YES
YES
3
YES
1 YES Is fuse for
transmission N
Is voltage between relay blown? 4
PM1A (20) and (17) When transmis-
as shown in Table 1 sion lever is ope- 6 YES
when transmission rated between N When transmission
lever is operated? and position other YES lever is at N, is
• Turn starting NO than N, is there voltage between SF4

sound of transmis- (4) and (2) normal?
switch ON. sion N relay being
actuated? 5 • Max. 1.5 V NO
• Turn starting When transmission • Turn starting
switch ON. lever is at position switch ON.
other than N, is
2 NO voltage between SF
When transmission (4) and (2) normal?
YES
• 20 – 27 V 7
other than N, is volt-
NO age between PM1A • Turn starting
switch ON. Is there continuity
(20) and (17) normal?
between SF (4)
NO and R02 (2)?
• Max. 1.5 V
• Turn starting
switch ON. • Remove transmis-
sion N relay. NO
YES
9
When transmission
lever is operated
position other than
N, is there sound of Is there continuity
YES between R02 (2)
NO transmission N 10
relay being and chassis
When transmission
actuated? ground?
lever is at both N and
Table 1 • Turn starting position other than • Remove transmis- NO
Position Voltage switch ON. NO N, is voltage sion N relay.
between SF (4) and
N 15 – 25 V (2) less than 1.5V?
Other than N Max. 1.5 V • Turn starting
NO
switch ON.
20-568 HD325-6
8
Cause Remedy
Blown fuse Replace

between PM1A (female) tion, repair
(20) and R02 (female) (6)
Replace
neutral relay
Replace
lever

Replace
tween P02 (1) and
chassis ground
harness between R02 Replace
• 20 – 27 V NO (female) (1) and fuse I-(5)
• Remove transmis-
sion N relay. Disconnection in wiring
harness between SF After inspec-
(female) (4) and R02 tion, repair
(female) (2)
harness between PM1A
After inspec-
(female) (20) - R02
tion, repair
(female) (6) or R02 (3) -
chassis ground
between R02 (female) (2) tion, repair
and SF (female) (4)
Replace
lever
Replace
neutral relay
HD325-6 20-569
8
d) When transmission lever is at position other than N, display does not change to time display
Cause Remedy
YES
1
Is voltage between Disconnection in wiring
PM1A (20) and (17) 3 YES harness between RM1A After inspec-
as shown in Table 1 YES Is there continuity (female) (20) and R02 tion, repair
when transmission 2 between R02 (3) (female) (6)
lever is operated? and chassis
When transmission Disconnection in wiring
• Turn starting lever is operated ground? harness between R02 After inspec-
switch ON. between N and NO (female) (3) and chassis tion, repair
position other than ground
NO N, is there sound of
being actuated?
relay Replace
switch ON.
Table 1
Position Voltage
N 15 – 25 V
Other than N Max. 1.5 V
LP-7 c), d) Related electrical circuit diagram
20-570 HD325-6
8
LP-8 E01 – E04 is displayed Cause Remedy

connectors are properly inserted. Short circuit with chassis
fl Always connect any disconnected YES ground in wiring harness After inspec-
3 between sensor connector tion, repair
connectors before going (2) and PM1A
Is resistance between
on to the next step. YES sensor connector Disconnection in wiring
(female) (2) and chassis 4 YES harness between sensor After inspec-
ground normal? connector (female) (2) tion, repair
2 Is resistance between
• Min. 1 MΩ sensor connector and PM1A
Is voltage be-tween
• Turn starting (female) (2) and chassis
YES sensor PM1A input NO ground normal?
(12), (13), (14), (15) switch OFF.
• Disconnect PM1A Go to A —
- (24) normal? • Max. 10 Ω NO
and sensor
1 • Max. 0.4 V • Turn starting
connector.
• Turn starting switch OFF.
Is voltage normal
switch ON. • Connect PM1A
between chassis Defective controller Replace
ground and sensor NO
connector (1)
shown in Table 1? Disconnection in wiring
• 17 – 19 V 6 YES harness between PM1A After inspec-
• Turn starting Is voltage (female) (10) and sensor tion, repair
switch ON. between PM1A connector (1)
NO (10) and (21)
normal?
• 17 – 19 V NO
• Turn starting
switch ON. Check with
5 YES JUDGMENT
Defective sensor system STANDARD, and
Is resistance be- replace if
From A tween sensor defective
connector (male)
(1) and (2) normal?
• 250±10 Ω NO
Table 1
Mounting Connector PM1A input
Sensor No. position No. terminal No.
1 RR 63 12
2 RL 62 13
3 FR 39 14
4 FL 13 15
HD325-6 20-571
8
LP-9 E11 – E14 is displayed

Cause Remedy
Short circuit of signal line

2 YES with power source line After inspec-
between PM1A and tion, repair
YES Is there continuity
1 between PM1A sensor
(female) (20) and
Is voltage normal sensor input pin?
between PM1A Defective controller Replace
sensor input pin • Pull out PM1A. NO
and PM1A (17) • Pull out sensor
shown in Table 1? connector. Check with
• Disconnect PM1A. JUDGMENT
• 1Max. 5 V Defective sensor system STANDARD,
• Pull out sensor NO and replace if
connector shown defective
in Table 1.
• Turn starting
switch ON.
Table 1
Mounting Connector PM1A input
Sensor No. position No. terminal No.
1 RR 63 (12)
2 RL 62 (13)
3 FR 39 (14)
4 FL 13 (15)
20-572 HD325-6
8
LP-10 E21 – E28 is displayed by sensor check
Cause Remedy
Carry out
Calibration weight offset calibration
again
HD325-6 20-573
8

3 YES
Is there continuity
YES between PM1A
(female) (10) and
chassis ground?
• Remove J04. NO
2
• Disconnect PM1.
When J04 is dis-
connected and
YES then power source 5 YES
is reset, is same When CN-62 is
error message replaced and CN-63
displayed? YES disconnected, and
• Remove J04. 4 then power source is
When J04 is replaced reset, is same error
• Turn starting
and CN-62 discon- message displayed?
switch ON. nected, and then
• Remove 63. NO
1 NO power source is
reset, is same error • Turn starting
When CN-02 is message displayed? switch ON.
disconnected and
then power source is • Remove 62.
message displayed? switch ON.
• Remove 02. 7 YES

• Turn starting When CN-13 is
switch ON.
YES replaced and CN-39
disconnected, and
6 then power source is
When CN-02 is reset, is same error
replaced and CN-13 message displayed?
disconnected, and NO
• Remove 39.
NO then power source is • Turn starting
message displayed? switch ON.
• Remove 13.
switch ON.
20-574 HD325-6
8
Cause Remedy

between PM1A (10) and tion, repair
J04

between J04 (1) and each tion, repair
sensor connector (1)
Defective RR sensor Replace
Defective RL sensor Replace

between 02 (6) and tion, repair
pressure sensors FL, FR
Defective FR sensor Replace
Defective FL sensor Replace
HD325-6 20-575
8

Cause Remedy
2 YES Short circuit between After inspec-

+24V line and line where tion, repair
YES Is resistance resistance is less than 1 Ω
1 between PM1A
(16) - (2), (3), (4),
When all lamp relays
(8), (9) normal?
are pulled out and Defective controller Replace
then power source is • Max. 1 Ω NO
Measure resist-
message displayed?
ance of relay coil
• Pull out R16 – 20. according to
Defective relay Table 1 and re-
place defective
switch ON. part
Table 1
Relay terminal Resistance Applicable relay
(1) – (2) 200 – 350 Ω 1
(1) – (2) 200 – 350 Ω 2
(1) – (2) 200 – 350 Ω 3
(1) – (2) 200 – 350 Ω 4
(1) – (2) 200 – 350 Ω 5
20-576 HD325-6
8
HD325-6 20-577
8

Cause Remedy
YES
Normal —
1
Is machine travel- YES
ing on or parked Defective controller Replace
on uphill slope of
more than 10°? 2
Is voltage 4 YES with wiring harness After inspec-
between PM1A between PM1A (18) and
Is resistance be- tion, repair
(18) and (17) YES tween PM3 (fe- PM3 (2)
NO
normal?
male) (2) and (1)
• Max. 1.6 V 3 normal? After checking
• Turn starting Is voltage be- Defective clinometer
• Max. 1 Ω NO mount, replace
switch ON. tween clinometer
• Disconnect PM3.
NO (3) and (1) nor-
mal?
• 18±1 V
• Turn starting
NO harness between PM1A tion, repair
switch ON.
(10) and PM3 (3)
20-578 HD325-6
8

Cause Remedy
YES
Normal —
1
Is machine travel-
ing on or parked
on downhill slope YES
of more than 10°?
Is voltage be- Defective contact or
tween PLM1A disconnection in wiring
(18) and (17) 3 YES harness between PM1A After inspec-
NO
normal? When PM3 is dis- (18) and PM3 (2) and tion, repair
• Max. 3.6 V connected and then chassis ground – PM1A
power source is (17)
• Turn starting NO reset, is same error
switch ON. message displayed?
NO
HD325-6 20-579
8
TROUBLESHOOTING LP-15, 16, 17
LP-15 Printer does not print anything (blank paper comes out)
Cause Remedy
1 YES Defective setting of Set printer

printer paper paper correctly
Is printer paper
inserted upside-
down?
NO
LP-16 Printer prints only “NO DATA”

Cause Remedy
1 YES
When dump body
is raised, does
weight display
show 0 ton?
See LP-7 a) —
NO
LP-17 Printer does not print out when PRT switch is pressed
Cause Remedy
20-580 HD325-6
8
TROUBLESHOOTING LP-18, 19, 20
LP-18 “PAPE” flashes

Cause Remedy
1 YES
Paper jam Clear paper jam
When error dis-
play is canceled,
does PAPE light up
again immediately?
Normal —
• Press CAL switch NO
and cancel error
display.
LP-19 Time is wrong

Cause Remedy
1 YES
Does clock gain
or lose more than
10 minutes a
month?
Normal Reset time
NO
Cause Remedy
Drop in backup battery

voltage (battery built into Replace battery
controller)
HD325-6 20-581
8
TROUBLESHOOTING OF PAYLOAD METER II
(CARD TYPE) SYSTEM
(LC MODE)
Service codes and self-diagnosis of payload meter II (card type) ..................................................... 20-602
Electrical circuit diagram for payload meter II (card type) system ..................................................... 20-606
LC-1 No display appears when starting switch is turned ON .......................................................... 20-608
LC-2 After starting switch is turned ON, all external display lamps do not light up ................... 20-608-2
LC-3 Condition does not exist for lamps to light up, but external display lamps light up ............ 20-610
LC-4 Level of lighting up of external display lamps is not correct .................................................. 20-611
LC-5 Cycle data is not recorded, ON/OFF data is not recorded:
Battery charge signal system: Engine is not started is detected ....................................... 20-613
LC-6 Calibration cannot be carried out, time display does not match conditions:
Shift lever N position signal system .................................................................................... 20-614
LC-7 Abnormality in display logic ...................................................................................................... 20-615
LC-8 b-FL remains displayed and does not change: Body FLOAT relay system:
When not dumping and when dump lever is not at FLOAT position ................................ 20-617
LC-9 F-09 is displayed: Drop in voltage of back-up battery built into payload meter .................... 20-618
LC-10 .FULL display appears ............................................................................................................. 20-618
LC-11 F-20 is displayed: Sensor power source voltage system ......................................................... 20-619
LC-12 F-21 – F-24 is displayed:
Disconnection, short circuit with ground in suspension pressure sensor system ........... 20-620
Short circuit in suspension pressure sensor system power source .................................. 20-622
LC-14 F.CAL is displayed: Calibration not carried out, damaged data inside payload meter .......... 20-624
LC-15 F-41 – F-45 is displayed: Short circuit in external display lamp system power source ......... 20-624
LC-16 L-bad is displayed: Cycle data saved when machine was swaying ........................................ 20-626
LC-17 Machine is not loading but external display lamps give load estimate display
After loading, display switches to time display before traveling 160 m ................................ 20-628
LC-18 F-31 is displayed: Disconnection, short circuit with ground in clinometer system ............... 20-628
LC-19 F-32 is displayed: Short circuit with clinometer system power source .................................. 20-629
LC-20 F-18 is displayed: Disconnection in battery charge signal ....................................................... 20-630
HD325-6 20-601
8
TROUBLESHOOTING SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER II (CARD TYPE)
SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER II

(CARD TYPE)
This is shown on the payload meter II (card type) display. (It is not shown on the monitor panel display.)
Order of
External display
priority fo Content service code
lamps
display
)-FL lights up All liaht UD
1 jump lever at position other than FLOAT (other than dumping soil)
)-FL lights up
2 Jemory card missing Cd flashes -
3 )rop in backup battery voltage F-09 flashes -
:ycle data memory FULL
ingine ON/OFF data FULL See next
4
-
ibnormality warning data memory FULL page (*I)
Qgregate payload, total cycle number data memory FULL
5 Xsconnection in terminal R F-18 flashes All flash
6 ibnormalitv in sensor power source (18VI F-20 flashes All flash
7 #hart circuit with ground, disconnection in front left suspension pressure sensor system F-21 flashes All flash
8 ‘hart circuit with ground, disconnection in front right suspension pressure sensor system F-22 flashes All flash
9 Nhortcircuit with ground, disconnection in rear left suspension pressure sensor system F-23 flashes All flash
10 Nhortcircuit with ground, disconnection in rear right suspension pressure sensor system F-24 flashes All flash
11 ihortcircuit with power source of front left suspension pressure sensor system F-25 flashes All flash
12 ;horf circuit with power source of front right suspension pressure sensor system F-26 flashes All flash
13 ;hortcircuit with power source of rear left suspension pressure sensorsystem F-27 flashes All flash
14 ihortcircuit with power source of rear right suspension pressure sensor system F-28 flashes All flash
15 short circuit with ground, disconnection in clinometer system F-31 flashes All flash
16 jhort circuit with power source in clinometer system F-32 flashes All flash
17 Calibration not carried out or abnormality in RAM FCAL flashes All flash
18 Short circuit in external display lamp No. 1 relay F-41 flashes F.Applicable lamp
Machine stopped:
Always ON
19 ihort circuit in external display lamp No. 2 relay F-42 flashes Traveling: OFF
Other lamps
20 jhort circuit in external display lamp No. 3 relay F-43 flashes When loading:
Specified actuation
21 ;hort circuit in external display lamp No. 4 relay F-44 flashes When stopped but
not loading: Flashes
22 jhort circuit in external display lamp No. 5 relay F-45 flashes Traveling: OFF
23 defective cycle data payload [see (*2) on page 20-6041 L.bad flashes -
24 1ver limit speed 3P:SP flashes -
F-71 flashes
F-73 flashes
F-80 flashes
F-81 flashes
F-91 flashes
25 defective communications or defective option code setting F-92 flashes -
F-93 flashes
F-94 flashes
F-95 flashes
F-96 flashes
F-97 flashes
F-98 flashes
*HD325 and 405 do not apply for Item 25 in the Order of priority for display column.
20-602 HD325-6
0
TROUBLESHOOTING SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER II (CARD TYPE)
(*I) Warning displays when memory is FULL 3) If more data are added, the 231st,
1. Cycle data 232nd, . .. are saved. But each time new
I) When more than 2,600 cycles are saved data are saved, the earliest abnormal-
(remaining capacity less than 300 ity and warning data are deleted in turn.
cycles), the following cycle is repeated. (The display is kept at the condition in
L: FULL flashes 7 times 2) above.)
flashes 1 time
2) When the machine is used more and 4. Aggregate payload, total cycle number data
2900 cycles are saved in memory (re- I) When the count for the total number of
maining capacity 01, the following cycles goes above 9,994 (remaining ca-
cycle is repeated. pacity less than 5) orthe difference be-
L: FULL lights up (3 seconds) tween the aggregate payload and
flashes 1 time 999900 tons (upper limit) goes below 5
3) If more cycles are added, the 2,90lst, rated loads, the follow.ing cycle is re-
2,902nd, . . . are saved. But each time a peated.
new cycle is saved, the data for the old- H: FUL flashes 7 times
est cycle are deleted in turn. (The dis- flashes 1 time
play is kept at the condition in 2) 2) If the operation is continued and the
above.) count for the total number of cycles
goes above 9,997 (remaining capacity
2. Engine ON/OFF data less than 2) or the difference between
I) When more than 105 times are saved the aggregate payload and 999,900
(remaining capacity less than 10 times), tons (upper limit) goes below 5 rated
the following cycle is repeated 2 times loads, the following cycle is repeated.
and then the display goes out. H: FULL lights up (3 seconds)
E: FULL flashes 7 times flashes 1 time
flashes 1 time 3) If the operation is continued and the
2) When the machine is used more and total number of cycles reaches 9,999 or
115 times are saved in memory (re- the aggregate payload goes above
maining capacity O), the following 999,900 tons, both the aggregate pay-
cycle is repeated 2 times and then the load and total cycle number will auto-
display goes out. matically be cleared and set to 0. After
E: FULL lights up (3 seconds) this, the count for both values will start
flashes 1 time again from 0. (The display will return
3) If the engine is turned ON/OFF more to the normal operation display.)
times, the 116th, 117th, . . . are saved.
But each time a new time is saved, the 5. To cancel the data FULL condition in Items
data for the earliest time are deleted in 1 - 3, see the Payload Meter II (card type)
turn. Operation and Maintenance Manual, “8.3
Operator check mode”.
3. Abnormality, warning data For Item 4, if data FULL is displayed, it is
I) When more than 220 times are saved not canceled until the system is automati-
(remaining capacity less than 10 times), cally cleared and set to 0. Clear the data
the following cycle is repeated. and set to 0 forcibly before data FULL is
E: FULL flashes 7 times displayed. For details of the method of
flashes 1 time operation, see the Payload Meter II Opera-
2) When the machine is used more and tion and Maintenance Manual, “8.2 Forc-
230 times are saved in memory (re- ible display of aggregate payload, total
maining capacity 01, the following cycle number”.
cycle is repeated.
E: FULL lights up (3 seconds)
flashes 1 time
HD325-6 20-603
0
TROUBLESHOOTING SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER II [CARD TYPE)
6. For the display of Items 1 - 4, there is no

order of priority. If multiple cases of data
FULL occur at the same time, they are dis-
played at any time except when loading.
(“2) Defective cycle data payload

1. Detection of the payload by the payload
meter is based on the suspension pres-
sure sensor signals. This detection is al-
ways carried out, but during loading op-
erations or immediately after loading op-
erations, the dynamic friction of the sus-
pension causes some instability. To en-
sure that accurate data for the payload are
saved to memory, when recording the
payload data, the payload meter detects
and saves the payload data immediately
before the load is dumped. In this way,
the dynamic friction of the suspension
occurring during loading is canceled
when the machine travels loaded. (It is
saved as part of the cycle data.)
2. For this reason, if the operator starts the
dumping operation (operates the dump
lever) before the swaying (pitching) of the
machine has stabilized when the machine
is stopped at the dumping point, there is
danger that the payload data saved in the
payload meter will not be accurate.
3. In addition, if the brakes are applied sud-
denly to stop the machine at the dump-
ing point or the wheels mount or hit the
wheels stoppers when stopping, there is
also danger that the payload data will not
be recorded accurately.
4. If the load is dumped before the swaying
of the machine has stabilized in the con-
ditions above, the payload meter will dis-
play [Insufficient cycle data payload] on
the abnormality and warning item display
to advise the operator to be careful. Even
in this case the detected payload is saved
to memory.
20-604 HD325-6
0
ELECTRICAL CIRCUIT DIAGRAM FOR PAYLOAD METER II
TROUBLESHOOTING (CARD TYPE) SYSTEM

(CARD TYPE) SYSTEM
HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
20-606 HD325-6
8
HD325-6 20-607
8

20-607-1 HD325-6
8
HD325-6 20-607-2
8
TROUBLESHOOTING LC-1
LC-1 No display appears when starting switch is turned ON

HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
fl Check that the 5A payload meter fuse inside the fuse box is not blown.
Cause Remedy
YES
Defective payload meter Replace parts
1
Is voltage be- harness between RM5 Repair wiring
3 YES
tween PM5 (1) (13) - PM1 (17) - J03 (8) - harness or
and (13) 20 - 30 V? Is resistance 30 (9) - battery relay replace
YES
between PM5 (13) terminal E
• Disconnect PM5. 2 and chassis more
Check, repair
• Turn starting Is voltage than 1 Ω? Defective contact of contact portion
switch ON. between PM5 (1) NO power source circuit of connector,
• Disconnect PM5. terminal
NO and chassis 20 - • Turn starting Repair disconnec-
30 V? switch ON. tion, defective con
• Disconnect PM5. -tact portion be-
disconnection in wiring tween PM5 (1) and
• Turn starting NO harness fuse, or check con-
switch ON. tact portion of fuse
holder terminal
LC-1 Related electrical circuit diagram
20-608 HD325-6
8

fl Check that the 5A payload meter fuse inside the fuse box is not blown.
Cause Remedy
YES
1
Is voltage be- harness between RM5 Repair wiring
3 YES
tween PM5 (1) (13) - PM1 (8) - J03 (8) - harness or
and (13) 20 - 30 V? Is resistance 30 (9) - battery relay replace
YES
between PM5 (13) terminal E
• Disconnect PM5. 2 and chassis more
Check, repair
• Turn starting Is voltage than 1 Ω? Defective contact of contact portion
switch ON. between PM5 (1) NO power source circuit of connector,
• Disconnect PM5. terminal
NO and chassis 20 - • Turn starting Repair disconnec-
30 V? switch ON. tion, defective con-
• Disconnect PM5. tact portion be-
disconnection in wiring tween PM5 (1) and
• Turn starting NO harness fuse, or check con-
switch ON. tact portion of fuse
holder terminal
HD325-6 20-608-1
8
LC-2 After starting switch is turned ON, all external display lamps do
not light up
HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
fl Set shift lever to N and turn starting switch ON.
fl Check that the 20A external display lamp fuse inside the fuse box is not blown.
fl Check that the lamp bulb is not blown.
Cause Remedy
2 YES
Defective payload relay Replace parts
YES
1 Is voltage
between R11 (1),
Turn power ON (3) - (6) 20 - 30 V? Disconnection in wiring
and connect Repair wiring
harness between fuse II-(15) -
payload lamp R11 (1), (3), or defective harness or
power source • Disconnect R11. NO replace
contact of R11 (2), (4) portion
relay. Can actua- • Turn starting
Short circuit with power
tion sound of switch ON.
source in wiring harness Repair wiring
relay be heard? • Connect shift lever N. between R11 (6) and SF (4), or
short circuit (No. 4) of chassis
harness or
• Disconnect R11. NO replace
with wiring harness between
• Turn starting R11 (5) and fuse II-(14)
switch ON.
• Connect R11.
• Connect shift lever N.
20-608-2 HD325-6
8

fl Set shift lever to N and turn starting switch ON.
fl Check that the 20A external display lamp fuse inside the fuse box is not blown.
fl Check that the lamp bulb is not blown.
Cause Remedy
2 YES
Defective payload relay Replace parts
YES
1 Is voltage
between R11 (1),
Turn power ON (3) - (6) 20 - 30 V? Disconnection in wiring
and connect Repair wiring
harness between fuse II-(15) -
payload lamp R11 (1), (3), or defective harness or
power source • Disconnect R11. NO replace
contact of R11 (2), (4) portion
relay. Can actua- • Turn starting
tion sound of switch ON.
source in wiring harness Repair wiring
relay be heard? • Connect shift lever N. between R11 (6) and SF (4), or
short circuit (No. 4) of chassis
harness or
• Disconnect R11. NO replace
with wiring harness between
• Turn starting R11 (5) and fuse II-(14)
switch ON.
• Connect R11.
• Connect shift lever N.
HD325-6 20-609
8
LC-3 Condition does not exist for lamps to light up, but external dis-
play lamps light up
Cause Remedy
to the next step.
Short circuit with power Repair wiring
YES source in wiring harness
harness or
1 between R11 (2), (4) -
each relay terminal (3) replace
Do lamps stay light
-ed up even when
relay is discon- 2 YES Defective payload lamp
nected from R11? power source relay Replace relay
When shift lever
• Turn starting is at N, is voltage
switch ON. NO between R11 (5) source in wiring harness Repair wiring
• Disconnect R11. and (6) 20 - 30V? between R11 (6) and SF (4), or
short circuit of chassis with harness or
• Turn starting NO wiring harness between R11 replace
switch ON. (5) and fuse II-(14)
• Disconnect R11.

HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
20-610 HD325-6
8

HD325-6 20-610-1
8
LC-4 Level of lighting up of external display lamps is not correct

fl Turn the starting switch ON and set the shift lever to N.
Cause Remedy
3 YES
Is resistance be-
tween PM5 terminal
YES corresponding to
relay of lighted lamp
2 and corresponding
relay, connector (1) If resistance is
When relay of 100 - 500 Ω? Disconnection in relay 100 - 500 Ω when
YES lighted lamp is relay is removed,
• Turn starting NO circuit
removed, does repair or replace
lamp go out? switch OFF. wiring harness
1 • Shift lever: Position other than N
• Disconnect PM5. Short circuit with power Repair wiring
When display is 0 source in wiring harness harness or
ton, do external NO in applicable lamp circuit replace
lamps light up?
4 YES Check if pressure inside

—
When calibration is suspension is normal
carried out again,
NO is condition still
abnormal? Carry out calibration Check model
NO again code again
HD325-6 20-611
1

HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
20-612 HD325-6
8

HD325-6 20-612-1
8
LC-5 Cycle data is not recorded, ON/OFF data is not recorded:

Battery charge signal system: Engine not started is detected
Cause Remedy
2 YES
Defective payload meter Replace
After engine is started,
is voltage between
YES PM5 (9) and chassis
1 more than 5V, or is
there pulse wave of Defective generation of
Is no data recorded more than 5V - 0V? electricity by alternator or
Repair or replace
(both cycle data or disconnection in wiring
• Connect T-adapter NO harness between PM5 (9)
engine ON/OFF to PM5.
data)? • Start engine. and alternator terminal R
(Engine ON/OFF data is recorded)

Go to LC-7
NO
HD325-6 20-613
1
TROUBLESHOOTING
LC-6 Calibration cannot be carried out, time display does not match
conditions : Shift lever N position signal system
Cause Remedy
YES
★ Defective payload Replace
3
Is voltage bet-
YES ween PM6 (10) and
(3) as shown in
4 YES
2 Table 1 when shift Go to A
lever is operated? In condition in
Is resistance
• Connect T-adapter Item 3, is voltage
YES between neutral
relay (1) and (2) to PM6. NO below 1.5V at
• Turn starting Neutral?
1 100 - 500 Ω? Go to B
switch ON.
Do external display NO
• Remove R02. • Operate shift
lamps work normally lever.
according to Opera-
tion and Maintenance
Manual? Defective neutral relay Replace
NO
Go to LC-2
NO
Short circuit with chassis Repair or

5 YES ground in wiring harness
replace wiring
Is resistance bet- between PM6 (10) and harness
ween PM6 (10) R02 (6)
From A
and chassis less Short circuit with chassis
than 1 Ω? ground in wiring harness
Repair or
replace wiring
• Connect T-adapter NO between BT1 (10) and
R02 (1) harness
to PM6, but discon-
nect payload meter
end.
• Disconnect R02.
• Turn starting switch Short circuit with chassis
OFF. Repair or
replace wiring
Is voltage bet- between R02 (2) and SF
Table 1 harness
ween R02 (2) and (4)
From B
Shift lever position Voltage chassis less than Defective contact or
1.5V? Repair or
20 – 30 V disconnection in wiring
N replace wiring
• Install T-adapter to NO harness between R02 (6) harness
Other than N Max. 1.5 V and PM6
PM6, but do not
connect relay.
• Turn starting switch
ON.
• Shift lever position:
Other than N
20-614 HD325-6
8

HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000

HD325-6 20-614-1
8
LC-7 Abnormality in display logic

a) After loading and starting to travel loaded, display remains at 0
bl After starting to travel loaded, travel distance display value does not change.
cl Travel speed is above speed limit, but SP:SP display does not appear.
+ If the payload display is given during loading, but it stays at 0 from the time of starting travel to the
time of dumping, it shows that the travel speed signal cannot be detected.
t Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Cause
between PM5 (7)

Are speedometer and (8) 500 - 1 Defective contact or
kR? Repair or
on electronic dis- disconnection in wiring
replace wiring
play panel and _ f Connect T-adapter NO harness between PM5 (7),
harness
transmission con to PM6, but disconnect payload (8) and TMA (I), (2)
-troller working meter end.
normally? * Turn starting switch OFF.
Carry out troubleshooting -
NO
Payload meter11 (card tvoel

I PM4 (M6)
PM5(MIC13) a---
@---
Susoension controller
I
TMA (S16) SU3 (S16) SSP2Bt04016)
I Tranwtssion ontroller
outrut shaft weed(t)
- Sional lnornal)
I I
ATC3At04020) TM2 (SNP14 black) N3 (X2) Transmission output
shaft speed sensor
Soeed GND ICOM)
1 4
TWH00356
dl Aggregate payload display is not given

* The aggregate payload display is given between the start of dumping and the completion of dump-
ing. The following procedures are necessary.
. Start of dumping means that the following conditions (I) to (3) are fulfilled.
(I) When the previous dumping operation was completed, and the dump body was moved from
LOWER to FLOAT, the load became less than l/5 of the rated load within 5 seconds.
(2) During the previous dumping operation, immediately after the lever was moved from LOWER
to FLOAT at the completion of the operation, b-SL display did not appear for 5 seconds.
(3) The present load being dumped is more than l/2 of the rated payload.
* If the b-FL display appears, carry out troubleshooting LC-8.)
HD325-6 20-615
0
e) Payload display, recorded payload are not correct

* The precision of the payload meter is +5%.
Ir The following are probable causes if the payload display value and recorded value vary more than 5%.
(I) Defective setting of payload meter model selection switch
(2) Defective adjusting of suspension
(3) Failure to perform calibration for payload meter
<Precautions*
i) If the chassis is swaying during the dumping operation and the payload display fluctuates, the
precision of the recorded value may be low. Carry out the dumping operation after the payload
display has stabilized.
ii) The payload display (immediately after loading) at the loading point may be slightly less (I to
5 tons) than the display value at the dumping point.
For details, see Operation and Maintenance, Manual 3. Using with precision.
Carry out testing and adjusting as follows.

(I) Checking payload meter model selection switch
When the power is turned ON, check the following table for the model code display during the self-
l
check display for the payload meter. If the applicable model has not been set, set the model
according to the Operation and Maintenance Manual.
--
PLM display: I_u:X.X
HD325 HD405 HD465 HD605 HD7:; ",,; HDgt;
x.x __-- -- -- --
i I _I I II_1 I II I I II-1 l-l I I--II_ I II-1
t;;up;ay l_l._I l_l.l_l 1-l. I l-l.1 I l-1. I l_l.l_l l_l._I
TWH00357
(2) Checking suspension gas pressure

i) Check the gas pressure of the suspension. For details, see STRUCTURE AND FUNCTION, Service
check mode (b) payload calculation data display. (Empty, on flat ground)
l Tolerance for difference between

left and right pressures: Front: Within 0.98 MPa {IO kg/cm?
Rear : Within 1.47 MPa (15 kg/cm?
lIf the difference is greater than the above range, adjust the suspension gas. For details, see
TESTING AND ADJUSTING, TESTING AND ADJUSTING SUSPENSION CYLINDER.
ii) When turning on a slope with the machine loaded, check that there is no contact between the
frame stopper and the rear axle housing.
(3) Carrying out calibration
To carry out calibration, follow the instructions in the Operation and Maintenance Manual.
20-616 HD325-6
0
LC-8 b-FL remains displayed and does not change : Body FLOAT relay
system: When not dumping and when dump lever is not at
FLOAT position
Cause Remedy
YES
1
Is voltage between
PM6 (9) and (3) as Short circuit with chassis
Repair or
shown in Table 1 2 YES ground in wiring harness
when dump lever between PM6 (9) and replace wiring
Is resistance be-
is operated? terminal NC of BF1 harness
tween terminal NC of
• Connect T-adapter body float switch BF1
to PM6. and chassis as
NO shown in Table 2
• Turn starting
switch ON. when dumping lever
• Operate dump is operated? Defective body float
Replace
lever. • Pull out terminal NO switch
NC wiring harness of body
float switch BF1 (0. 5brW).
• Leave starting switch OFF.
• Operate dump lever.
Table 1 Table 2
Dump lever position Voltage Dump lever position Resistance
Other than FLOAT Max. 1.5 V Other than FLOAT Max. 1 Ω

HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
HD325-6 20-617
8
TROUBLESHOOTING LC-8, LC-9, LC-10

LC-9 F-09 is displayed:

Drop in voltage of back-up battery built into payload meter
Cause Remedy
Replace (see
Drop in voltage of backup Operation and
battery Maintenance
Manual)
LC-10 .FULL display appears

• L.FULL: No. of cycles Data has exceeded memory capacity
• E.FULL: Times of engine ON/OFF Data has exceeded memory capacity
• F.FULL: Abnormality, warning Data has exceeded memory capacity
• H.FULL:Aggregate payload, total no. of cycles Data has exceeded memory capacity
<Remedy> After downloading the data to a PC, clear the data from memory and set to 0. For
details, see Operation and Maintenance Manual.
20-618 HD325-6
8
LC-11 F-20 is displayed : Sensor power source voltage system

Cause Remedy

ground in wiring harness Repair or
2 YES between PM6 (2) - each
replace wiring
Is resistance (2) of connectors 13, 39,
62, 63, or between PM6 harness
YES between PM6 (2)
(2) and PM3 (3)
and chassis less Check abnormality,
than 1 Ω? Defective suspension warning display to
1 locate problem
• Turn starting pressure sensor
NO sensor, then
Is voltage be- switch OFF. replace
tween PM6 (2) • Disconnect PM6.
and (3) 18 ± 3V? • Disconnect suspension
pressure sensor
• Connect T-adapter connectors 13, 39, 62,
only to payload and 63.
meter end of PM6.
• Turn starting Defective payload meter Replace parts
NO
switch ON.

HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
HD325-6 20-619
8

20-619-1 HD325-6
8
LC-12 F-21 – F-24 is displayed : Disconnection, short circuit with ground

in suspension pressure sensor system
Cause Remedy

ground in wiring harness be-
YES tween applicable terminal of Repair or
★ 2 payload meter connector replace wiring
(PM6) and applicable sensor harness
When applicable
sensor in Table 1 is
connector (3)
YES disconnected, is re-
YES Disconnection in wiring Repair or
sistance between that replace wiring
harness between applicable
connector (female) 3
(2) and chassis terminal of PM6 and harness
ground less than 1 Ω? In condition in applicable terminal of PM1
Item 2, is ★ re-
• Connect T- 4 YES
1 adapter. NO sistance more Go to A ——
than 1 M Ω? In condition in
Is voltage between • Leave starting
chassis and applic- Item 2, is ★
switch OFF.
able sensor con- resistance 105.1 ±
• Measure resistance NO
nector (female side) 0.3 Ω?
(2) in Table 1 18 ± 3 between connector Defective payload meter Replace
V? (2) and chassis. NO
• Connect T-adapter.
• Turn starting Disconnection in wiring
switch ON. 6 YES harness between PM6 (2) After inspec-
and applicable sensor tion, repair
Is voltage
connector (2)
between PM6 (2)
NO and (3) 18 ± 3V?
• Connect T-adapter. NO
• Turn starting
switch ON. Disconnection in wiring
5 YES harness between Repair or
Is resistance applicable terminal of replace wiring
between chassis PM6 and applicable harness
From A and applicable sensor connector (3)
sensor connector
(female side) (3) in
Table 1 more than
1 MΩ? Defective sensor Replace
• Connect T-adapter. NO
• Turn starting
switch OFF.
Table 1 Failure codes and applicable sensors and connectors
Location of Sensor Connector terminal No.

Failure code sensor connector No. PM6 PM1* J04
F-21 Front left FL 13 (4) (15) (2)
F-22 Front right FR 39 (5) (14) (3)
F-23 Rear left RL 62 (6) (13) (4)
F-24 Rear right RR 63 (7) (12) (5)
* HD325-6 Serial No.: 5680 – 6000

HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
20-620 HD325-6
8

HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000

HD325-6 20-621
8

Short circuit in suspension pressure sensor system power source
Cause Remedy

source (24V line) in Repair or
YES wiring harness between replace wiring
★ 1 applicable PM6 terminal harness
Is voltage between and sensor connector (3)
chassis ground and Short circuit in wiring
applicable PM6 con- harness between applicable Repair or
YES
nector terminal in PM6 terminal - sensor replace wiring
Table 1 more than 20 2 connector (3) and PM6 (2) - harness
V? each sensor connector (2)
In condition in
• Connect T-adapter Item ★, is voltage
to PM6. 3 YES
NO more than 15 V?
• Turn starting switch Does condition Defective sensor Replace
become normal
ON. when applicable
NO sensor (Table 1) in
failure code is
replaced? Defective payload meter Replace
NO
Table 1 Failure codes and applicable sensors and connectors

Failure code sensor connector No. PM6 PM1* J04
F-25 Front left FL 13 (4) (15) (2)
F-26 Front right FR 39 (5) (14) (3)
F-27 Rear left RL 62 (6) (13) (4)
F-28 Rear right RR 63 (7) (12) (5)
* HD325-6 Serial No.: 5680 – 6000

HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
20-622 HD325-6
8

HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000

HD325-6 20-623
8
TROUBLESHOOTING LC-14, 15
LC-14 F.CAL is displayed:

Calibration not carried out, damaged data inside payload meter
<Remedy> Follow the procedure given in the Operation and Maintenance Manual.

Short circuit in external display lamp system power source
Cause Remedy
YES Failure in relay (short

Replace parts
circuit inside coil)
2
In condition in Short circuit with power
YES Item 1, does source in wiring harness
failure display go 3 YES Repair or replace
between PM5 connector and
out? Is voltage between pin 2 of each connector in
1 (13) and applicable Table 1
Is resistance be- terminal of PM5 in
tween applicable Table 1 20 - 30 V?
relays (1) and (2) in NO
failure code in Table Defective payload meter Replace
• Disconnect P1. NO
1 100 - 500 Ω? • Turn starting
• Remove relay. switch ON.
• Turn starting Failure in relay (failure in
switch ON. Replace parts
NO diode)
Table 1 Failure code and applicable circuit
Relay connector PM5 connector PM1 connector

Failure code No. terminal No. terminal No.*
F-41 R20 (2) (2)
F-42 R19 (3) (3)
F-43 R18 (4) (4)
F-44 R17 (5) (8)
F-45 R16 (6) (9)
* HD325-6 Serial No.: 5680 – 6000

HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
20-624 HD325-6
8

HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
HD325-6 20-625
8

20-625-1 HD325-6
8
LC-16 L-bad is displayed : Cycle data saved when machine was swaying
fl When the load is dumped, the payload is measured precisely and the result recorded as the cycle
data.
However, if the machine is swaying when the load is dumped, the precision of the measurement will
be poor.
The L-bad display is used to inform the operator that the machine was swaying when the load was
dumped.
Therefore, wait for at least 5 seconds after the machine is stopped before carrying out the dumping
operation. (For details, see the Operation and Maintenance Manual.)
fl If the L-bad display appears during the dumping operation, the display will continue until the ma-
chine starts to travel empty.
fl If the L-bad display always appears, and the cycle data payload is abnormal, carry out troubleshoot-
ing according to the flowchart below.
Cause Remedy
Change ground
YES of equipment
Excessive variation in
being used and
voltage in ground circuit check if there is
1
defective contact
Does voltage between
payload meter PM5 Check and clean
(13) and chassis 3 YES Defective contact of connector of
ground vary when YES Is L-bad connector sensor signal
other equipment is circuit
operated? 2 displayed when
sensor is
• Turn starting Use Table 1 to
check voltage of replaced?
switch ON. Failure in sensor Replace parts
suspension NO
• Variation in pressure sensor.
voltage: NO Is variation in
Max. 0.5 V voltage excessive?
• Operate other • Stop machine. Failure in payload meter Replace parts
equipment • Connect T-adapter NO
PM6.
• Turn starting switch
ON.
• Variation in sensor
voltage: Within ±5%
of central value
Table 1 Place of suspension pressure sensors and connectors

sensor connector No. PM6 PM1* J04
Front left FL 13 (4) (15) (2)
Front right FR 39 (5) (14) (3)
Rear left RL 62 (6) (13) (4)
Rear right RR 63 (7) (12) (5)
* HD325-6 Serial No.: 5680 – 6000

HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
20-626 HD325-6
8

HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000

HD325-6 20-627
8
TROUBLESHOOTING LC-17, 18
LC-17 Machine is not loading but external display lamps give load esti-
mate display.
After loading, display switches to time display before traveling
160 m
<Remedy> Load to rated payload, then carry out calibration after dumping load.
LC-18 F-31 is displayed :

Disconnection, short circuit with ground in clinometer system
Cause Remedy
YES
Normal —
Contact with chassis Repair or

1 replace wiring
Is resistance be- between PM6 (8) and harness
Is machine travel- YES tween PM3 (fe- PM3 (2)
ing on or parked male) (2) and (3)
on uphill slope of 3 less than 1 Ω?
more than 10°? Defective clinometer Replace
YES Is voltage be- • Connect T-adapter NO
tween PM3 (3) to PM6, but do not
2 and (1) 18 ± 3 V? connect clinometer.
Is voltage be- • Turn starting switch Defective contact or
• Connect T-adapter OFF. Repair or
tween PM6 (8) disconnection in wiring
to P3. replace wiring
NO and (3) less than NO harness between PM6 (2)
• Turn starting harness
1.6 V? and PM3 (3)
switch ON.
• Connect T-adapter
to P3.
switch ON.
20-628 HD325-6
8

HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000

HD325-6 20-628-1
8
LC-19 F-32 is displayed:

Short circuit with clinometer system power source
Cause Remedy
YES
Normal —
1
Is machine travel- Short circuit with power Repair or
ing on or parked 3 YES source in wiring harness replace wiring
on downhill slope When PM3 is between RM6 (8) and harness
of more than 10°? YES removed and then PM3 (2)
power source is
2 reset, is same error
Is voltage be- message displayed?
tween PM6 (8) NO
NO and (3) less than
3.6 V?
to P3. NO
• Turn starting
switch ON.

HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
HD325-6 20-629
8

20-629-1 HD325-6
8
LC-20 F-18 is displayed : Disconnection in battery charge signal

Cause Remedy
See A-19 b. (Abnormality

YES
in battery charging —
1 circuit)
Is there abnormal
display on
2 YES
transmission Defective payload meter Replace
After engine is
controller also? started, is voltage
• E.d7 display between PM5 (9) and
chassis more than
• Turn starting NO 5V, or is there pulse Defective generation of
switch ON. wave of more than electricity by alternator or
5V - 0V? disconnection in wiring
NO harness between PM5 (9)
to PM5. and alternator terminal R
• Start engine.
20-630 HD325-6
1
TROUBLESHOOTING OF ARSC [AUTOMATIC RETARDER
SPEED CONTROLLER] SYSTEM (R MODE)
Outline ............................................................................................................................................. 20-702
Electrical circuit diagram for ARSC [Automatic Retarder Speed Controller] system ....................... 20-706
R-l 0.1 (Abnormality in power source voltage) is displayed ....................................................... 20-708
R-2 1.0 (Disconnection in engine speed sensor system) is displayed ......................................... 20-709
R-3 1.3 (Disconnection in transmission output shaft speed sensor system) is displayed ......... 20-710
R-4 1.5 (Failure in retarder oil temperature sensor system) is displayed ................................... 20-711
R-5 1.7 (Failure in accelerator signal system) is displayed .......................................................... 20-712
R-6 1.8 (Failure in suspension pressure sensor “left” system) is displayed.. ............................. 20-713
R-7 1.9 (Failure in suspension pressure sensor “right” system) is displayed ............................ 20-714
R-8 4.2 (Disconnection in exhaust brake selector signal system) is displayed.. ......................... 20-715
R-9 4.3 (Disconnection in ARSC caution lamp system) is displayed ........................................... 20-716
R-10 4.4 (Disconnection in READY lamp system) is displayed ...................................................... 20-717
R-II 4.5 (Disconnection in panel caution and buzzer system) is displayed.. ................................ 20-718
R-12 5.2 (Short circuit with ground in exhaust brake selector signal output system)
is displayed ......................................................................................................................... 20-719
R-13 5.3 (Short circuit with ground in ARSC caution lamp system) is displayed.. ....................... 20-720
R-14 5.4 (Short circuit with ground in READY output circuit system) is displayed ...................... 20-721
R-15 5.5 (Short circuit with ground in panel caution lamp and buzzer output system)
is displayed ......................................................................................................................... 20-722
R-16 6.0 (Failure in engine speed system) is displayed.. ................................................................ 20-723
R-17 7.0 (Disconnection in travel speed display UP output system) is displayed.. ...................... 20-724
R-18 7.1 (Disconnection in travel speed display DOWN output system) is displayed ................. 20-725
R-19 7.2 (Disconnection in travel speed display CLEAR output system) is displayed ................. 20-726
R-20 7.3 (Short circuit with ground in travel speed display UP output system) is displayed.. .... 20-727
R-21 7.4 (Short circuit with ground in travel speed display DOWN output system) is displayed ... 20-728
R-22 7.5 (Short circuit with ground in travel speed display CLEAR output system) is displayed ... 20-729
R-23 8.1 (Short circuit with ground in pressure control valve system) is displayed.. .................. 20-730
R-24 8.3 (Disconnection in pressure control valve system) is displayed ...................................... 20-731
R-25 8.5 (Failure in pressure control valve (pressure control valve remains open)) is displayed ... 20-732
R-26 8.7 (Failure in pressure control valve (pressure control valve does not open)) is displayed.. 20-733
R-27 8.9 (Short circuit with ground in pressure switch valve system) is displayed.. ................... 20-734
R-28 9.0 (Disconnection in pressure switch valve system) is displayed ....................................... 20-735
R-29 9.1 (Failure in pressure switch valve system (remains open)) is displayed ......................... 20-736
R-30 9.2 (Failure in pressure switch valve system (does not open)) is displayed ........................ 20-737
R-31 9.3 (Disconnection in system switch system) is displayed.. .................................................. 20-738
R-32 9.4 (Short circuit with ground in system switch system) is displayed ................................. 20-739
R-33 9.5 (Disconnection, short circuit with ground in travel speed setting switch system)
is displayed ......................................................................................................................... 20-740
R-101 Set speed cannot be set ........................................................................................................... 20-741
R-102 Failure code is always cleared (controller display window always shows “-“I
or failure code cannot be cleared .................................................................................... 20-744
R-103 Effect of retarder is too strong when machine is empty, or too weak when
machine is loaded (does not judge loaded/unloaded condition properly). .................. 20-745
R-104 Abnormality appears in other controller ................................................................................ 20-745
R-105 When traveling downhill, even when set speed is exceeded, no control is carried out.. ... 20-746
R-106 Monitor lamp (buzzer) stays ON (or OFF) ............................................................................... 20-747
R-107 READY lamp does not light UP (or stays lighted up). ............................................................ 20-748
R-108 Exhaust brake does not work properly ................................................................................... 20-750
[Exhaust brake is actuated when exhaust brake switch is OFF; or exhaust brake
is not actuated when exhaust brake switch is ON].. ....................................................... 20-750
R-109 There is difference between travel speed rod value and actual machine value.. ................ 20-752
R-l IO Retarder lamp does not light up, or stays lighted up ............................................................ 20-754
R-l 11 Travel speed display always gives display (or does not give any display) .......................... 20-755
HD325-6 20-701
0
TROUBLESHOOTING OUTLINE
OUTLINE
1. OUTLINE 1) Remedy pattern 1
This explains the procedure for inspection and If the central warning lamp and the ARSC
repair if any problem or failure occurs in the caution lamp flash and the buzzer sounds
ARSC. This means that a serious problem has oc-
The ARSC is equipped with a self-diagnostic curred in the ARSC system.
function, so for failures which the controller Operation of the ARSC system is stopped
can recognize, the central warning lamp, alarm and the retarder is released. Operate the
buzzer, and ARSC caution lamp inform the brake pedal or retarder lever as necessary
operator when a failure occurs. It also displays to ensure safety.
an error code on the controller display to When the system switch is turned OFF, the
inform the operator of the nature of the fail- central warning lamp and ARSC caution
ure. lamp go out and the buzzer stops.
The following explains the troubleshooting *If the service code is “9.3” or “9.4”, it
and inspection method for the location of the shows that there is a failure in the sys-
failure if an error code is displayed. tem switch, so even if the system switch
is turned OFF, the central warning lamp
2. PRECAUTIONS WHEN CARRYING and ARSC caution lamp will flash and the
OUT TROUBLESHOOTING buzzer will sound.
1) Before carrying out troubleshooting, always 2) Remedy pattern 2
carry out a re-enaction test. When only the ARSC caution lamp flashes
2) With failures in the electrical system, there The ARSC system continues to be actuated,
are cases where failures occur because of but an abnormality has occurred in the sys-
vibration of the machine (for example, when tem.
the engine is running at high speed or the Turn the system switch OFF to stop use of
truck is traveling at high speed on rough the ARSC.
road surfaces), particularly at the initial When the system switch is turned OFF, the
stage of the occurrence of the failure. ARSC caution lamp will go out.
Therefore, it is necessary to investigate the *In the case of patterns 1 and 2 above, turn
conditions under which the failure occurred. the system switch OFF quickly, stop use
(In particular, in cases where the problem of the ARSC.
cannot be re-enacted or the abnormality
cannot be found.) Note 1: The set travel speed display is also
3) If there is a failure in the electrical system, equipped with a self-diagnostic func-
check carefully that there is no improper tion, and a failure code is displayed on
connection of the connectors. the set travel speed display.
4) Always check that there is no effect from
any radio or other electrical equipment that No Failure
. code Details Method of resetting
was installed later. (Remove the equipment
and carry out a re-enaction test.) Turn the machine starting
1 El
Abnormality
If there is any effect from electrical equip- switch ON again or turn the
in CPU
system switch ON again.
ment, modify the method and location for
installing that equipment. Turn the machine starting
2 E2 bbnormality
5) Read the precautions fortroubleshooting in switch ON again or turn the
In memory
system switch ON again.
the shop manual carefully before starting
troubleshooting.
3. METHOD FOR PROCEEDING WITH

TROUBLESHOOTING
If a failure occurs in the ARSC, distinguish the
service codes for each failure based on the
table on the next page. Then carry out the
inspection for the respective service code to
locate the location of the failure, and carry out
repairs or replacement.
20-702 HD325-6
0
4. WHEN SYSTEM IS NORMAL 6. METHOD OF CLEARING SERVICE

A code is displayed on the controller LED un- CODE
der the assistant’s seat. Turn the machine starting switch to ON (the
engine is not started) and disconnect connec-
tors CR1 and CR2 under the assistant’s seat.
When accelerator pedal is being When this is done, ‘I- -n is displayed on the
controller LED.
When accelerator pedal is not being When the ‘I- -rr changes from flashing and
stays lighted up (3 seconds), the failure code
has been cleared.
* When using the ARSC for the first time, al-
+ If the above code is not displayed when ways clear the service codes. After clear-
the accelerator pedal is being depressed ing the codes, connect connectors CR1 and
or not being depressed, it is necessary to CR2.
adjust the accelerator link. If it is not prop-
erly adjusted, the ARSC system will not
be able to judge correctly if the accelera-
tor pedal is being depressed or not, so
the ARSC may not work normally.
5. METHOD OF MODEL SELECTION,

TIRE LARGE DIAMETER/SMALL
DIAMETER, REFERENCE FOR FAIL-
URE CODE
When the machine starting switch is turned
ON, the codes below are automatically dis-
played in the following order ((I I- (6)) on the
controller LED.
@ LEDs all light up.
@ Model
Code Model name

32 HD325-6, HD465-6
46 HD465-5, HD605-5
98 HD985-5
@Tire diameter
For the HD325-6 and HD405-6, ti--N is dis-

played.
For the HD985-5, II- -I‘ is displayed.
@ Initial service code
@ Service code that occurred immediately be-
fore the service code in @
@Service code that occurred immediately be-
fore the service code in @
HD325-6 20-703
0
7. SPEED CODE JUDGMENT TABLE
Categor)
Retarder does not work when machine is em
20-704 HD325-6
0
ELECTRICAL CIRCUIT DIAGRAM FOR ARSC
TROUBLESHOOTING (AUTOMATIC RETARDER SPEED CONTROLLER) SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR ARSC (AUTOMATIC RE-

TARDER SPEED CONTROLLER) SYSTEM
Tire large diameter/small diameter

C iod e
serection connector
Snal I diameter: CLOSED
Laree diamete OPEN
TI
IX
To transmission
controller
To wiring harness
I II I I
‘I I ,A, outside cab
JO.?-EL2 (Sl6) -r
To paylord meter
PM4-1
RHI-ELI
To main harness
inside cab
To main harness inside cab

To main harnAs inside cab
TWH00360
20-706 HD325-6
0
ELECTRICAL CIRCUIT DIAGRAM FOR ARSC
TROUBLESHOOTING (AUTOMATIC RETARDER SPEED CONTROLLER) SYSTEM
Pressure control Pressure switch

Connector when valve ,
changing lower Connector
limit speed for Suspension * ,
for 1st from clearing pressure
IOkm/h to i3km/h. error code sensor
. . . 8
or when changing (aiwav
to shift lever CLOSED car
type (always open1
I relay
SPF
it421
Warning
: Buzzer lamp
Resistor
(25OQl
SPD I s
ARSC ARSC Travel speed

To monit’or Panel
taut ion stanbv display
I amp I amo
(red) (green)
ARSC system switch ARSC s witch
TWH0036 I
HD325-6 20-707
0
TROUBLESHOOTING R-l
R-l 8.1 (Abnormality in power source voltage) is displayed
Troubleshooting is carried out while the abnormality is being generated, so when the connector is
disconnected and the T-adapter is inserted, or when the T-adapter is removed and the connector is
connected again to its original position, if the error code is not displayed on the monitor, the system
has been reset.
The ARSC controller is used to observe the power source voltage. If the power source voltage is less
than 19V and the engine speed is more than 500 rpm continuously for 0.2 seconds, the error is
detected.
Divide into battery - fuse and fuse - controller when checking. If the voltage at the inlet port of the
controller is normal, judge that the controller is defective.
Remedy
3 YES
Is voltage between
2 Defective contact or After inspec-

disconnection in wiring tion, repair or
YES Is fuse Ill-(26) harness between fuse Ill- replace wiring
-2O-30V NO
- normal (not (26) and controller harness
1 -Turn starting
blown)?
switch ON. Short circuit with chassis After inspec-
Are other con-
ground in wiring harness tion, repair or
trollers (electronic between fuse 111426)-
NO replace, replace
display panel, _ controller ARC1 (female) Fuse
transmission con- (8). (18)
troller) normal? 1 After carrying out
troubleshooting,
repair or replace
harness between battery (for other con-
NO and fuse, defective trollers, see
battery
I Troubleshooting
A-l, etc.)
R-l Related electrical circuit diagram
To main harness
ARSC controller
inside cab
Fuse box 111
Spare terminal
Power source
Power source
To transmission
controller
TWH00362
20-708 HD325-6
0
TROUBLESHOOTING R-Z
R-2 1.0 (Disconnection in engine speed sensor system) is displayed
has been reset.
The controller observes if there is any disconnection or other problem in the engine speed sensor.
The engine speed sensor is shared by the transmission controller and electronic display panel. On
the electronic governor specification machine, it is also shared by the engine controller.
Divide into sensor - junction TMD and TMDI - ARC3 (5) when checking. If there is no abnormality,
judge that the controller is defective.
Cause Remedy
F=
3 YES
- Defective controller Replace
When connector is
connected again,
2
Mating of ARC3 contactor
YES Is resistance bet- is defective (reset to Repair or replace
1 _ ween ARC3 (fe- _ NO normal)
male) (5) and
~ (12) normal?
Are other con- disconnection in wiring Repair or
trollers (transmis- -500-lOOOR harness between ARC3 replace wiring
sion controller) - -Turn starting NO (female) (5). (12) - TMDl harness
switch OFF.
normal?
J .
I
(13). (14)
Disconnect See A-7 in
Troubleshoot-
, connector. - ing of transmis-
NO sion controller
system
R-2 Related electrical circuit diagram

To main harness
inside cab
ARSC controller TMDl

I (S16)
ARC3(04016)
Engine speed @
PULSE GND @
TMD2
t.516)
To transmission
controller
TWH00363
HD325-6 20-709
0
TROUBLESHOOTING R-3
R-3 1.3 (Disconnection in transmission output shaft speed sensor sys-

tern) is displayed
has been reset.
The controller observes if there is any disconnection or other problem in the transmission output
shaft speed sensor.
The transmission output shaft speed sensor is shared by the transmission controller and electronic
display panel.
Divide into sensor - junction TMA and TMAI - ARC3 (4), (12) when checking. If there is no abnormal-
ity, judge that the controller is defective.
1
YES
Mating of ARC3 contactor 1

is defective (reset to Repair or replace
normal)
(female) (4) and
Are other con-

I.
Repair or
replace wiring
See A-7 in
Troubleshooting
connector.
of transmission
NO controller
system (A Mode)

To main harness
inside cab
ARSC controller _ TMAl

I 00 (S16)
ARC3(04016)
speed sensor input (t)

PULSE GND 0
_ TMA2
00 (S16)
I I
To transmission
controller
TWH00364
20-710 HD325-6
0
TROUBLESHOOTING R-4
R-4 1.5 (Failure in retarder oil temperature sensor system) is displayed
* Troubleshooting is carried out while the abnormality is being generated, so when the connector is
has been reset.
* Before carrying out troubleshooting, check that ail the related connectors are properly inserted.
t The controller observes if there is any disconnection or short circuit with the ground in the retarder
oil temperature sensor.
I Cause Remedy
~S~~~~~~~~~” Rep’ace
mission con-
troller) normal?

t t
JO2-
ARSC cant rot ler
I EL1
ARC2 (04020)
Retarder oil
temperature input (+)
ARC3 (04016)
PULSE GND
JO2-
t
To transmiss ion con troller
TWHO0365
HD325-6 20-711
0
TROUBLESHOOTING R-5
R-5 1.7 (Failure in accelerator signal system) is displayed
It Troubleshooting is carried out while the abnormality is being generated, so when the connector is
has been reset.
+ Always connect any disconnected connectors before going on to the next step.
* The controller observes if there is any disconnection or short circuit with the ground in the accelera-
tion sensor signal sensor.
Cause Remedy
YES
Disconnection, short
tween ARC2 (9)
and (19) normal? circuit with ground in
Are other con- wiring harness between
ARC2 (female) (19) - TMAl Repair or replace
trollers (trans- SO.6 - 4.75 v NO
mission con- (female) (13). ARC2
(female) (9) - TM61 SeeA- in
(female) (9) Troubleshooting
- of transmission
controller
system (A Mode’

ARSC controller
1
ARC2 (04020)
Acceleration signal
sensor inPut C-1
Signal GND
TMA2 TMB2
(S16) x El61 x
I 1
To transmission controller
TWHO0366
20-712 HD3256
0
TROUBLESHOOTING R-6
R-6 1.8 (Failure in suspension pressure sensor “left” system) is displayed
Ir Troubleshooting is carried out while the abnormality is being generated, so when the connector is
has been reset.
Ir The controller observes if there is any disconnection or short circuit with the ground in the suspen-
sion pressure sensor (left).
+ Selection connector: HD325, connect connectors SPR and SP2.
Cause Remedy
2 YES
Iefective controller
Xsconnection, short
:ircuit with ground in
viring harness between Repair or replace
~ iRC3 (female) (9) and JO4
:Ll (female) (2) or (4)
See SP-2 in
Troubleshooting
- of suspension
NO controller
system (P Mode)

JO4- @,
EL1 T
\RSC controller
I SP2 SPR
ARC3 (04Oi6) (M2) (M2)
I
Suspension Pressure
@ 3
sensor (right) input (+I
Suspension Pressure
a 3
sensor (left) input (+I
I
JO4- r
EL2
(S12)
To harness outside cab

TWH00367
HD325-6 20-713
0
TROUBLESHOOTING R-7
R-7 1.9 (Failure in suspension pressure sensor “right” system) is dis-

played
Ir Troubleshooting is carried out while the abnormality is being generated, so when the connector is
has been reset.
* Selection connector: HD325, connect connectors SPR and SP2.
Cause Remedy
chassis ground (ER)

‘{-_I Defective controller
Disconnection, short
Replace
normal? circuit with ground in

ve otner con- II wiring harness between Repair or replace
rollers (suspension -l-5v NO ARC3 (female) (1) and JO4-
.^_._^I,^_ “1 &”
C”llll”llOl, rLl”l I-’
Turn starting EL1 (female) (3) or (5)
controller) normal? .. . m..
swmzn UI\I. See SP-2 in
Troubleshooting
- of suspension
NO controller
system (P Mode)

ARSC controller
I I SP2 SPR
ARC3 (04016) (M2) (M2)
SusPens ion Pressure
c 3
sensor (right) input (+I
Suspension Pressure
@ 3
sensor (left) input (+I
JO4-
EL2
(s12)
To harness outside cab

TWH00367
20-714 HD325-6
0
TROUBLESHOOTING R-8
R-8 4.2 (Disconnection in exhaust brake selector signal system) is dis-

played
has been reset.
The controller observes if there is any disconnection in the exhaust brake selector signal system
*
YES
Defective FIB relay Replace
1
I I
Does condition
become normal 3 YES
when RB relay is Is resistancebe-
replaced? YES
tween ARC3 (female)
2 - (16)and chassis - Defective contact or dis-
Is resistance be- ground (ER) normal? connection in wiring harness
tween ARC3 between RB (female) (2) and Repair Or rep’ace
- Max. 350 R NO
NC (female) (16) and RB- chassis ground (ERI
Ifemale) (1) normal? * Turn starting switch OFF.
* Disconnect connector. Defective contact or
* Max. 350 R disconnection in wiring
harness between ARC3 Repair or replace
- Turn starting NO
switch OFF. (female) (16) and RB (1)
- Disconnect
connector.
I I I
RB relay
I
ARSC controller
TWH00368
HD325-6 20-715
0
TROUBLESHOOTING R-9
R-9 4.3 (Disconnection in ARSC caution lamp system) is displayed
has been reset.
The controller observes if there is any disconnection in the output circuit of ARSC caution lamp.
Check for defective contact or disconnection in wirinn harness between the controller and lamp, in
the lamp itself, and lamp - cab ground.
Cause Remedy
YES
1 I Defective lamp Replace
IS there any abnormal-
1 Defective contact or
ity. such as a blown
ARSC caution lamp -
2
bulb? (Does condition
YES harness between ARC1
Is there defective con- Repair or replacc
become normal when (female) (10) and RED,
tact or disconnection
lamp is replaced?) and between RED and
in wiring harness be-
NO tween ARC1 (female)
chassis ground (ER)
(10) and chassis i i
ground IER)? Loi Defective controller Replace
ARSC controller
I
ARC1 (MIC21)
RED
ARSC taut ion
lamp (red)
TWH00369
20-716 HD325-6
0
TROUBLESHOOTING R-10
R-10 4.4 (Disconnection in READY lamp system) is displayed
has been reset.
* The controller observes if there is any disconnection in the READY lamp output circuit system.
Cause Remedy
YES
Defective RZ relay leplace
3 YES
become normal Defective controller leplace
when RZ relay is
Y&z%KJ I
I
ground (ERI normal? connection in wiring harness
lepair or replace
between RZ (female) (2) and
* Max. 400 R NO chassis ground
(female) (1) normal? * Turn starting switch OFF.
- Disconnect connector.
* Max. 400 R harness between ARC3 iepair or replace
-Turn starting NIO (female) (7) and RZ
switch OFF. (female) (1)
- Disconnect
connector.
RZ relay
ARSC controller
I
RZ
ARC3(04016)
Standby lamp a
TWH00370
HD325-6 20-717
0
TROUBLESHOOTING R-l 1
R-l 1 4.5 (Disconnection in panel caution and buzzer system) is displayed
t Troubleshooting is carried out while the abnormality is being generated, so when the connector is
has been reset.
* The controller observes if there is any disconnection in the panel caution and buzzer output circuit
system.
Cause Remedy
‘11 Defective RW relay Replace
Does condition
become normal 3 YES
when RW relay is
YEIS Is resistancebe-
replaced? 1 tween ARC3 (female) -
2 (8) and chassis
I
ground (ER) normal?
NO
L Is resistance be-
tween ARC3
(female) 18) and RW
- Max. 400 R NO
- Turn starting switch OFF.
connection in wiring harness
between RW (female) (6) ant Repair or replace
chassis ground (ER)
(female) (51 normal?I Defective contact or
* Disconnect connector.
- Max. 400 R harness between ARC3 Repair or replace
- Turn starting NIO (female) (8) and RW
switch OFF. (female) (5)
- Disconnect
connector.
R-l 1 Related electrical circuit diagram
Rw relay
ARSC controller
I
ARC3 (04016)
buzzer system output
TWH00371
20-718 HD325-6
0
R-12 5.2 (Short circuit with ground in exhaust brake selector signal out-
put system) is displayed
has been reset.
J, Always connect any disconnected connectors before going on to the next step.
Sr The controller observes if there is any short circuit with the ground in the RB relay output.
Cause Remedy
YES
Defective RB relay Replace
1
Does condition
become normal
when RB relay is 2 YES
replaced? Is resistance be-
tween ARC3
NO (female1 (16) and RB - Short circuit with chassis
(female1 (21 normal?
Repair or replac
-200-400R NO between ARC3 (female)
* Turn starting (16) and RB (female) (1)
switch OFF.
* Disconnect
connector.
RB relay
O/6
ARSC controller - RB
I
ARC3 (04016) (i)(?)@(Q(&
selector signal output
TWH00368
HD325-6 20-719
0
R-13 5.3 (Short circuit with ground in ARSC caution lamp system) is dis-
played
has been reset.
The controller observes if there is any short circuit with the ground in the ARSC caution lamp system
output circuit.
I Cause Remedy
YES
1 Defective lamp Replace
y,
1isthere any abnormal-l
such as a blown
rRSC caution lamp
Repair or replace
ARC1 (female1 (101

ARSC controller
I 1
ARC1 (MIC21)
RED
iV$iu;aution lamp
ARSC taut ion
I amp (red)
I
n4r RED TWH00369
20-720 HD325-6
0
R-14 5.4 (Short circuit with ground in READY output circuit system) is
displayed
has been reset.
The controller observes if there is any short circuit with the ground in the READY lamp output circuit
system.
Cause Remedy
YES
1 1 Defective RZ relay teplace
become normal
when RZ relay is 2 YES
Is resistance
between ARC3 (7)
and RZ (2) Short circuit with chassis
NO
‘I
I.
normal? ground in wiring harness
lepair or replace
*200-400R NO between ARC3 (female)
* Turn starting (7) and RZ (female) (1)
switch OFF.
* Disconnect
connector.
RZ relay
I I
ARSC controller
Standby lamp
TWH00370
HD3256 20-72 1
0
R-15 5.5 (Short circuit with ground in panel caution lamp and buzzer
output system) is displayed _
has been reset.
The controller observes if there is any short circuit with the ground in the panel caution lamp and
buzzer system.
Cause Remedy
YES
1 Defective RW relay Replace
Does condition
become normal
when RW relay is 2 YES
replaced?
Is resistance
between ARC3
NO (female1 (8) and RW Short circuit with chassis
(female) (51 normal? ground in wiring harness
Repair or replac
NO between ARC3 (female)
*200-400R
(8) and RW (female) (5)
. Turn starting
switch OFF.
* Disconnect
connector.
Rw relay
I I
ARSC controller
I
ARC3 (04016)
Panel caution &
@
buzzer system output
TWH00371
20-722 HD325-6
0
TROUBLESHOOTING
R-16 6.0 (Failure in engine speed system) is displayed
has been reset.
Always connect any disconnected connectors before going on
to the next step. Cause Remedy
The mutual relationship between the engine speed sensor and
the transmission output shaft speed sensor is observed by the
controller. 3 YES Replace
Judge from the condition of the machine Defective controller
1Iscondition between r controller
when the abnormality occurred to locate YE
the failed sensor or wirino 7
harness.
-Is there any effect
from radio waves (remove
NO
Abnormality
harness
in wiring
Repair or replac
any electricequipmentthat
was installedafter the
machinewas deliveredand
carry out re-enactmenttest) Defective engine speed
sensor
IO
5 YES
machineis traveling Replace
Is conditionbetween r controller
Abnormality in wiring
harness Repair or replac
_ When machine
is traveling
I carry out re-enactmenttest) Defective transmission

Replace
NO output shaft speed sensor
R-16 Related electrical circuit diagram To main harries: inside cab

-
ARSC controller
I
ARC3 (04016)
Transmission ou
speed sensor input (+I
Engine speed
PULSE GND
TWH00372
HD325-6 20-723
0
R-17 7.0 (Disconnection in travel speed display UP output system) is dis-

played
has been reset.
The controller observes if there is any disconnection in the UP output to the travel speed display.
Cause Remedy

When travel speed
YES display is replaced,
1 r does problem_
appear agarn?
Defective travel speed
Replace
between ARC1 display
(female) (21) and
* Turn starting Repair or replace
harness between ARC1
switch OFF. NO (female) (21) and SPDIS-
* Disconnect
R3
connector.
ARSC controller
I SPDIS
ARC1 (MIC21)
OR2
Travel sDeed
display UP output
R3 Travel
OR4 speed
8;; display
TWH00373
20-724 HD3256
0
R-18 7.1 (Disconnection in travel speed display DOWN output system) is

displayed
Sr Troubleshooting is carried out while the abnormality is being generated, so when the connector is
has been reset.
-k Always connect any disconnected connectors before going on to the next step.
Ir The controller observes if there is any disconnection in the DOWN output to the travel speed display.
Cause Remedy
2 YES
1 1
NO
Defective travel speed
display
Replace
- Turn starting I harness between ARC1 Repair or replac
* Disconnect FM
connector.
ARSC controller
I SPDIS
ARC1 (MIC21)
OR?.
display DOWNoutput
R3 Travel
OR4 speed
8;; display
TWH00374
HD325-6 20-725
0
R-19 7.2 (Disconnection in travel speed display CLEAR output system) is

displayed
has been reset.
The controller observes if there is any disconnection in the CLEAR output to the travel speed display.
Cause Remedy
2 YES
When travel speed
YES displav is replaced, _
1 does problem
p appear again? Defective travel speed
Is there continuity Replace
between ARC1 NO display
(female) (II) and
SPDIS- R2? Defective contact or
- Turn starting
harness between ARC1 Repair or replac
* Disconnect
R2
connector.
ARSC controller
I SPDIS
ARC1 (MIC21)
speed
OR.2
Travel
CLEAR
(TJ R3 Travel
display output
OR4 soeed
8;; display
TWH00375
20-726 HD325-6
0
R-20 7.3 (Short circuit with ground in travel speed display UP output
system) is displayed
has been reset.
The controller observes if there is any short circuit with the ground in the UP output to the travel
speed display.
Remedy
Repair or replao
(21) and SPDISR3

Is there continuity
between ARC1
chassis ground Ml?
When travel speed
- Turn starting display is replaced,
switch OFF. NO does problem
appear again?
- Disconnect Defective travel speed
Replace
connector. NO display
ARSC controller
I SPDIS
ARC1 (MIC21)
OR2
disPlav UP outPut
R3 Travel
OR4 speed
8;; display
TWH00373
HD325-6 20-727
0
R-21 7.4 (Short circuit with ground in travel speed display

_ - DOWN output
system) is displayed -
has been reset.
The controller observes if there is any short circuit with the ground in the DOWN output to the travel
speed display.
Cause Remedy

YES ground in wiring harness
Repair or replace
1 I between ARC1 (female)
(20) and SPDIS-R4
Is there continuity
between ARC1
(female1 (20) and 2 YES
chassis ground (ER)? Defective controller Replace
_ When travel speed
- Turn starting display is replaced,
switch OFF. NO does problem
appear again?
* Disconnect Defective travel speed Replace
ARSC controller
I SPDIS
ARC1 (MIC21)
Travel speed
0R2
display DOWN output
@j R3 Travel
OR4 speed
8;; display
TWH00374
20-728 HD325-6
0
R-22 7.5 (Short circuit with ground in travel speed display CLEAR output
system) is displayed
has been reset.
The controller observes if there is any short circuit with the ground in the CLEAR output to the travel
speed display.
Cause Remedy

YES ground in wiring harness
Repair or replace
1 between ARC1 (female)
(11) and SPDIS-R2
Is there continuity
between ARC1
chassisground (ER)? Defective controller Replace
_ When travel speed
-Turn starting display is replaced,
NC does problem
switch OFF.
appear again? Defective travel speed
- Disconnect
Replace
ARSC controller
I SPDIS
ARC1 (MIC21)
OR2
Travel speed
display CLEAR
OR3 Travel
output
OR4 speed
8;; display
TWH00375
HD325-6 20-729
0
R-23 8.1 (Short circuit with ground

_ in pressure control valve system) is
displayed
has been reset.
The controller observes if there is any short circuit with the ground in the command system circuit to
the pressure control valve.
Divide into controller - relay connector, relay connector - valve, and pressure control valve proper
when checking.
2
2 YES
neparr or repldl;
between BRJ (male) (7),
(8) - BSOR (female) (1). (2)
I” -nc. I ,,e111a15,
I
vhe” ARC1 and Short circuit with chassis
we disconnected? n ground in wiring harness
Repair or repk
between ARC1 (female) (7).
1 (16) - BRJ (female) (7). (8)
-II
switch OFF.
ntinuity
* Disconnect Short circuit with chassis
RCI (fe-
male) (7) ano HnL
* . _^.I Pn”“LP+“r 4 YES ground in wiring harness
Repair or replac
1Isthere continuitv be- 1 7 between ARC1 (female) (71,
(16) BRJ (female) (7). (8)
* Turn
switch
starting
OFF.
Is there continuity
,,etwez..
ARC,(fe_
3
II -r --- ----:--
(ER) when ARC1 and
ERJ are disconnected? II
1
h1f-S
between BRJ (male) (7). (8
Repair or repi?
* Disconnect and chassis -

male1 (7) G+““11ti,.
- BSOR (female) (I), (2)
connector. NO ground ERI when * Discon nect connector.
ARC1 and BSOR are
5 YES
disconnected?
I I Defective controller Replace
Is resistance of pres-
* Turn starting
surecontrolvalve
switch OFF.
~0 normal when check-
* Disconnect
ed as individualpart? ‘,, Ds;;;tive pressure control
connector. :place
- Approx. 20 R
. Turn starting
switch OFF.
* Disconnect
connector.
Pressure
ARSC controller control valve
I I BRJ “l
L -.
ARC1 (MIC!?l) (I481 BSOR
I
3
8
I ~-
3 I
I
TWH00376
20-730 HD325-6
R-24 8.3 (Disconnection in pressure control valve system) is displayed
has been reset.
The controller observes if there is any disconnection in the pressure control valve.
Divide into ARC1 - relay connector: BRJ, relay connector: BRJ - BSOR, and pressure control valve
proper when checking.
Cause Remedy
2 YES
Iefective controller Replace
Is resistance of pres-
r
(ES sure control valve
r normal when check-
ed as individual part?
Defective pressure contrc
Is there continuity be-
Replace
valve
tween ARC1 (femaleI
* Approx. 20 R NO
(71, (161.BSOR (fe- *Turn starting switch OFF.
male1 /l), 121 when - Disconnect connector. Defective contact or dis-
ARC1and BSORare connection in wiring
3 YES
disconnected? harness between BRJ Repair or replace
Is there continuity 1 (male) (7). (8) - BSOR
- Turn starting between ARC1 tfe-
switch OFF. male) (71, (81- BRJ (female) cl), (2)
* Disconnect NO (female) (7). (8) when -
connector. ARC1 and BRJare
disconnected? connection in wiring
harness between ARC1 Repair or replacf
* Turn starting NO (female) (7). (16) - BRJ
switch OFF.
(female) f7L (8)
- Disconnect
connector.
Pressure
ARSC controller control valve
I BRJ
2 __--_--,
ARC1 (MIC21) (~8) BSOR I
valve output (-)

V
3 I
TWHD0376
HD325-6 20-73 1
0
R-25 8.5 (Failure in pressure control valve (pressure control valve remains
open) is displayed
fl Troubleshooting is carried out while the abnormality is being generated, so when the connector is
has been reset.
fl The controller observes failures in the pressure control valve from the mutual relationship between
the pressure switch and the command value to the pressure control valve.
fl “Pressure control valve remains open” means that the solenoid is energized and the pressure con-
trol valve is open (supplying air).
Cause Remedy
YES
Defective pressure switch Replace
2
When pressure 4 YES
YES switch is replaced, Defective controller Replace
YES When pressure
does problem ap-
pear again? 3 control valve is re-
Is air flowing in placed, does prob-
1 lem appear again?
opposite direction Defective pressure control
Is there continuity Replace
from double check NO valve
between BRR (fe-
male) (1) and chas- NO valve of auto
retarder air system
sis ground (ER)
circuit?
when connector BRR Defective double check
is disconnected?
Replace
• When manual NO valve
• Turn starting retarder or service brake
switch OFF. are operated.
• Disconnect Defective wiring harness
connector. Replace
NO (short circuit with ground)
Note) The connector type of pressure switch (BRR) is changed to DT-T for HD325-6 Serial No. 6001 and
up, HD325-6W Serial No. 6001 and up, and HD405-6 Serial No. 2001 and up.
20-732 HD325-6
8
R-26 8.7 (Failure in pressure control valve (pressure control valve does
not open) is displayed
has been reset.
fl The controller observes if there is any failure in the pressure control valve from the mutual relation-
ship between the pressure switch and the command value to the pressure control valve.
Cause Remedy
YES Defective pressure switch

2 Replace
When pressure
YES switch is re-
1 placed, does 3 YES
problem appear Defective controller Replace
Is there continuity When pressure
again?
between BRR control valve is
(male) (1) and replaced, does
ARC2 (female) (5) NO problem appear
when connector again? Defective pressure
BRR is disconnect- Replace
NO control valve
ed? when connec-
tor BRR is discon-
nected? Repair or
• Turn starting disconnection in wiring replace wiring
NO harness harness
switch OFF.
• Disconnect
connector.
HD325-6 20-733
8
R-27 8.9 (Short circuit with ground in pressure switch valve system) is
displayed
has been reset.
fl The controller observes if there is any short circuit with the ground in the pressure switch valve
output circuit.
fl Divide into ARC3 - relay connector BRJ, relay connector BRJ - SHUT, and pressure switch valve
Cause Remedy
2 Short circuit with chassis

YES ground in wiring harness Repair or
Is there continuity
between ARC3 between ARC3 (female) replace
YES (female) (15) and (15) and BRJ (female) (5)
1 chassis ground
(ER) when BRJ is Short circuit with chassis
Is there continuity removed? ground in wiring harness Repair or
between ARC3 NO between BRJ (male) (5)
(female) (15) and •Turn starting replace
switch OFF. and SHUT (female) (1)
chassis ground
•Disconnect
(ER) when ARC3 connector.
and SHUT are dis- 3 YES
connected? Is resistance of Defective controller Replace
pressure switch
• Turn starting
valve normal
switch OFF.
when checked as
• Disconnect NO individual part?
connector. Defective pressure switch
Replace
•Approx. 35Ω NO valve
Note) The connector type of pressure switch (SOSW) is changed to DT-T for HD325-6 Serial No. 6001 and
20-734 HD325-6
8
R-28 9.0 (Disconnection in pressure switch valve system) is displayed

has been reset.
fl The controller observes if there is any short circuit with the ground in the pressure switch valve
output circuit.
fl Divide into ARC3 - relay connector BRJ, relay connector BRJ - SHUT, and pressure switch valve
Cause Remedy
2 YES
Is resistance of Defective controller Replace
YES pressure switch
valve normal
when checked as
1 individual part? Defective pressure switch
Replace
Is there continu- • Approx. 35Ω NO valve
ity between • Turn starting
ARC3 (female) switch OFF. Defective contact or
(15) and SHUT • Disconnect 4 YES disconnection in wiring
(female) (1) connector.
when ARC3 and Is there continu- harness between BRJ (male) Repair or
SHUT are dis- 3 YES ity between BRJ (5), (2) - SHUT (female) (1), (2) replace
connected? Is there continu- (female) (2) and
ity between chassis ground? Defective contact or
• Turn starting Repair or
ARC3 (female) disconnection in wiring
switch OFF. • Turn starting replace
(15) and BRJ (fe- NO harness between BRJ
• Disconnect switch OFF.
NO male) (5) when (female) (2) and chassis
connector. • Disconnect
BRJ is discon- connector. ground
nected? Defective contact or Repair or
• Turn starting NO disconnection in wiring replace
switch OFF. harness between ARC3
• Disconnect (female) (15) and BRJ
connector. (female) (5)
HD325-6 20-735
8
R-29 9.1 (Failure in pressure switch valve system (remains open)) is dis-
played
has been reset.
fl The controller observes if there is any failure in the pressure switch valve from the mutual relation-
ship between the pressure switch and the command value to the pressure switch valve.
Cause Remedy
YES disconnection in wiring Repair or
harness between ARC2 replace
1
(female) (2) and SOSW
Is there continu- (female) (1)
ity between
SOSW (1) and YES
chassis ground 2 Defective pressure switch Replace
(ER) when SOSW
is disconnected? When pressure
switch is re-
• Turn starting placed, does YES Defective pressure
switch OFF. NO problem appear 3 Replace
control valve
• Disconnect again?
connector. Does air flow in
opposite direc-
tion from pres- 4 YES
NO sure control Defective controller
When pressure Replace
valve?
switch valve is
replaced, does
NO problem appear
again? Defective pressure switch Replace
NO valve
20-736 HD325-6
8
R-30 9.2 (Failure in pressure switch valve system (does not open)) is dis-
played
has been reset.
fl The controller observes if there is any failure in the pressure switch valve from the mutual relation-
ship between the pressure switch and the command value to the pressure switch valve.
Cause Remedy
YES
3 Defective pressure switch Replace
When pressure
YES switch is re-
placed, does
problem appear
4 YES
When pressure Defective controller Replace
2 again?
switch valve is
Is there replaced, does
YES continuity NO problem appear
between SOSW again?
1 (female) (2) and Defective pressure switch Replace
chassis ground? NO valve
Is there continuity
between SOSW • Turn starting Defective contact or
(female) (1) and switch OFF. disconnection in wiring
ARC2 (female) (2) • Disconnect Repair or
when SOSW and connector. harness between SOSW
NO replace
ARC2 are discon- (female) (2) and chassis
nected? ground (ER)
• Turn starting
Defective contact or Repair or
switch OFF.
• Disconnect NO disconnection in wiring replace
connector. harness between ARC2
(female) (2) and SOSW
(female) (1)
HD325-6 20-737
8
R-31 9.3 (Disconnection in system switch system) is displayed
has been reset.
The controller observes if there is any disconnection in the system switch from the mutual relation-
ship between the system ON input and the system OFF input.
When system Defective controller Replace

YES switch is re-
3 _ placed, does
problem appear
~ again?
Is there continu- Defective system switch Replace
YES ity between SW _ NO
2 r (female) (4) and
ity between * Turn starting Defective contact or

ARC2 (female) - switch OFF. disconnection in wiring
(1) and SW (fe- - Disconnect NO Repair or
harness between ARC2
male) cl)? connector. replace
(17) and SW (female) (2)
-Turn starting
switch OFF. Defective contact or
* Disconnect NO
harness between ARC2 replace
connector.
(1) and SW (female) (1)

ARSC system switch
To main harness
inside cab
t
To transmission
controller
TWH00379
20-738 HD325-6
0
R-32 9.4 (Short circuit with ground in system switch system) is displayed
has been reset.
* The controller observes if there is any short circuit with the ground in the system switch from the
mutual relationship between the system ON input and the system OFF input.
Cause Remedy
YES disconnection in wiring Repair or
harness between SW replace
(female) (2) and TMCI (I)
ity between SW
(female) (2) and Defective contact or
YES
TMCl (I) when disconnection in wiring Repair or
SW is discon- Is there continu- harness between SW replace
ity between SW (female) (1) and TMCI (1)
(female) (I) and
* Turn starting TMCI (1) when
switch OFF. N YES
SW is discon- When system Defective controller Replace
. Disconnect
switch is re-
connector.
* Turn starting placed, does
switch OFF. problem appear
* Disconnect again?
Defective system switch Replace
connector. NO

ARSC system switch
To main haI ness

inside cab
ARSC controller
Eg7ggW
1 I
To transmission
controller
TWH00379
HD325-6 20-739
0
R-33 9.5 (Disconnection, short circuit with ground in travel speed set-
ting switch system) is displayed
has been reset.
Cause Remedy
to the next step.
The controller observes if there is any disconnection or short
circuit with the ground from the travel speed set switch input. Short circuit with chassis
S ground in wiring harness qepair or
between SPSW - ARC3 (21- .eplace
resistor CN-250 (250R) (2)
1 4 YES
Is there continui- GotoA
ty between Is resistance bet-
SPSW (female) ween SPSW tfe-
(I) and chassis 3 YES
- male) (1) and IIefective contact or
ground (ER) _ ARC2 (female)
,disconnection
Is
in wiring
when SPSW is Is voltage bet- (10) normal? Tepair or
disconnected? Inarness between SPSW
7 YE ween ARC2 .eplace resistor
*250f25RR NO ’ t:female) (1) and ARC2
(male) (IO) and -
* Turn starting
chassis ground
* Turn starting switch (:female) (10). or defective
1
switch OFF. 2 OFF.
normal?
- Disconnect connector. Iresistor (250 R)
- Disconnect there continui- Replace
connector. ty between ARC3 * Approx. 5 V IDefective controller
-Turn starting NO :ontroller
(female) (2) and
switch ON.
NO SPSW (female)
. Disconnect Defective contact or
(l)?
connector. disconnection in wiring ?epair or
. Turn starting L harness between ARC3
.eplace
switch OFF. NO (female) (2) and SPSW
* Disconnect (female) (1)
connector.
7
YE! ;
When travel Defective controller Replace
speed setting
S YES_ switch is re-
placed, does
Is resistance bet- problem appear
ween SPSW (fe- -[ Defective travel speed
again?
YES mate) (2) and . NC ) setting switch
5 SPSW (female)
p
Is resistance bet- p
(3) normal? IDefective contact or
ween resistor ~1020f102n ,disconnection in wiring Repair or
From A - CN-1020 (fe- - . Turn starting
NO
Iharness between SPSW replace
male) (I) and (2) switch OFF. /[female) (2), (3) - CN-1020
normal? . Disconnect (male) (2L (1)
connector.
~1020t102R
* Turn starting 1 IDefective resistor (1020 R) Replace
switch OFF. NO
- Disconnect
connector.
R-33 Related electrical circuit diagram Resistor Resistor

(25OQ) (I 02021)
Signal GND @
SPSW (M3)
+5v output @ 3 - EP
-3 - CMS
ARC3 (04016) -3 - ccs

ARSC set input a ARSC set switch
TWH00380
20-740 HD325-6
0
R-101 Set speed cannot be set
a) Nothing is displayed in controller display window
* If nothing is displayed in the ARSC controller display window when the starting switch is ON, check
the controller power source voltage.
1) Check according to R-l 0.1 (Abnormality in power source voltage) is displayed.
2) Check for continuity between ARC1 (9), (19) - TMCI (1). (If there is no continuity, there is defective
contact or a disconnection in the wiring harness.)
b) There is no response. “8.8” is displayed on the controller.
Ir Check according to R-l 0.1 (Abnormality in power source voltage) is displayed.
HD325-6 20-74 1
0
c) Tap up/down, cancel cannot be operated
* This is a failure in setting switch system circuit or a failure in shift lever system circuit.
Cause Remedy
YES -
- ;ee Item f9.51
4 YES
;o to A
YEdI!%z%&l[
Is error code I 1 Defect inside ARSC set

qeplace
Lg.51 displayed? 3 * Setting switch ON: lk #witch
Is there continui- 1020 f 1020
* At tap up: 68 i 6.8 R
YE SPSW (female) * At tap down:
(2) and ARC2 (fe- 198 k 19.8 R
* At cancel: 418 k 41.8 R
* Turn starting switch
* Turn starting OFF.
NO
L resistor connected
switch OFF.
- Disconnect
connector.
- Disconnect connector.
Iefective contact or
lisconnection in wiring
rarness between SPSW
Repair or
replace
to CN-250 and NO
female) (3) and ARC2 (9)
1020 is removed?
* CN-250: 250 t 25 R I
* CN-1020: Iefective resistor Zonnect
1020 ? 102 R NO onnection ‘esistor again
*Turn startina switch
OFF. _
* Disconnect
connector. lefective controller qeplace
YES Is there continuity
c
between TM61 (4)
Is there and ARC2 (8). bet-
continuity ween TMBl (5) and
between TMBI ARC2 171,between
(4) and TMB2 (4), TM61 (6) ARC2
between TMBl (61, between TM81
; (5) and TMB2 (5),
YE - between TMBl (7) and ARC2 Ki),
and between TMBl
(6) - TMB2 (6). (81 and ARC2 (18)? defective wiring harness ‘lepair or
I
between TMBl ,eplace
(7) and TMB2 (7), Turn starting
When TMBl and switch OFF.
TMB2 are re- Disconnect
moved, and TMB connector.
connected, are
I qepair or
From A - Turn starting defective wiring harness
and transmission NO replace
switch OFF.
controller actuat- - Disconnect
See A-10 in
connector.
Troubleshooting
of transmission
NO :ontroller
system (A
Mode)
20-742 HD3256
0
To main harness
inside cab
A
i/ \ 1
TMBI - 1
ARSC controller
I (SlS) 2
ARC2 (04020)
Shift lever 3 @
Shift lever 4 @,
Shift lever 5 a
Shift lever D @, 0
Signal GND @
+5v ou tput @ ,I-
Shift lever L 1 q
ARC3(04016) 1 _III
250
TMB2 r
(S16
To transmission
ARSC set switch controller
TWH0038 1
HD325-6 20-743
0
TROUBLESHOOTING
R-102 Failure code is always cleared (controller display window always

shows JJ--“ ) or failure code cannot be cleared
* Disconnect connectors CR1 and CR2, and after approx. 3 seconds, the operation to clear the failure
code is completed.
a) When failure code cannot be cleared

1 YES ground in wiring harness Repair or
between ARC2 (20) and replace
Is there continu-
ity between CR1 CR1 (I)
(1) and chassis -
ground ER)?
* Turn starting
NO
switch OFF.
* Disconnect
connector.
b) When failure code is continuously cleared

Cause I Remedy
2 YES
Defective connector Repair or
Is there defec-
H
replace
YES tive contact of
1 connectors CR1
H
and CR2?
Is there continui-
ty between ARC2 Defective connector
NO
(20) and CR1 (1)
or between CR2 Defective contact or
(1) and ARC2 (9)? jisconnection in wiring
Repair or
narness between ARC2 replace
- NO :20) - CR1 (I) or between
bTurn starting
switch OFF. CR2 (1) - ARC2 (9)
^.
* ulsconnect
connector.
Error code connector for CLEAR

ARSC controller
(a I ways CLOSED)
I
ARC2(04020) CR2 (Ml) CR1 (Ml)
Signal (GND) @
Memory cancel @
TWH00382
20-744 HD325-6
0
TROUBLESHOOTING R-103, RI04
R-103 Effect of retarder is too strong when machine is empty, or too weak
when machine is loaded (do& not judge loaded/&ioaded condi-
tion properly)
Check the suspension pressure sensor systems (left and right) according to error codes 1.8 and 1.9.
Check also that there is no abnormality in the suspension itself or in the installation of the pressure
sensors.
Check that the connections of connectors SPF, SPR, and SP2 are correctly matched for each model.
HD325, HD405: SPR and SP2 are connected
HD465, HD605: SPF and SP2 are connected
HD785, HD985: SPF and SP2 are connected
R-104 Abnormality appears in other controller
Ir The existing connector is joined by the ARSC in a T- adapter condition through a connector, so check
the effect.
a) Transmission controller system

a-1) Accelerator abnormal: see Troubleshooting A-l 1 for transmission controller system
Check wiring harness between TMAI (13) and TMA2 (13)
Check wiring harness between TMBI (9) and TMB2 (9)
a-2) Abnormality in transmission output shaft speed sensor
Check wiring harness between TMAI (I I,(2) and TMA2 (I I,(2)
a-3) Abnormality in engine speed sensor
Check wiring harness between TMDI (13),(14) and TMD2 (13),(14)
a-4) Other abnormality
Check wiring harness between TMAI and TMA2, TMBI and TMB2, TMCI and TMC2
a-5) Travel speed display is strange
Check wiring harness between TMAI (l),(2) and TMA2 (l),(2)
a-6) Engine speed is strange
Check wiring harness between TMDI (13),(14) and TMD2 (13),(14)
a-7) Shift lever position is strange
Check wiring harness between TMBI W,(5),(6),(7),(8) and TMB2 (4),(5),(6),(7),(8)
b) Suspension controller system

b-l) Abnormality displayed on suspension controller
Check wiring harness between J04-EL (I I,(2),(3),(4),(5) and 1J04-EL2 (I ),(2),(3),(4),(5)
c) Payload meter system

c-l 1 Abnormality displayed in payload meter (PLM)
Check wiring harness between ARC3 (6) and PM4-1 (5)
HD325-6 20-745
0
R-105 When traveling downhill, even when set speed is exceeded, no con-
trol is carried out
* If no control is carried out when the accelerator pedal is not being depressed, it means that the
voltage input to the accelerator sensor is not normal.
Ir The ARSC controller LED display is “0.0” when the accelerator pedal is being depressed, and “0.0”
when the accelerator pedal is not being depressed.
Cause Remedy
1 YES
Is LED display on
ARSC controller -
normal? Replace
Defective accelerator
sensor, or defective accelerator
-When accelerator NO adjustment of accelerator sensor, or
is OFF, display is link adjust
‘0.0’
accelerator link
-When accelerator
is ON, display is
“0.0’
20-746 HD3256
0
R-106 Monitor lamp (buzzer) stays on (or off)
Cause Remedy
Repair or
replace
YE or disconnection
in wiring harness - 3 YES Repair or
between RW (2). Is there short cir- Defective wiring harness
replace
(4) and chassis cuit with ground
ground (ER)? or disconnection
1 - in wiring harness - 41 (El Defective between lamp Repair or
NO between RW (3) - When WL(BZ)- (buzzer) and monitor replace
When RW relav 1 WL-ELI (2) (or panel
EL1 and WL(BZ)-
between RW (1) - EL2 are re-
BZ-EL (2)? moved, and
WL(BZ) is joined,
NO does problem [ Defective wiring harness Repair or
1appear again? NC between WL(BZ)-ELI ant replace
WL(BZ)- El2
Defective relay Teplace
RW relay To main harness

I inside cab
To transmission
controller
TWH00383
HD325-6 20-747
0
R-107 READY lamp does not light up (or stays lighted up)
Is READY lamp YES

I-
r-
Is there short cir-
cuit with ground
or disconnection
in wiring harness
between RZ (fe-
male) (3) - RHl-
EL2 (male) (3).
and between
RHl-EL2 (female)
4
Is there short cir-

cuit with ground
pr disconnection
YES
I;;; PLl (female) In wmng harness - YES

between RZ (fe- 5 )
male) (5) and Is there discon-
GREEN? nection in wiring
. GREEN: - harness between -
_.
,,,o GREEN and 6
problem appear ARSC standby
chassis ground
lamp (green) (ER)? Is RHEOSTAT
- knobatOVout- -
NO put?
20-748 HD325-6
0
Cause Remedy
Defective lamp Replace
Disconnection, defective
Replace
contact, short circuit with
Disconnection, defective
Replace
contact, short circuit with
Disconnection, defective Replace

contact in wiring harness
Defective adjustment of Adjust

RHEOSTAT
Defective RZ relay Replace
RZ relay
To main harness
Standby lamp
inside cab
ARSC standby
Iamp (green1 TWH00384
HD325-6 20-749
0
R-108 Exhaust brake does not work properly

Exhaust brake is actuated when exhaust brake switch is OFF;
or exhaust brake is not actuated when exhaust brake switch is
ON
Sr Before carrying out troubleshooting, check that all the related connectors are properly inserted.
_ YES
When TMC 1 and

2 are removed
ES
I/
and TMC is con-
nected, does YES
problem appear 3
again?
_ Is there short cir-
cuit with ground
_ or disconnection _
4 YES
NO in wiring harness
between RB (3) Is there short
and TMC2 (9)? circuit with 5
ground or
When RB relay is
- disconnection in - [ Is there short
NO circuit with ground I YES
problem appear or disconnection
in wiring harness
behween ARC2
(16) and RHI-EL2 H
uo
20-750 HD3256
0
I Cause Remedy
See A-6 and A-

12 in Troublesho
oting of
- transmission
controller
system(A Mode)
Defective wiring harness Repair or

replace

replace

replace
/ Defective relay Replace

RI3 relay
ARSC controller
signal
I’
output
I EXH Exhaust brake switch
ARC2 (04020)
switch input
TWH00385
HD325-6 20-75 1
0
R-109 There is difference between travel speed rod value and actual ma-
chine value
a) Abnormality in model selection (when starting switch is turned ON, model shown on LED display
is not correct)
Cause Remedy
YES
1
(short circuit with ground)
Isthere continuity
between ARC2 (fe-
male) (13) and
chassis ground Defective wiring harness Replace
when ARC2 and 2
BRJ are discon-
nected?
7
* Turn starting
switch OFF.
* Disconnect ARC2
and BRJ.
7-l..
Is there continuity
between BRJ (fe-
male) (2) and (4)?
FJO
-Turn starting
Is there contrnurty
between ARC2 (fe-
male) (12) and
(short circuit with ground)
Replace
4 YE!
ir
switch OFF. chassis ground
when ARC2 and Defective wiring harness
* Disconnect
connector. BRJ are discon- Is there continui-
nected? ty between BRJ
(female) (2) and
. Turn starting
NO 6)?
switch OFF. 1 Defective controller Replace
. Disconnect ARC2 * Turn starting
NC
and BRJ. switch OFF.
* Disconnect
connector.
R-109 a) Related electrical circuit diagram
4RSC controller
I
ARC2(04020)
Not connec
I TWH00386
20-752 HD3256
0
b) Tire large diameter/small diameter setting is strange
Cause I Remedy
YES
2 replace
Is there continuity
YES between TIRE2 3
- (male) (1) and Is there continuity _YES Defective wiring harness Repair or
ARC2 (fernate) (9)? between TIRE1 (fe-
replace
* Turn starting male) (1) and
1 switch OFF. ARC3 (female) (3);
For large diamet- - Disconnect 4YES
NO ;;~i;t$t;c~a;_
er tire, is TIRE connector. Defective wiring harness Repair or
connector OPEN sis ground when replace
Is there defective
and for small di- - ,MtiM;; discon- - contact of TIRE -
ameter tire, is connector?
TIRE connector
CLOSED? * Turn starting Replace
switch OFF. NO NO
- Disconnect
connector.
Defective connection Connect again

NO
R-l 09 b) Related electrical circuit diagram
ARSC controller
ARC2 (04O;O) TIRE2tXl)

Sensor GND @
Tire large/small
selection connector
ARC3 (04016) TIRE1 (Xl) Sma11: CLOSED
Large: OPEN
TWH00387
HD325-6 20-753
a
R-110 Retarder lamp does not light up, or stays lighted up

Cause Remedy
Check
YES according to
— error code
1 [8.7(8.5)]
See P-1 in
Is error code [8.7
(8.5)] displayed? 2 YES —
Is there continui-
ty between D02
(female) (2) and
3 YES
chassis ground
Is there continuity Defective wiring harness Repair or
NO when D02 and
TMC1, 2 are dis- between TMC1 (7) replace
connected? and D02 (female)
(2) and is there con-
tinuity between
NO D02 (female) (2)
and chassis ground 4 YES
when TMC1, Defective wiring harness Repair or
TMC2, and D02 are Is there continui- replace
disconnected? ty between
• Turn starting TMC1 (7) and
switch OFF. NO TMC2 (7)?
• Disconnect Defective controller Replace
connector. NO
20-754 HD325-6
8
TROUBLESHOOTING R-III
R-l 11 Travel speed display always gives display (or does not give any dis-
play)
Cause Remedy
I YIES
r Defective wiring harness Repair or
replace
1. Is there con-
SPDISR5 and
SW (female) (2) Defective system switch Replace
and is there con- switch is re-
YES
tinuity between
SPDIS-R5 and problem appear
chassis when
SPDIS and SW Defective set travel spee,
are disconnect- display Replace
* Turn starting Defective wiring harness

-.switch OFF. (defective contact or
Repair or
replace
disconnection)
Defective wiring harnes

Repair or
* Disconnect NO (defective contact c
replace
connector. disconnection)
ARSC system switch

-

A
SPDIS TMCl
(7) 612
R20
Travel RjO 0
speed R40
disolav ~50
R60 TMC2
Ls12
TWH00389
HD325-6 20-755
TROUBLESHOOTING H-l
H-l Machine does not start

Ask the operator the following questions
l Did the problem suddenly happen?
Yes = Internal seizure, damage
l When this happened, was there any abnormal noise?
Yes = Broken part
Checks before troubleshooting

Is the oil level in the transmission case correct?
Is the torque converter, transmission input shaft
broken? (Check with the transmission input shaft
speed sensor.)
Is the drive shaft broken?
Is there any dragging of the brakes?
The following symbols are used to indicate the

action to be taken when a cause of failure is
ot start in any speed range
transmission is low
I I I I I I I I I I I I I I ,
HD325-6W only ftT
20-802 HD3256
0
TROUBLESHOOTING H-l
Clutch combination table
HD325-6 20-803
0
TROUBLESHOOTING H-2, H-3
H-2 Machine does not travel smoothly (machine jerks)

l There is hunting.
l Lock-up lamp flashes
1__________._
CalJ#?S Remedy
* Drop in main relief pressure

A.SeeH-6
*Worn clutch seal ring
H-3 Lock-up clutch cannot be disengaged (engine stalls)

l Is the oil level in the transmission case correct?

located.
X: Replace A: Repair
A: Adjust C : Clean
20-804 HD3256
0
H-4 Excessive shock when starting or shifting

Judgement standard
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 cases.
l It is clear that the shock has suddenly become excessive.
l The shock is excessive compared with other machines of the same class.
Cause
l Defective operation because of dirt caught in the ECMV pressure control valve spool and flow detector
valve spool, or defective operation of the ECMV proportional solenoid.
l Defective operation because of dirt caught in the pressure control valve spool and flow detection valve
spool of the front wheel clutch, or defective operation of the proportional solenoid of the front wheel
clutch. (HD325-6W only)
H-5 Transmission does not shift up

a Does not shift up
* Shifts up on downhill slopes.
Causes Remedy I
Slipping or damage of torque converter lock-up clutch x A

+ he above is the most probable cause, but for details, see “Torque converter lock-up does not engage”.
b Does not shift up

Cause5 I Remedy
Defective operation of ECMV for clutch which does not shift up c Ax

Defective piston seal ring, defective groove for clutch which does not shift up X
Drop in main relief pressure AcAx
HD325-6 20-805
0
TROUBLESHOOTING H-6
H-6 Machine lacks power or speed when traveling

a. Abnormality at all speed ranges

l Is there any external oil leakage from the piping or valve joints?
l Is there any dragging of the parking brake, service brake, or retarder?
Checking for abnormalities

Engine high idling speed
Torque converter stall speed
Machine travel speed
Transmission clutch pressure
Torque converter lock-up pressure
Main relief pressure

located.
A: Adjust C : Clean
laIb/c/d/e/f/g/h/i/i/k/
bnormal noise comes from between pump and
transmission is low
Hydraulic pressure at pump outlet port is low
11 When oil temperature rises, oil pressure drops

I loI ~1L--T-i
20-806 HD325-6
0
TROUBLESHOOTING H-6
b. Torque converter lock-up does not engage

Yes q internal seizure, damage
l When this happened, was there any abnormal noise?
Yes = Broken part

l Is there any external oil leakage?
l Is electricity flowing to the lock-up solenoid? (Use a checker.)

l Main relief pressure
l Lock-up oil pressure
l Machine travel speed

located.
X: Reolace A: Repair
I A: Adjust C : Cl&an I
No.
Problems
1 Main relief pressure is low 0

2 With Item 1 normal, lock-up pressure is low or “0’ 00 0
3 Solenoid is normal in Item 2 (proper continuity, no 0

short circuit)
Solenoid is defective in Item 2 (no continuity, there is
4 short circuit) 0
5 With Items 1 - 4 normal, lock-up pressure is low 00
6 Oil pressure is normal in Item 5 0
7 Lock-up pressure is low and main pressure is also 0
8 Lock-up takes time to engage 00
HD325-6 20-807
0
TROUBLESHOOTING H-6
c)-1 Abnormality at some speed ranges

[Troubleshooting without using shift
checker]

4th 3th 2th Ith R
l Is there any dragging of the parking brake, service (RotatingI lRamingl
brake, or retarder?
R 0 0
l Machine travel speed
lol I I I
No.
Problems of transmission controller
(I) Fl is normal, but F2 is defective 2.5 3.5 4.5 4.5

1
Returns to normal when replaced with any ECMV
(2) except 2nd.
(1) F2 is normal, but Fl is defective or only Fl is 2.4 3.4 4.4 5.4

defective
2
(2) Returns to normal when reolaced with anv ECMV
(I) Fl and F2 are normal, but F3 is defective 2.2 3.2 4.2 5.2
3
(2) Returns to normal when replaced with any ECMV
exceot H.
(1) Fl, F2, and F3 are normal, but F4 is defective 2.6 3.6 4.6 5.6
4
(2) Returns to normal when replaced with any ECMV
except 3rd.
(1) Fl - F5 are normal, but F6 is defective 2.7 3.7 4.7 5.7
5 (2) Returns to normal when replaced with any ECMV

exceot 4th.
(1) F3, F5, and F7 are normal, but others are defective 2.3 3.3 4.3 5.3
6 (2j Returns to normal when replaced with any ECMV

except L.
(I) Only R is defective 2.8 3.8 4.8 5.8
7 (2) Returns to normal when replaced with any ECMV

except R.
+ Remove all the mud and dirt from around the ECMV, and clean it before replacing.
* After replacing, tighten the ECMV mounting bolts to the specified tightening torque.
w kgm ECMV mounting bolt : 30.89 f 3.43 Nm (3.15 f 0.35 kgm}
20-808 HD325-6
0
I
0 0
0 0
TROUBLESHOOTING H-7
H-7 Time lag is excessive when starting or shifting gear

l Is operation of control valve normal?
Checking for abnormalities Clutch combination table

l See the STANDARD VALUE TABLE to check
if the time lag is actually excessive.
Abnormal noise comes from pump

There is time lag when transmission is placed in any
3 1 Fl is normal, but there is time lag when shifting to F2 I

4 F2 is normal, but there is time lag when shifting to Fl
Fl and F2 are normal, but there is time lag when
5 shifting to F3
Fl, F2, and F3 are normal, but there is time lag when
6 shifting to F4
Fl - F5 are normal, but there is time lag when

7
shifting to F6
F3, F5, and F7 are normal, but there is time lag when
Transmission modulating pressure is low when
Torque converter oil temperature goes above

11
operating range
20-810 HD325-6
TROUBLESHOOTING H-7

located.
A: Adjust C : Clean
HD325-6 20-811
0
TROUBLESHOOTING H-8
H-8 Torque converter oil temperature is high

l Does oil temperature go up when torque converter is stalled and go down when torque converter is
not stalled?
Yes = Normal (incorrect selection of speed range)

l Is oil level in transmission or steering case correct?

l Use STANDARD VALUE TABLE to judge if torque converter oil temperature is actually high.
* If oil temperature is normal but oil temperature gauge on machine goes above operating range
+ defective oil temperature gauge

located.
A: Adjust C : Clean
No.
Problems
1 1 Pump makesabnormal noisewhen oil temperature 1 A 1 / 1 1 1

is low v
I
2 High idling and low idling speeds are low 0
3 Torque converter outlet port oil pressure is low 0
4 I Torque converter inlet port oil pressure is low I I I bll

5 IT ransmission modulating pressure is low IOIOIII I
6 tExcessive leakage inside torque converter I Il.llol
1 If troubleshooting shows
that all other items are
normal, this is the cause.
20-812 HD325-6
0
TROUBLESHOOTING H-9
H-9 Torque converter oil pressure is low


l Pump outlet port oil pressure
2 1 Oil pressure is low between pump and relief valve I loI I I

3 1 Torque converter inlet port pressure is low I I lolol
4 Transmission and lock-up pressures are normal, but
torque converter inlet pressure is low I I I loI
5 When set pressure of torque converter relief valve is
0
raised, relief pressure becomes high
HD3256 20-813
0
TROUBLESHOOTING H-10
H-10 Front brake is ineffective, or effective only on one side

HD325-6,HD405-6
l Is the oil level in the brake tank correct?
l Is there air in the brake oil?
l Is there external leakage of oil between the brake
chamber and wheel cylinder?
l Is the air pressure within the operating range?

l Air pressure
l Brake chamber outlet port pressure
Items 1 - 5 are normal, but brake is ineffective or

6
braking effect is poor
20-814 l-D3256
0
HD325-6W
l Is oil level in the brake tank correct?
l Does not air mix in brake oil?
l Is there any external oil leakage between brake
chamber and wheel cylinder?
l Is air pressure inside operating range?
Checking for following

l Air pressure
l Brake chamber outlet pressure

action to be take when a cause of failure is
HD3256 20-814-l
0
TROUBLESHOOTING H-II
H-l 1 Rear brake is ineffective, or effective only on one side

Is there air in the brake oil circuit?
l Is there air in the brake oil circuit?
l Is the transmission oil level correct?
l Is there external leakage of oil between the brake
chamber and brake?
l Is the air pressure within the operating range?

l Air pressure
l Brake chamber outlet port pressure

located.
X: Replace
A: Adjust
1 Oil pressure at master cylinder outlet port is low

(outlet port hose disconnected) 000 00
2 Air pressure at brake chamber inlet port is normal 00
3 Air pressure at brake chamber inlet port is low 000
4 Leakage of air from brake chamber 0

Items 1 - 4 are normal, but slack adjuster outlet port
5
pressure is low 0
Items 1 - 5 are normal, but brake piston pressure is
6
low
0
7 Excessive contamination of cooling oil 0

8 Oil level in final drive case rises 0 0
9 In Item 7, brake piston oil pressure is normal 0

10 Items 1 - 5 are normal, but brake is ineffective or
braking effect is poor
0
HD3256 20-815
0
H-12 Steering wheel is heavy

l Is the oil level in the hydraulic tank correct?
l Is there any external oil leakage between the pump and steering valve?
. Is the steering wheel play correct?

l Operating effort of steering wheel
l Time taken to turn the steering wheel from lock to lock
l Relief pressure of steering circuit
The following symbols are used to ind

No.
Problems
cxxaAa,nx
X
1 Circuit pressure is too high at engine low idling or

pressure rises to relief pressure 0
20-816 I-ID3256
0
H-13 Steering wheel does not work

Is the oil level in the hydraulic tank correct?
l Is there any external oil leakage between the pump and steering valve?
l Is the steering wheel play correct?

l Relief pressure

located.
I X: Replace
A: Adjust
A: Repair
C : Clean
ia/b/c/dlelf/e/h/i /i/k/
4 1 Hoist is normal I I I I I I I lolololol

5 Relief pressure is low at end of cylinder stroke (Item 0 00
4 normal)
Item 5 is abnormal and noise of oil blowing is heard 0
6
from relief valve
Abnormal noise comes from between pump and
7 filter 0
8 Steering wheel works when engine is at low idling 0 0
When steering wheel is turned to right (left) and

9 hose on opposite side is removed, rod does not
move but oil flows out I I I I I I no
10 Pump discharge amount is too low 00
11 Excessive play in steering wheel 0
H-14 Steering wheel vibrates
Causes Remedy
Air in hydraulic oil C
Leakage of air inside steering cylinder A x
HD325-6 20-817
0
H-15 Hoist cylinder lacks lifting force (lifting speed)

l Is the actuation of the control levers normal?
l Is the control linkage bent, gouging?
l When the linkage is disconnected at the hoist valve end, does the movement of the control valve lever
become normal?
l Is there any external oil leakage between the pump and cylinder?

l Relief pressure
l Body lifting speed

located.
A: Adrust C : Clean
from valve is found
12 items 1 - 9 are normal but dump body lifting speed is

slow 0
Abnormal noise comes from between pump and

l3 filter 0 0
20-8 18 HD325-6
0
H-16 Hoist cylinder does not work

Yes = Seizure, damage to equipment
l Had drop in lifting speed or other symptoms appeared before?
Yes = Worn parts, deteriorated spring, etc.

l Is the operation of the control levers normal?
l When the linkage is disconnected at the hoist valve end, does the movement of the control valve
become normal?

l Relief pressure

located.
A: Adjust C : Clean
ist circuit relief pressure is low at engine
10 Pump discharge amount is low 00

When hoist lever is operated to RAISE, and hose on
11 opposite side is removed, cylinder does not move, 0
but oil comes out
HD3256 20-819
0
H-17 Excessive hydraulic drift of dump body

l When the control lever linkage is disconnected at the
valve end, does the hydraulic drift come within the stan-
dard range?
Yes q Bent linkage, gouging

l Hydraulic drift of cylinder

action to be taken when a cause of failure is /
located.
X: Replace
A: Adjust
When engine is stopped and control lever is

operated to RAISE, hydraulic drift becomes
When engine is stopped I Oil continues toflnw nllt lOI I I I

with body fully raised and i-1 I I 1
head piping is removed
20-820 HD325-6
0
H-18 Air pressure does not rise (Low-pressure buzzer does not stop.
Air gauge does not rise to green range.)

l Is air gauge normal?
l Is there any leakage of air from air piping?

located.
A: Adjust C : Clean
1 When compressor outlet port is removed, no air

00
comes out
I I I I I
Even when unloader valve is disassembled and
2 0
cleaned, there is no change
When hose between governor and unloader valve is

3
removed, pressure rises t 0
4 Compressor is abnormally hot
Even when pressure gauge indicator rises to green TF#

5 range, buzzer does not stop (pressure gauge is
normal) I I I loI
Air pressure does not rise, but air blows out from
6
safety valve C,
HD325-6 20-821
0
TROUBLESHOOTING OF MONITOR
PANEL SYSTEM
(P MODE)
Method of self-diagnostic display for monitor panel and controllers ................................................ 20-903
Action taken by self-diagnostic device and problems on machine (monitor panel system) ........... .20-904
Electrical circuit diagram for monitor panel system ............................................................................ 20-908
P-l Check pattern for wiring harnesses between modules.. ............................................................ 20-910
P-2 Nothing on monitor panel works ................................................................................................. 20-914
P-3 LH, RH module and fuel gauge do not work ............................................................................... 20-915
P-4 LH, RH module and fuel gauge do not work.. ............................................................................. 20-916
P-5 RH module does not work.. .......................................................................................................... 20-917
P-6 LH module does not work ............................................................................................................ 20-918
P-7 Travel calculator does not work.. ................................................................................................. 20-919
P-8 Service meter display does not work correctly .......................................................................... 20-920
P-9 Central warning lamp does not work, or monitor panel detects failure code fA0021.. .......... ..20-92 1
P-IO Central warning lamp stays lighted up ....................................................................................... 20-922
P-II Alarm buzzer does not work, or monitor panel detects failure code [A0031 ............................ 20-923
P-12 Alarm buzzer continues to sound ................................................................................................ 20-924
P-13 All data from shift controller (speedometer, tachometer, shift indicator, etc.)
are abnormal (nothing is displayed, or display does not change), or monitor panel detects
service code fA0131, or monitor panel detects service code [A0181 ......................................... 20-925
P-14 Suspension mode, power/economy mode displays are abnormal (nothing is displayed,
or display does not change), or monitor panel detects service code IA0161 ........................... 20-926
P-l 5 Gauge displays are abnormal (nothing is displayed, or display does not change). ............... .20-927
P-16 Cooling water level drop caution lamp does not work, or monitor panel detects service code [A0011 .............. 20-928
P-17 Cooling water level drop caution lamp stays lighted up ........................................................... 20-929
P-18 Emergency steering pilot lamp does not work, or monitor panel detects service code [A0011 .... .20-930
P-19 Emergency steering pilot lamp stays lighted up ........................................................................ 20-931
P-20 Engine oil pressure drop caution lamp does not work, or monitor panel detects service code [AOOII.. ......... .20-932
P-21 Engine oil pressure drop caution lamp stays lighted up ........................................................... 20-933
P-22 Exhaust brake pilot lamp does not work, or monitor panel detects service code [A0011 ..... ..20-93 4
P-23 Exhaust brake pilot lamp stays lighted up .................................................................................. 20-935
P-24 Charging circuit abnormality caution lamp does not work, or monitor panel detects service code [A0011.....20-936
P-25 Charging circuit abnormality caution lamp stays lighted up.. ................................................... 20-937
P-26 Transmission filter clogging caution lamp does not work, or monitor panel detects service code [A0011 ..... .20-938
P-27 Transmission filter clogging caution lamp stays lighted up.. .................................................... 20-939
P-28 Brake stroke caution lamp does not work, or monitor panel detects service code [A0011 .... .20-940
P-29 Brake stroke caution lamp stays lighted up ................................................................................ 20-941
P-30 Preheating switch pilot lamp does not work, or monitor panel detects service code [AOOII.. ...... .20-942
P-31 Preheating switch pilot lamp stays lighted up.. .......................................................................... 20-943
P-32 Tilt warning lamp does not work, or monitor panel detects service code [AOOII.. .................. 20-944
HD325-6 20-901
0
P-33 Tilt warning lamp stays lighted up .............................................................................................. 20-945
P-34 Body FLOAT (except FLOAT) pilot lamp does not work, or monitor panel detects service code [A0011 ........ ..20-94 6
P-35 Body FLOAT (except FLOAT) pilot lamp stays lighted up .......................................................... 20-947
P-36 Rear brake pilot lamp does not work, or monitor panel detects service code [A001 I ............. 20-948
P-37 Rear brake pilot lamp stays lighted up.. ...................................................................................... 20-949
P-38 Parking brake pilot lamp does not work, or monitor panel detects service code [A001 I ....... .20-950
P-39 Parking brake pilot lamp stays lighted up.. ................................................................................. 20-951
P-40 Maintenance caution lamp does not work, or monitor panel detects service code IA0011 .. ..20-95 2
P-41 Maintenance caution lamp stays lighted up ............................................................................... 20-953
P-42 Steering oil temperature caution lamp does not work, or monitor panel detects service code [A0011........... .20-954
P-43 Steering oil temperature caution lamp stays lighted up ........................................................... 20-955
P-44 Differential lock pilot lamp does not work, or monitor panel detects service code [AOOII.. . ..20-95 6
P-45 Differential lock pilot lamp stays lighted up ............................................................................... 20-957
P-46 High beam display does not light up .......................................................................................... 20-958
P-47 Turn signal lamp (right) does not light up .................................................................................. 20-960
P-48 Turn signal lamp (left) does not light up ..................................................................................... 20-961
P-49 Lamp check switch does not work ............................................................................................... 20-962
P-50 Exhaust brake switch does not work.. ......................................................................................... 20-963
P-51 Mode change switch (I) does not work ...................................................................................... 20-964
P-52 Mode change switch (2) does not work ...................................................................................... 20-965
P-53 KPH/MPH speedometer unit selector does not work ................................................................. 20-966
P-54 Defective operation of all switch inputs.. .................................................................................... 20-967
P-55 Monitor panel detects service codes [A0141 or IA0191 .............................................................. 20-968
P-56 Monitor panel detects service code [A0151.. ............................................................................... 20-969
P-57 Monitor panel detects service code [A01 11.. ............................................................................... 20-970
P-58 Monitor panel detects service code IA0121.. ............................................................................... 20-970
P-59 Monitor panel detects service code [A0001............................................................
20-970
20-902 HD325-6
0
METHOD OF SELF-DIAGNOSTIC DISPLAY
TROUBLESHOOTING FOR MONITOR PANEL AND CONTROLLERS
METHOD OF SELF-DIAGNOSTIC DISPLAY FOR MONITOR

PANEL AND CONTROLLERS
1. After the starting switch is turned ON, all lamps light up for 3 seconds to carry out self-diagnosis of
the monitor itself. After that, the normal display is shown.
2. For details of the method of display if any abnormality occurs in the monitor itself or the other con-
trollers, see MONITOR PANEL USER CODES AND SERVICE MODE FUNCTION in the Foreword of the
Troubleshooting Section.
3. Check for blown bulbs of the pilot lamps and warning lamps by pressing the caution and pilot lamp
bulb check switch at the right edge of the panel.
ielf-diagnostic service code table
No. Service code Nature of failure Display conditions

Display conditions, Display in service
1 A000 Short circuit in output system code,trouble data display mode
2 A001 Short circuit in lamp output system

Display when lamp check switch
3 A002 Short circuit in central warning lamp output system is pressed for at least 2.5 seconds
and then released
4 A003 Short circuit in alarm buzzer output system
Display in service code, trouble
5 A011 Abnormality in network system data display mode
6 A012 Network system connection data does not match
7 A013 Abnormality in network system (transmission controller)
8 A014 Abnormality in network system (PMC)

Display when lamp check switch
9 A015 Abnormality in network system (engine controller) is pressed for at least 2.5 seconds
and then released
10 A016 Abnormality in network system (suspension controller)
11 A018 Abnormality in model selection data
12 A019 Abnormality in option data
13 A021 Abnormal drop in air pressure
14 A022 Engine water temperature overheat warning
15 A023 Torque converter oil temperature overheat warning
16 A024 Brake oil temperature overheat warning
HD3256 20-903
0
ACTIOlf I TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON

MACH11 blE MOtilTOR PANEL l SYSTEM
Ietails of abnormality Check the wiring harnesses and equipment
Display Abnormal system given below ,-& : Disconnection, short circuit in wiring harness
+): Positive, (-): Negative
short circuit in lamp output 1. Between (+) lamp inside dash panel and monitor panel ,.&
system inside dashboard
(For details, see troubleshooting P-16, 18, 20, 22,24,26,28,30,32,34,
Ir Short circuit in output
system 36, 38, 40,42, 44)
2. Defective lamp
A001
short circuit in central warn- 1. Between (+) DP08 (2) and WL (2) 4
ng lamp output system
2. Defective central warning lamp
system
A002
short circuit in alarm buzzer 1. Between (+) DP08 (2) and Bf (2) ,&
output system
2. Defective alarm buzzer
A003
Abnormality in network sys- 1. Defective setting of shift controller model selection

em
k Connection data does
not match.
A012
Abnormality in network sys- 1. Between (+) DP05 (3) - TMD (IO) - ATC4 (6) &
iem
2. Between (+) DP05 (4) - TMD (12) - ATC4 (12) &
* Transmission controller
system 3. Between (-1 DP05 (5) - TMD (9) - ATC4 (IO) &
A013 4. Between (-1 DP05 (5) - TMD (11) - ATC4 (IO) &
5. Defective shift controller
Abnormality in networksys- 1. Between (+I DP05 (3) and PMC (I 1

tern
2. Between (+I DP05 (4) and PMC (2)
* PMC system
3. Between (-1 DP05 (5) and PMC (3)
A014 4. Defective PMC
20-904 HD325-6
0
Action of control- Symptoms that appear

Condition when normal 6 : Check with tester ler when abnor- in machine when there
Voltage (V), current (A), resistance value R mality is detected is abnormality
Lamp ON: Between monitor panel connector and chassis 1. Other mechatronics Applicable lamp always
caution lamp flashes. OFF.
ground 6 : Max. 0.1 V 2. Displays user code.
3. Applicable lamp forc-
ibly turned OFF.
Central warning lamp ON: Between DP08 (I) and WL (2) 3 : 1. Other mechatronics Central warning lamp al-
caution lamp flashes. ways OFF.
Max. 0.1 V
2. Displays user code.
3. Central warning lamp
forcibly turned OFF.
Buzzer ON: Between DP08 (2) and BZ (2) 6 : Max. 0.1 V 1. Other mechatronics Buzzer does not sound
caution lamp flashes.
2. Displays user code.
3. Alarm buzzer forcibly
stopped.
Model selection setting of shift controller and actual mount- 1. Other mechatronics If the setting for machines
caution lamp flashes. with the electronic gover-
ing condition of controller in network match
2. Displays user code. nor specification, the en-
gine output will become
smaller and the engine
speed may not rise.
1. Between (+I DP05 (3) - TMD (IO) - ATC4 (6) 6 :0 R 7. Other mechatronics For machines with elec-
caution lamp flashes. tronic governor specifica-
2. Between (+) DP05 (4) - TMD (12) - ATC4 (12) 3 :0 R
2. Displays user code. tion, the engine mode
3. Between (-1 DP05 (5) - TMD (9) - ATC4 (IO) 3 :0 R 3. Display is fixed for all switching, the engine
4. Between (-1 DP05 (5) - TMD (1 I) - ATC4 (IO) 6 :0 R data from transmis- mode selection or AISS
sion controller (speed- may not work. In addition,
ometer, tachometer, the engine output may be-
gauges, etc.). come smaller orthe speed
may not increase.
1. Between (+) DP05 (3) and PMC (1) 3 :0 R 7. Other mechatronics Sometimes MOM or DAD
caution lamp flashes. may not function properly.
2. Between (+) DP05 (4) and PMC (2) 6 :0 Q
2. Displays user code. For machines with elec-
3. Between (-) DP05 (5) and PMC (3) 3 :0 R tronic governor specifica-
tion, the engine output
may become smaller or
the speed may not in-
crease.
HD325-6 20-905
0

lisplay Abnormal system given below & : Disconnection, short circuit in wiring harness
(+): Positive, (-): Negative
abnormality in network sys- 1. Between (+) DP05 (3) - J09E (1) - EC4 (6) &
am
2. Between (+) DP05 (4) - J09E (2) - EC4 (12) &
r Engine controller system
3. Between (-1 DP05 (5) - J09E (4) - EC4 (IO) &
4. Between (-) DP05 (5) - J09E (2) - EC4 (IO) &,
A015 5. Defective engine controller
ibnormality in network sys- 1. Between (+) DP05 (3) - SU3 (9) - SSPI (1) &j
em
t Suspension 2. Between (+) DP05 (4) - SU3 (13) - SSPI (12) Q$$
controller
system 3. Between (-) DP05 (5) - SU3 (12) - SSP2 (9) 4
4. Between (-1 DP05 (5) - SU3 (14) - SSP2 (9) &
A016
5. Defective suspension controller
ibnormality in networksys- 1. Defective setting of shift controller model selection

EmModel selection data
2. Between (+) DP05 (3) - TND (IO) - ATC4 (6) &j’
3. Between (+) DP05 (4) - TND (12) - ATC4 (12) &
4. Between (-) DP05 (5) - TND (9) - ATC4 (10) &
A018 5. Between (-1 DP05 (5) - TND (11 b- ATC4 (20) &
6. Defective shift controller
qbnormality in network 1. Between (+I DP05 (3) and PMC (1) &j
k Option data
2. Between (+) DP05 (4) and PMC (2) ,&
3. Between (-1 DP05 (5) and PMC (3) &
4. Defective PMC
A019
20-906 HD3256
0
Action of control- Symptoms that appear

Condition when normal 6 : Check with tester ler when abnor- in machine when there
Voltage W), current (A), resistance value R mality is detected is abnormality
1. Between (+I DP05 (3) - J09E (I 1- EC4 (6) 3:OR 1. Other mechatronics In some cases, the engine
caution lamp flashes. may not start.
2. Between (+I DP05 (4) - J09E (3) - EC4 (12) 6 :0 R
2. Displays user code. The engine output may
3. Between (-1 DP05 (5) - J09E (4) - EC4 (IO) 3 :0 R 3. Even in engine de- become smaller or the
4. Between (-) DP05 (5) - J09E (2) - EC4 (IO) 6 :0 R layed operation (en- speed may not increase.
gine controller auto-
matically lowers out-
put), high power
mode or economy
mode do not flash.
1. Between (+I DP05 (3) - SU3 (9) - SSPI (2) 6 :0 R 1. Other mechatronics In some cases, suspension
caution lamp flashes. control cannot be carried
2. Between (+I DP05 (4) - SU3 (13) - SSPI (12) 6 :0 R
2. Displays user code. out.
3. Between H DP05 (5) - SU3 (12) - SSP2 (9) 6 :0 R 3. Suspension mode dis-
4. Between (-) DP05 (5) - SU3 (14) - SSP2 (9) 6 :0 R play does not change
or all lamps go out.
1. Shift controller model selection setting is correct. 1. Other mechatronics In some cases, the trans-
caution lamp flashes. mission may stay only in
2. Between (+) DP05 (3) - TND (IO) - ATC4 (6) 6 :0 R
2. Displays user code. neutral or the engine may
3. Between (+) DP05 (4) - TND (12) - ATC4 (12) 6 :0 R 3. In addition to 1 and 2, stay only in low idling.
4. Between (-1 DP05 (5) - TND (9) - ATC4 (IO) 6 :0 R only the travel speed
unit, turn signal lamp,
5. Between(-)DP05(5)-TND(11)-ATC4(10)~:OR and high beam pilot
lamp are displayed.
1. Between (+) DP05 (3) and PMC (I 1 3 :0 R 1. Other mechatronics Sometimes MOM or DAD
caution lamp flashes. may not function properly.
2. Between (+) DP05 (4) and PMC (2) 3 :0 R with elec-
2. Displays user code. For machines
3. Between t--j DP05 (5) and PMC (3) 6 :0 R tronic governor specifica-
tion, the engine output
may become smaller or the
speed may not increase.
MOM:MESSAGE FOR OPERETION
AND MANAGEMENT
DAD:DATA ADMINISTRATION DE-
VICE
HD325-6 20-907
0
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR PANEL SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR PANEL SYSTEM
Buzzer
Ceniral
warnIns
-
--
Cooling
Engine oil
Charge
water
Pressure
level
level
-
Transmission filter cloesed
Tilt warning
Brake I Ine
Rheostat
-1 rt+rER
Ground
Hazard tauv Hazard IaIv Head Iaav

relay relay relav(Hil relay Exhaust brake
swl tch switch TWH00390
20-908 HD325-6
0
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR PANEL SYSTEM
MPH ===
==." Bulb check
selection 5:: switch Starting switch
connector ==-
--U 1B IBRIRIIRZICIACCj
I I
_______.-_____-______-----___----
Front comblnatlon
lamD(rieht)
r----- CN-707
Head lamp
(Hi) (55W)
CN-30
(SWPl4)
sihnal
l25w)
Chassis
ground
Head lamp
(Hi) (55W)
Clearance
lamp (lOWI
ground Front combination

lam0 (left1
u ;l;ide Outside
cab
(ET21
Fuse box II
TWH00391
HD325-6 20-909
0
TROUBLESHOOTING P-l
P-l Check pattern for wiring harnesses between modules

When carrying out troubleshooting of the monitor panel, if the item in the troubleshooting flowchart or
the item in the Remedy column indicates “Carry out check of wiring harnesses between modules”, refer
to the number displayed in Tables a to c below, and check the female connector of the wiring harnesses
between modules.
Ir Before carrying out troubleshooting, check that all the connectors related to the wiring harnesses
between the modules are properly inserted.
* When carrying out the check of the wiring harnesses between modules, turn the starting switch OFF,
and disconnect the connector that is to be checked.
* Check visually for disconnection in the wiring harness, cracks, or other failures.
* Keep the starting switch at the OFF position when carrying out the check of the wiring harnesses
between modules.
P-l Related electrical circuit diagram
To startina switch ACC

TWH00392
20-910 HD3256
0
TROUBLESHOOTING P-l
Table a Wiring harness continuity check - if there is continuity between X and Y in the
table, the condition is normal
Table b Check for short circuit between wiring harness and

ground - if there is no continuity between the wiring
harness and the chassis ground, the condition is nor-
mal.
/ No. / Connector / Pin No. 1 Signal name
I (1) 1 VB.(ZOV) I
(2) LCD TX OUT
(3) LCD TX IN
RESET
P/SDATE
DPIO
t B-9 1 SHIFT/LOAD
HD3256 20-911
0
TROUBLESHOOTING P-l
Check for short circuit in wiring harness - if there is no continuity between X and Y
Table c
in the table, the condition is normal.
1No.Itzizzs
T
I
Pin No.
Signal name
& Remarks
C-l
DP05 (6) Power supply DP02

(+24V)
DPlO wi
c-13
c-14
c-15 DP02 (1) VB(2OV) DP02
C-16
c-17
C-18
c-19
c-20 t
c-21
c-22
C-23 DP02 (2) LCD TX OUT DP02 /+f---j
C-24
C-25
DPlO /--#--j
C-26
C-27 1 (4) 1
DP02 +I
DP02 (3) LCD TX IN
1 C-32 1
u
1 C-35
c-33
c-34
1 DP02 (4) SCK

DP02 (6)
(7)
H C-36
c-37
t
DPIO
(1)
(2)
(6)
DP02
fj-j DP02 (5) LCD LOAD (7)
DPIO (1)
20-912 HD325-6
0
TROUBLESHOOTING P-l
X Y
No. Signal name Remarks
Connector 1 Pin No. Connector 1 Pin No.
1 C-41 1 DP02 1 (5) / LCD LOAD 1 DPIO I (2) 1
DP02 (6) LCD COM
c-45 (1)
DP02 (7) RESET DPIO
C-46 (2)
c-47 DPIO (I) P/S DATE DPIO (2)
P-l Related electrical circuit diagram
1 J
To starting switch ACC

TWH00392
HD325-6 20-913
0
TROUBLESHOOTING P-2
P-2 Nothing on monitor panel works

* Before carrying out troubleshooting, check that all the connectors related to the wiring harnesses
sr Always connect any disconnected connectors before going on to the next step.
* For details of Table b, see P-l.
Remedy
2 YES
Defective center module Replace
Is result of check of
YES wiring harnesses
- between modules -
normal? (Check 8-1 Short circuit with chassis
After inspec-
1 in Table b) ground in wiring harness
tion, repair or
p NO between DP02 (1) - DPll
Is voltage replace
(1) - DP04 (1)
between DP05 _
(female) (6) and
(12) normal?
*20-30V disconnection in wiring After inspec-
3 YES
- Disconnect DP05. harness between DP05 (6) - tion, repair or
* Turn starting Is there continuity fuse 11-112).or between fuse replace
switch ON. between DP05 II-(12) -startingswitch ACC
No- (female) (12) and -
chassis ground? After inspec-
tion, repair or
* Turn starting NO harness between DP05
(12) - JO3 (8) - ER replace
switch OFF
* Disconnect DP05.
P-2 Related electrical circuit diagram
Starting switch
Fuse box 11
(BT21
Monitor Panel
I I I
DP05 (04012) I
I I \ I I
Power source +24V JO3 Ck30
(S16) (SWP14)
Battery
relay
TWH00393
20-914 HD3256
0
TROUBLESHOOTING P-3
P-3 LH, RH module and fuel gauge do not work

t Before carrying out troubleshooting, check that all the connectors related to the wiring harnesses
Ir For details of Table b. see P-l.
Cause I Remedy
’ YES
Isr~ I Defective center module Replace
wiring harnesses
between modules - Short circuit with chassis
normal? (Check 6-4 ground in wiring harness
After inspec-
and B-5 in Table b) between DP02 (4) - DPlO
tion, repair or
NO (4) - DP04 (51, or between
DP02 (5) DPlO (5) - DP04 rep’ace
(6)
, I
I
1
Fusf&cy II
J
I 10
1”_11 To starting switch ACC TI.,,,..
I nnu0392
HD325-6 20-915
0
TROUBLESHOOTING P-4
P-4 LH, RH module and fuel gauge do not work

* For details of Tables a and b, see P-l.
Cause Remedy
2 YES
Defective RH module Replace
Is result of check of
1 - between modules - Short circuit with chassis
Is result of check of normal? (Check B-3 ground in wiring harness After inspec-
wiring harnesses be- and B-6 in Table b) between DP02 (3) - DP04 tion, repair or
tween modules NO (41, or between.DP02 (6) - replace
normal?(Check A-1, DPlO (7) - DP04 (7)
A-3, A-4, A-5, A-6, A-
7, and A-8 in Table a) After inspec-
harness between modules
bon, repair or
NO where there is improper
replace
continuity
I I I I
Fus&8;~x II
To startlns switch ACC

TWH00392
20-9 16 HD3256
0
TROUBLESHOOTING P-5
P-5 RH module does not work

Ir For details of Table a, see P-l.
Cause Remedy
1 YES See Trouble-

Is result of check of shooting P-13
wiring harnesses
between modules _
normal? (Check A-
4, A-5, A-6, and A-7 Disconnection in wiring
After inspec-
in Table a) harness between modules
tion, repair or
NO where there is improper
replace
continuity
) ?&I~
- TWH00392
HD325-6 20-917
0
TROUBLESHOOTING P-6
P-6 LH module does not work

Sr For details of Tables a and b, see P-l.
Cause Remedy
; YES
Is result of check of Defective LH module Replace
1~ between modules
Is result of check of normal? (Check B-2 Short circuit with chassis
H
wiring harnesses in Table b) ground in wiring harness After inspec-
between modules between DP02 (2) and tion, repair or
NO
normal? (Check A-l, DPlO (3) replace
A-2, A-4, A-5, A-6, A-
7 and A-8 in Table al Disconnection in wiring
After inspec-
harness between modules
tlon, repair or
where there is improper
NO replace
continuity
20-918 HD325-6
0
TROUJ3LESHOOTlNG P-7
P-7 Travel calculator does not work

F
Cause Remedy
2 YES I Defective odometer

Replace
module
harness between DP05 tion, clean or
(female) (I). (2), (12) - replace
DP12 (female) (l), (3). (2)
- Turn starting switch ON.

* Between (1) (12): . Disconnect DPl2. After inspec-
7-9v Defective center module tion, clean or
- Between (2) - (12): No replace
4-6V
- Turn starting switch
ON.
HD325-6 20-919
0
TROUBLESHOOTING P-8
P-8 Service meter display does not work correctly

Cause Remedy
ES
Defective service meter Replace
YES &I Defective contact or dis-
1
r1 ;;yz;;; and [ 3 YES
connection in wiring
harness between DPOI
(female) (1) - JO1 (1)
After inspec-
tion, clean or
replace
1
*20-30V alternator terminal R
alternator terminal
- Start engine. N ml- Defective contact or
Fi and chassis - Disconnect DPOI.
harness between DPOl tion, clean or
* Turn starting NO [female) (4) and chassis replace
switch OFF. ground
*20-30V
* Disconnect DPOI.
. Start engine.
Defective alternator
N0
Monitor Panel
Alternator
JO1 (S16)
I I TWH00395
20-920 HD325-6
TROUBLESHOOTING P-9
P-9 Central warning lamp does not work, or monitor panel detects
failure code (monitor panel display) [A0021
Cause Remedy

YES harness between DP08
Replace
(female) (1) and WL
(female) (2)
Is voltage between ik
DP08 (female) (1)
and chassis l-l Defective center module Replace
1 YES
:;$;ct DP08 Nq E);;’ Iamp light harness between DP08 tion, clean or
[female) (1) and WL replace
*Turn starting switch [female) (2)
- Connect DP08 Does lamp light
ON.
(female) (1) and n up? 4YEE Defective central warning
chassis ground. Replace
lamp
- Turn starting switch
ON. - Connect WL (2) Defective contact or
. ni.x.nnn&“+ npna disconnection in wiring
After inspec-
harness between WL
tion, clean or
-2O-30V NC [female) (1) -fuse II-(12).
switch ON. replace
- Turn starting switch or between fuse II- (12) -
starting switch ACC
ON. -
- Disconnect WL.
Startino srttch
I TWH00397
HD325-6 20-92 1
0
TROUBLESHOOTING P-IO
P-10 Central warning lamp stays lighted up

Cause Remedy

After inspec-
YES with wiring harness
between DP08 (female) (I) tion, repair or
and WL (female) (2) replace
Contact of chassis ground with
central warning lamp body, or After inspec-
contact of chassis ground with tion, repair or
NO wiring harness between central
replace
warning lamp and WL (male)
(2)
1 1 - B$conry?ct DP08
* Disconnect DP08.
- Turn starting NO
switch ON.
P-IO Related electrical circuit diagram
StartInn switch
Monitor panel D
I
DP08 (04016)
Caution IamP
TWH00397
20-922 HD325-6
0
TROUBLESHOOTING P-II
P-II Alarm buzzer does not work, or monitor panel detects

Wonitor panel display
failure code
TWH0039tl
Cause Remedy

Replace
(female) (2) and BZ
1 (female) (2)
Is voltage between
DP08 (female) (2) _ YES
and chassis ground
2
normal?
*20-3ov Defective contact or

Does buzzer disconnection in wiring After inspec-
. Disconnect DP08 - sound? YES
harness between DP08 tion, clean or
and BZ. NO
(female) (2) and BZ replace
* Turn starting
switch ON. * Connect DP08 (female) (2)
Defective buzzer Replace

ON. . Connect BZ (2) and Defective contact or
* Disconnect DP08. disconnection in wiring
4fter inspec-
1- 1 harness between BZ
switch ON. - tion, clean or
.20-30V (female) (1) -fuse II-(12).
replace
* Turn starting or between fuse II- (12) -
switch ON. starting switch ACC
. Disconnect BZ.
P-l 1 Related electrical circuit diagram
Startino switch
TWH00399
HD325-6 20-923
0
TROUBLESHOOTING P-12
P-12 Alarm buzzer continues to sound

YES
IContact between chassis
ground and wiring After inspec-
harness between DP08 tion; repair or
(female) (2) and 82 replace
(female) (2)
Contact between chassis After inspec-

ground and wiring tion, repair or
NO harness of BZ (male) (2) replace
k iirctive center module Replace
Startino sultch
TWH00399
20-924 HD325-6
0
P-l 3 All data from shift controller (speedometer, tachometer, shift indicator,
etc.) are abnormal (nothing is displayed, or display does not change), or
Honitor Panel display
monitor panel detects service code or

TWH00400
monitor panel detects service code

Cause Remedy
TWH0040 I
t Before carrying out troubleshooting, checkthat all
the connectors related to the wiring harnesses be-
tween the modules are properly inserted. 4 YES Defective transmission
* Always connect any dis- ;ES Is result of continui- controller
connected connectors ty check on network
Is suspension wiring harnesses in
before going on to the mode display nor- Disconnection in wiring After inspec-
Table 1 normal?
next step. mat (automatic harness where there is tion, repair or
YE _ suspension setting _ -Turn starting NO improper continuity replace
machine) or does switch OFF.
monitor panel de-
* Disconnect DP05
2 tect service codes
IA0131 or [A0181? and ATC4.
Is model selec- Defective center module Replace
NO
YE tion of transmis-
sion controller For details of ad-
justing, see TEST
-ING AND AD-
JUSTING, SET-
Do high beam pilot TI NG ROTARY
Defective model selection
SWITCH (MODEL
of transmission controller
NO DATA, NETWORE
DATA) WHEN
REPLACING
TRANSMISSION
CONTROLLER.
- See Trouble-
shooting P-2
Table 1
Transmission I
I I
4
NO. Monitor panel end Judgment
controller end
1 DP05 (female) (3) ATC4 (female) (6) Continuity = NC)rmal

2 DP05 (female) (4) ATC4 (female) (12) Continuity = Normal
1 3 1 DP05 (female) (5) IATC4 (female) (IO) 1 Continuitv = Normal I

4 DP05 (female) (3) ATC4 (female) (10) No continuity = Normal
5 DPO5 (female) (4) ATC4 (female) (10) No continuity = Normal
TWH00402
HD325-6 20-925
0
P-l 4 Suspension mode, power/economy mode displays are abnormal

(nothing is displayed, or display does not change), or
Monitor Panel display

TWH00403
* Before carrying out troubleshooting, check that all the connec-

Cause Remedy
tors related to the wiring harnesses between the modules are
properly inserted.
Ir Always connect any disconnected connectors before going on
to the next step. 3 YES Iefective suspension
Replace
:ontroller
YEsJ%ZZJ---
3isconnection in wiring After inspec-

?arness where there is tion, repair or
- Turn starting NO replace
mproper continuity
1 switch OFF.
- Disconnect DP05, SSPl,
and SSP2A.
Defective RH module See Trouble-
NO shooting P-13
tion of trans-
mission con- For details of
adiusting, see
TESTING AND
ADJUSTING,
SETTING ROTAR)
Defective model selection
SWITCH (MODEL
NO of transmission controller
DATA, NETWORK
DATA) WHEN
REPLACING
TRANSMISSION
CONTROLLER.
Table 1
Transmission Judgment
No. Monitor panel end
controller end

4 DP05 (female) (3) ATC4 (female) (9) No continuity = Normal
5 DP05 (female) (4) ATC4 (female) (9) No continuitv = Normal
TWH00402
20-926 HD325-6
0
P-15 Gauge displays are abnormal

(nothing is displayed, or display does not change)
Before carrying out troubleshooting, check that all the connectors related to the wiring harnesses
For details of Tables a and b, see P-6.
Remedy
2 YES - See Trouble-

shooting P-3
Do speedometer
and tachometer
1
IIL’
work normally?
I See Trouble-
shooting P-13
Are all gauges
(including fuel
gauge) ab-
normal?
I1 NO
3 YES I
- See Trouble-
llAreallgauges_1 - shooting P-6
Replace
HD325-6 20-927
0
P-l 6 Cooling water level drop caution lamp does not work, or

TWH00404
* Before carrying out troubleshooting, check that all

the connectors related to the wiring harnesses be-
tween the modules are properly inserted. Cause Remedy
* Always connect any disconnected connectors before
going on to the next step.
YES See.Trouble-
-
shooting P-12
Does monitor Short circuit in wiring

After inspec-
service code tion, repair or
2 (female) (3) and PL2
[A0131 or lA0181? replace
(female) (2)
DP08 (female) (3)

YES
and chassis ground 3efective center module Replace
No normal?
~ Does cooling
*20-30V water level drop Disconnection in wiring
* Disconnect DP08 NO- caution lamp After inspec-
4 YES harness between DP08
and PL2. tion, repair or
(female) (3) and PL2
* Turn starting replace
. Disconnect DP08. water level drop (female) (2)
switch ON.
. Connect DP08
(female) (3) and
chassis ground. GotoA
. Turn starting switch ’ Connect I%? (2) NC
ON. and chassis ground.
* Turn starting switch ON
After inspec-
5 YES
Defective caution lamp tion, repair or
replace
From Disconnection in wiring
harness between PL2
After inspec-
(female) (1) and fuse II-
tion, repair or
*20-30V NO (12), or between fuse II-
replace
(12) and starting switch
* Disconnect PL2.
ACC
* Turn starting
switch ON.
Starting switch
ater
D
I TWH00405
20-928 HD325-6
0
P-17 Cooling water level drop caution lamp stays lighted up

F
Remedy

After inspec-
tion, repair or
Is there continuity between DP08 (female) (3
replace
and PL2 (female) (2)
YES between PLY
1 - (female) (2) and Caution lamp body in contac
with chassis ground, or After inspec-
chassis ground?
contact of chassis ground tion, repair or
water level drop _ * Disconnect DP08 NO with wiring harness betweer replace
and PL2. caution lamp and PL2 (2)
* Disconnect DP08. )I Defective center module Replace

* Turn starting N
switch ON.
Starting switch
ns water
lamp
TWH00405
HD325-6 20-929
0
P-18 Emergency steering pilot lamp does not work, or monitor panel
detects service code

TWH00404
Cause Remedy
to the next step.
YES see Trouble-

I - shooting P-12
E;hort circuit in wiring 4fter inspec-

panel detect YES _t rarness between DP08 tion, repair or
service code (female) (4) and PLl
2 replace
IA0131 or [AO181? (female) (5)
_Is voltage between
_ DPOB (female1 (4) _
YES
and chassis -_[ Defective center module qeplace
NO ground normal?
*20-30V Does emergency

N; steering pilot
lamp light up?
4YE: s: Iisconnection in wiring
rarness between DP08
(female) (4) and PLI
4fter inspec-
tion, repair or
replace
* Turn starting
switch ON. * Disconnect DP08. (female) (5)
* Connect DP08
chassis ground.
- Turn starting
- Connect PLI (5) Nc D(;o to A
and chassis ground.
switch ON. *Turnstarting switch ON.
4fter inspec-
5 YES tion, repair or
--I Iefective pilot lamp
replace
Prom j-H_
CIisconnection in wiring
rarness between PLl After inspec-
-t female) (4) and fuse II-(121, tion, repair or
.20-30V NO c)r between fuse h-(12) and replace
* Disconnect PLl. starting switch ACC
. Turn starting
switch ON.

Starting switch
Fuse box 11
(BT2)
Emergency
Monitor Panel &Jjl PLl (S I amp
DP08 (04Oi6) I
Emergency steering
TWH00406
20-930 HD3256
0
P-19 Emergency steering pilot lamp stays lighted up

Cause Remedy
Short circuit with chassis After inspec-

tion, repair or
between DP08 (female)
Is there continuity replace
(4) and PLl (female) (5)
YES between PLl
1- (female) (5) and - Pilot lamp body in contact
chassis ground?
Does emergency - - contact of chassis ground with tion, repair or
steering pilot _ * Disconnect DP08 NO wiring harness between pilot replace
and PLl. lamp and PLl (male) (5)
lamp light up?
* Turn starting
switch OFF.
- Disconnect DP08. 1 Defective center module Replace
- Turn starting NO
switch ON.
Starting switch
Fuse box 11
lamp
TWH00406
HD3256 20-93 1
0
P-20 Engine oil pressure drop caution lamp does not work, or monitor panel
000 0
detects service code m l-----a

1 ItIll IU
TWH00404
Cause Remedy
For A013 or A016

YES See Troubleshoot-
- ing P-12;forA015:
See Trouble-
shootingP-56
Does monitor Short circuit in wiring After inspec-
tion, repair or
replace
(female) (3)
After inspec-
harness between DP08 tion, repair or
(female) (5) and PL2 replace
(female) (3)
* Connect DP08
(female) (3) and
chassis ground.
I - , GotoA
* Connect PL2 (3) and k
- Turn starting chassis ground.
switch ON. * Turn starting switch ON.
5 YES After inspec-
replace
harness between PL2 (1) After inspec-
and fuse II-(12). or tion, repair or
between fuse II-(12) and replace
* Disconnect PL2. starting switch ACC
* Turn starting
switch ON.

Starting switch
El BR RI R2 C ACC
OFF 0
Fuse box II
Monitor panel Engine oi

Pressure amp
Engine oil Pressure

I I , I ,
TWH00407
20-932 HD325-6
0
P-21 Engine oil pressure drop caution lamp stays lighted up

Cause Remedy
1
Short circuit with chassis *fter inspec_
YES Is there continuity between DP08 (female) (5) :kod(azair Or
between PL2 and PL2 (female) (3)
1 - (female) (3) and Cautionlamp body in contact
chassis ground? with chassisground, or contact After insPec-
Does engine oil c of chassisground with wiring tion, repair or
pressure drop _ * Disconnect DP08 NO harnessbetween caution lamp replace
caution lamp and PL2. and PL2 (female) (3)
& 111 Defective center module

Replace
Starting switch
Fuse box 11
(BT2)
Monitor Panel Engine oil
Pressure I amp
DPO8(04016)
9’
I I I
I TWH00407
HD3256 20-933
0
P-22 Exhaust brake pilot lamp does not work, or monitor panel detects
Monitor me/ display
service code
TWH00404
+ Before carrying out troubleshooting, check that all the connec-

tors related to the wiring harnesses between the modules are Cause Remedy
properly inserted.
to the next step.
YES - see Trouble-
shooting P-12
11
4fter inspec-
panel detect YES harness between DP08
:ion, repair or
service code (female) (6) and PLl
2 ,eplace
IA0131 or fA0181? (female) (3)
Is voltage between
_ DP08 (female) (6) _
YES
and chassis defective center module 3eplace
NO
ground normal?
*20-30V Does exhaust

. Disconnect DpO8 - brake Pilot famP After inspec-
r
4YES harness between DP08
and PLl. :ion, repair or
(female) (6) and PLl
(female) (3)
switch ON. ____..&_I “P”‘. u brake oilot lame u
GotoA
* Connect PLI (3) NO
‘Turn starting switch and chassis around,
^..
UN.
*Turn starting &itch ON.
After inspec-
5 YES
Defective pilot lamp tion, repair or
replace
Prom jpH_
harness between PLl
(female) (1) R07 (female) After inspec-
(6) or R07 (female) (3) -fuse tion, repair or
.20-30V NO l-(7) or fuse l-(7) - JO7 - replace
battery relay or PLl (1) - DO2
* Disconnect PLl.
(1) or DO8 (female) (2) LS
-Turn starting (female) (2)
switch ON.
P-22 Related electrical circuit diagram Marker lamp relay

I I
Battery relay
Circuit break-r JO7
To combination
Rheostat switch
LS 043)
=-l
Monitor Panel Exhaust brake
0 PLl (SlO)
I Pilot lam0
DP08 (040 16) ---a
Exhaust brake lamp 3
TWH00408
HD325-6
20-934
0
P-23 Exhaust brake pilot lamp stays lighted up

+ Before carrying out troubleshooting, check that all the connectors related to the wiring harnesses
Cause 1 Remedy

2 YES After inspec-
between DP08 (female) (6) tion, repair or
Is there continuity
and PLl (female) (3) replace
YES between PLl
1- (female) (3) and - Pilot lamp body in contact with
chassis ground? chassis wound, or contact of I After insoec-
chassis ground with wiring tion, repeir or
brake pilot lamp - Disconnect DP08 NO harness between pilot lamp replace
light up? and PLl. and PLl (male) (3)
L
I * Turn starting switch OFF.
* Disconnect DP08.
- Turn starting NO
switch ON.
Marker Iamb relax
Battery relax
R07
-To combination
Rheostat switch
GND
LS (M3)
OUT 2
I >cl
+24v
Monitor Panel Exhaust brake

I I Pilot lamp
I I
DPO8 (040 16)
\ I
(3
TWH0040B
HD325-6 20-935
0
P-24 Charging circuit abnormality caution lamp does not work, or monitor
Wonitor Panel display
panel detects service code

TWH00404
sr Before carrying out troubleshooting, check that all the connec-

properly inserted. Cause Remedy
to the next step.
- See Trouble-
shooting P-12
1

After inspec-
panel detect YES larness between DP08
iion, repair or
service code female) (7) and PL2
2 replace
IA0131 or [AOl81? - female) (4)
- Is voltage between
DP08 (female) (7)
YES
and chassis defective center module Replace
NC ground normal? 3
- Does charging
-2O-30V circuit abnormality lisconnection in wiring
s i;dc;;;,ect DP08 NG ;;ming lamp light -1 After inspec-
4YES larness between DP08
tion, repair or
female) (7) and PL2
* Turn starting Does charging replace
* Disconnect DP08. circuit abnormality female) (4)
switch ON.
* h;;a;;; Intend Nt-, y;ming lamp light
chassis ground. ;o to A
. Connect PL2 (4) NO
‘Turn starting switch and chassis ground,
ON.
* Turn starting switch ON.
After inspec-
5 YES
Iefective caution lamp tion, repair or
replace
From A]-[- Disconnection in wiring
harness between PL2 After inspec-
(female) (I) and fuse II- tion, repair or
*20-30V NO (12). or between fuse II-
replace
* Disconnect PL2. (12) and starting swtich
* Turn starting ACC
switch ON.

Starting switch
Fuse box II
TWH00409
HD325-6
P-25 Charging circuit abnormality caution lamp stays lighted up

Cause Remedy

After inspec-
tion, repair or
Is there continuity between DP08 (female) (7)
replace
YES between PL2 and PL2 (female) (4)
1 - (female) (4) and Warning lamp body in contact
chassis ground? with chassis ground, or contad After inspec-
Does charging 3 of chassis ground with wiring tion, repair or
circuit abnormality _ . Disconnect DP08 NO harness between caution lamp replace
warning lamp light and PL2. and PL2 imale) (4)
up? = Turn starting
* Disconnect DP08. switch OFF.
- Defective center module Replace
* Turn starting NO
switch ON.
Starting switch
TWH00409
HD3256 20-937
0
P-26 Transmission filter clogging caution lamp does not work, or


TWH00404
* Before carrying out troubleshooting, check that all the con-

nectors related to the wiring harnesses between the modules
are properly inserted. Cause Remedy
to the next step.
See Trouble-
shooting P-12

After inspec-
tion, repair or
service code (female) (8) and PL2
2 replace
[A0131 or [AOl81? F (female) (5)
~ Is voltage between
DP08 (female) (8)
YES
and chassis ground Replace
NO normal?
~ Does transmis-
.20-30V
. Disconnect DP08 After inspec-
harness between DP08 tion, repair or
and PL2.
(female) (8) and PL2 replace
. Turn starting
switch ON. - Disconnect DP08. (female) (5)
(female) (8) and

* Connect PL2 (5) NC
. Turn starting switch and chassis ground.
ON.
*Turnstarting switch ON.
After inspec-
5 YES
replace
From jFH_ Disconnection in wiring
(female) (1) and fuse II- tion, repair or
*20-30V NO (12), or between fuse II- replace
(12) and starting switch
* Disconnect PL2.
ACC
* Turn starting
switch ON.
Starting switch
c IACC~
FIISF! box 11
Transmission
Monitor Panel filter clog ins
DP08 (04016)
i , 1
Transmission
II filter caution I i I
II TWH00410
20-938 HD325-6
0
P-27 Transmission filter clogging caution lamp stays lighted up

Remedy
After inspec-
tion, repair or
replace
ARer inspec-
tion, repair or
replace
Replace
Related electrical circuit diagram
Starting switch
Fuse box 11
Transmission
Monitor Panel -
filter clogs ins
r I lamp
I I
Transmission
DP08 (04Oi6)
L-3
(4)
II filter caution lamp)@+
I I TWH00410
HD325-6 20-939
0
P-28 Brake stroke caution lamp does not work, or monitor panel detects
Monitor panel disolay
service code
TWH00404
Sr Before carrying out troubleshooting, check that all the connectors related to the wiring harnesses
Cause Remedy
Ir Always connect any disconnected connectors before going on
to the next step.
YES See Trouble-

-
shooting P-12
1
After inspec-
tion, repair or
2 replace
[A0131 or [A0181? (female) (9)
DP08 (female) (9) _
YES
and chassis ground Defective center module Replace
NO 3 -
normal?
*20-30V Does brake stroke
- caution lamp Disconnection in wiring After inspec-
. Disconnect DP08
NO light up? 4YES harness between DP08
and PL2. tion, repair or
- Turn starting (female) (9) and PL2 replace
~ Does brake stroke (female) (9)
switch ON. * Disconnect DP08. L caution lamp
* Connect DP08 NO light up?
(female) (9) and GotoA
chassis ground. * Connect PL2 (9) NC
’ Turn starting switch and chassis ground,
ON. * Turn starting switch ON.
After inspec-
5 YES
replace
From 4=/P Disconnection in wiring
replace
- Disconnect PL2. (12) and starting switch
*Turn starting ACC
switch ON.

Starting swi tch
Brake I ine
Brake stroke
TWH00411
20-940 HD325-6
0
P-29 Brake stroke caution lamp stays lighted up

Cause Remedy

After inspec-
tion, repair or
and PL2 (female) (9) replace
I
Caution lamp body in
contact with chassis After inspec-
Does brake stroke ground, or contact of tion, repair or
Disconnect DP08 NO chassis ground with wiring replace
caution lamp
and PLZ. harness between caution
light up?
- Turn starting lamp and PL2 (male) (9)
.. I _rr
- Disconnect DPOS.
* Turn starting
switch ON.
Starting switch
Fuse box II
(RT2)
Monitor Panel
I I Brake stroke _
ml----
l ’ TWH004 I 1
HD3256 20-941
0
P-30 Preheating switch pilot lamp does not work, or monitor panel detects
service code
lWH00404
sr Before carrying out troubleshooting, check that all the connec-

properly inserted.
to the next step.
YES See Trouble-
-
shooting P-12
1
After inspec-
tion, repair or
(female) (I 1) and PLl
replace
(female) (2)
.20-30V
* Disconnect DP08 After inspec-
h
and PLI. tion, repair or
* Turn starting I replace
switch ON. - Disconnect DP08.
* Connect DP08
(female) (11) and I I I c,. +_*
I
chassis ground.
* Connect Pl
* Turn starting switch and chassil
ON. .T.,_.. _..._.:...
After inspec-
tion, repair or
Is voltage between replace
From A IPL2 (female) (1) II IDisconnection in wiring
h--^_- 5etween PLI
llcllI,czJJ I.
(female) (I’,, - rlyr

Dn7 (female)
(6) or R07 (femalt, .\ I=\ IuDs After inspec-
,+, - .G*..,
__ __ 147) or fuse 147) - JO7 - tion, repair or
* Disconnect PLI. NO battery relay or PLl replace
(female) (I) DO8 (female)
. Turn starting
(I) or DO8 (female) (2) LS
switch ON.
(female) (2)
I- I
Battery relay
R07
Fuse box 1
JUI (~~11
B Circuit breaker
dH---k n!
1 ,"""Ap LX-J
Rheostat
Diode
LS (M3)
/I/ I
L-l OUTH >@I- DO8
Monitor Panel Preheating

snitch lamp
DP08 (040 16)
(3>
TWH00412
20-942 HD325-6
0
P-31 Preheating switch pilot lamp stays lighted up

Cause Remedy
I

After inspec-
between DP08 (female) hon. repair or
(I 1) and PLl (female) (2)
YES between PLl
1 - (female) (2) and - Pilot lamp body in contact
chassis ground? with chassis ground, or After inspec-
Does preheating contact of chassis ground tion, repair or
switch pilot lamp _ - Disconnect DP08 NO with wiring harness between replace
light up? and PLI. pilot lamp and PLl (male) (21
* Turn starting
. Disconnect DP08. switch OFF.
- Turn starting NO
switch ON.
Marker lamp relay

I
Battery relay
R07
Fuse box I
fRT1)
Circuit breaker
Rheostat
-d_
Diode
GND
Monitor Panel Preheating

I 0 PLl (Sl 0) switch IamR
DPO8 (040 16) -3
Preheating (3
3
switch lamp
TWH00412
HD325-6 20-943
0
P-32 Tilt warning lamp does not work, or monitor panel detects
service code
TWH00404
* Before carrying out troubleshooting, check that all the connec-

Cause Remedy
properly inserted.
+ Always connect any disconnected connectors before going on
to the next step.
YES - See Trouble-
shooting P-12
1
After inspec-
tion, repair or
2 replace
[A0131 or IAOl81? p (female) (6)
DP08 (female) (13)
YES
and chassis Replace
3 Defective center module
NO ground normal?
*20-30V Does tilt warning Disconnection in wiring

* ~~dcroo~,ect DP08 NC lamp light up? - After inspec-
4 YES harness between DP08
tion, repair or
-Turn starting replace
* Disconnect DP08. Does tilt warning (female) (6)
switch ON.
. Connect DP08 lamp light up?
(female) (13) and NO
* Connect PL2 (6) NC
and chassis ground.
ON.
After inspec-
5 YES
Defective warning lamp tion, repair or
replace
Prom dEH_
Iisconnection in wiring
Ifemale) (7) and fuse II-(12), tion, repair or
*20-30V NO replace
or between fuse II-(12) and
* Disconnect PL2. starting switch ACC
* Turn starting
switch ON.

Starting switch
1 / B ~R/RIIR~~ c IACC~
OFF 0
Rlo-QO 0
Fuse box 11
(BT2)
Monitor Panel lolop
Tilt warning
DP08 (04016) PL2 Kilo)
I
I
I
I Ti it warning tarn,)@&
_
I amp
TWH00413
20-944 HD325-6
0
P-33 Tilt warning lamp stays lighted up

Cause Remedy

After inspec-
between DP08 (female) tion, repair or
(13) and PL2 (female) (6) replace
(female) (6) and Warning lamp body in contac

chassis ground?
L-
contact of chassis ground wit tion, repair or
Does tilt warning - Disconnect DP08 NO wiring harness between warn replace
lamp light up? and PLZ. ing lamp and PL2 (male1 (6)
-Turn starting
switch OFF.
- Disconnect DP08. Defective center module Replace
- Turn starting NO
switch ON.
Starting switch
Fuse box II
(BT2)
Monitor Panel
DP08 (04016)
I Tilt warning lam,)&
TWH00412
HD325-6 20-945
0
P-34 Body FLOAT (except FLOAT) pilot lamp does not work, or monitor panel

TWH00404
Ir Before carrying out troubleshooting, check that all the connec-

properly inserted. Remedy
Cause
to the next step.
YES - See Trouble-

shooting P-12
1
4fter inspec-
panel detect ES harness between DP08
tion, repair or
service code (female) (14) and PLI
2 replace
[A0131 or [A0181? ~ (female) (8)
DP08 (female) (14)
YES
and chassis Defective center module Replace
NO ground normal?
Does body FLOAT
*20-30V
* Disconnect DP08 After inspec-
F harness between DP08
and PLl. tion, repair or
- Turn starting (female) (8) replace
ON.
: ~ZZZG&‘F~
NqzG$‘otIamp H
GotoA
. Connect PLl (18) N(
ON. -Turn starting switch ON.
After inspec-
5 YES
Defective pilot lamp tion, repair or
replace
From jEH_
harness between PLI After inspec-
*20-30V NO or between fuse II-(12) and replace
. Disconnect PLl. starting switch ACC
* Turn starting
switch ON.

Starting switch
rJ%ypqy
Fuse box II
(BT2)
Monitor Panel
Body FLOAT
I 1 I
I TWH00414
20-946 HD325-6
0
P-35 Body FLOAT (except FLOAT) pilot lamp stays lighted up

Cause Remedy

(14) and PLl (female) (8) replace
(female) (8) and Pilot lamp body in contact

contact of chassis ground tion, repair or
FLOAT (other _ . Disconnect DP08 NO with wiring harness between replace
than FLOAT) Clot and PLl. pilot lamp and PLl (male) (8)
lamp light up’?
* Disconnect DP08. Replace
* Turn starting
switch ON.
Starting switch
Monitor Panel
I! 61V
Body FLOAT lamp

I
\,
I
TWH00414
HD325-6 20-947
0
P-36 Rear brake pilot lamp does not work, or monitor panel detects service
Honitor Panel diulu
code
TWH00404
Before carrying out troubleshooting, check that all the connec-

properly inserted.
to the next step.
- See Trouble-
shooting P-12
1
Does monitor :short circuit in wiring
After inspec-
panel detect YES tlarness between DP08
tion, repair or
service code 2
replace
[A0131 or [A0181? ~ (female) (7)
DP08 (female) (15)
YES
NO and chassis -I Defective center module Replace
3
ground normal?
*20-3ov Does rear brake

. Disconnect DPO8 - Pilot lamp fight - Iisconnection in wiring After inspec-
ND up? 4YE: Sf larness between DP08
and PLl. tion, repair or
. Turn starting (female) (15) and PLl replace
~ Does rear brake
switch ON. * Disconnect DP08. (female) (7)
- pilot lamp light -
* Connect DP08
(female) (15) and NO “‘7
chassis ground.
I 1 -_( ;otoA
* Connect PLl (7) k 0
ON.
*Turn starting switch ON
After inspec-
5 YES
-_[ lefective pilot lamp tion, repair or
CIisconnection in wiring replace
Prom (-HP rarness between PLl
I female) (1) R07 (female)
16) or R07 (female) (3) - fus
After inspec-
tion, repair or
NO I -(7) or fuse l-(7) JO7 -
*20-30V replace
t)attery relay or PLl
* Disconnect PLl. female) (1) - DO8 (female)
* Turn starting
switch ON.
I 1) or DO8 (female) (2) LS
(female) (2)
Battery relay
InI R07
Rheostat switch
DO8
Rear brake
Pilot lamp
DP08 (040 16)
\ I 13
\,‘/
I TWH00415
20-948 HD325-6
0
P-37 Rear brake pilot lamp stays lighted up

t Always connect any disconnected connectors before going on to the next step.
Remedy

After inspec-
(15) and PLl (female) (7)
YES between PLl
chassis ground? with chassis ground, or After inspec-
1 contact of chassis ground tion, repair or
* Disconnect DP08 NO with wiring harness between replace
pilot lamp light
pilot lamp and PLl (male) (7)
up?
L
- Disconnect DP08.
Iii Defective center module Replace
* Turn starting
switch ON.
Marker lamp relay
r-
Battery relay
lIzI A 1
R07
Fuse box I
Circuit breaker JO7 (BTl)
I I I
_To comblnatton
Rheostat switch
Diode
Monitor Panel Rear brake

I I Pilot lamp
(3
TWH00415
HD325-6 20-949
0
P-38 Parking brake pilot lamp does not work, or monitor panel detects
service code
TWH00404
Always connect any disconnected connectors before going on Cause Remedy
to the next step.
See Trouble-
-
shooting P-12

After inspec-
tion, repair or
2 . (female) (7) and PLl
replace
(female) (6)
Is voltaqe between
qeplace
After inspec-
H
tion, repair or
[female) (7) and PLI replace
Irking [female) (6)
lot lamp
?
chassis ground.
I I GotoA
. Connect PLl (6) Fz
* Turn starting switch and chassis gro,,nd,
ON.
*Turn starting switch ON.
Vter inspec-
5 YES -
Defective pilot lamp ion, repair or
.eplace
From dEH_
3isconnection in wiring
larness between PLl After inspec-
[female) (9) and fuse H-(12), tion, repair or
-2o-3ov NO x between fuse II- and replace
- Disconnect PLI. starting switch ACC
-Turn starting
switch ON.

Starting switch
Fuse box 11
MO
I
DP05 (04012) I I
20-950 HD3256
0
P-39 Parking brake pilot lamp stays lighted up

t Before carrying out troubleshooting, check that all the connectors related to the wiring harnesses
Cause Remedy

After inspec-
tion, repair or
between DP05 (female)
(7) and PLl (female) (6) replace
Pilot lamp body in contact

~-_ contact of chassis ground tion, repair or
with wiring harness between replace
pilot lamp and PLl (male) (6)
1 * Turn starting
- Disconnect DP05. switch OFF.-
- Turn starting NO
switch ON.
Starting switch
Fuse box 11
I St
L 1-1 (BT2)
Monitor Panel
I I
~~05 (040 i 2) I
Parking brake lamp
TWH00416
HD325-6 20-951
0
P-40 Maintenance caution lamp does not work, or monitor panel detects
service code
TWH00404
Always connect any disconnected connectors before going on Cause Remedy
to the next step.
YES See Trbuble-

-
shooting P-55
Does monitor
1 I Short circuit in wiring
After inspec-
tion, repair or
service code (female) (8) and PLS
2 replace
[A0131 or [A0181? ~ (female) (2)
p Is voltage between
L DP05 (female) (8) _
YES
and chassis Defective center module Replace
NO ground normal7
Does maintenance
Disconnection in wiring After inspec-
4YES harness between DP05
tion, repair or
(female) (8) and PLS
Does maintenance (female) (2)
switch ON. * Disconnect DP05.
caution lamp light
* Connect DP05

- ConnectPLS (2) NO
* Turn starting switch and chassis ground,
ON.
After inspec-
5 YES
replace
Prom j-H_ Disconnection in wiring
harness between PLS After inspec-
(female) (I) and fuse II- tion, repair or
.20-30V NO (12). or between fuse II-
replace
- Disconnect PLS. (12) and starting switch
. Turn starting ACC
switch ON.

Starting switch
rJqKppj
Fuse box 11
Maintenance
caution lamp
TWH00417
20-952 HD325-6
0
P-41 Maintenance caution lamp stays lighted up

Short circuit with chassis After inspec_

tion, repair or
Is there continuity between DP05 (female)
(8) and PLS (female) (2) replace
YES between PLS
1 (female) (2) and - Caution lamp body in
chassis ground? contact with chassis After inspec-
Does main- ground, or contact of tion, repair or
tenance caution _ - Disconnect DP05 NO chassis ground with wiring replace
lamp light up? and PLS. harness between caution
* Turn starting lamp and PLS (male) (21
* Turn starting Defective center module Replace
NO
switch ON.
Starting switch
ACC O--o 0
Fuse box II
St0U-UU~ (BT2)
I\
Monitor Panel
I I
Y (M4) Maintenance
caution laml
I , DP05 (04012) II,
\ -I
I I Mainte-----
rrr,<t i<
HD325-6 20-953
0
P-42 Steering oil temperature caution lamp does not work, or monitor panel

TWH00404
Cause Remedy
YES - See Trouble-

shooting P-12
1
4fter inspec-
:ion, repair or
service code (female) (9) and PLS
2 .eplace
[A0131 or IA0181? ~ (female) (3)
_ DP05 (female) (9) _
YES
NO and chassis Defective center module Replace
ground normal?
~ Does steering oil
*20-30V
IDisconnection in wiring After inspec-
s Iharness between DP05 tion, repair or
,[female) (9) and PLS
*Turn starting ,[female) (3)
replace
switch ON. * Disconnect DP05.
* Connect DP05 caution lamp light
I GotoA
chassis ground. - Connect PLS (3)
* Turn starting switch and chassis groundy
ON. * Turn starting switch ON
After inspec-
5 YES
Defective warning lamp hon. repair or
replace
Prom (El_ Disconnection in wiring
harness between PLS
After inspec-
(female) (1) and fuse II-
tion, repair or
replace
* Disconnect PLS. (12) and starting switch
. Turn starting ACC
switch ON.

Starting switch -
1 13lBRlRlIR21C IACC
n--'-I '
Fuse box 11
(BT2)
Monitor panel Steering oil
temperature lamp
Steering oil
temperature lamp
I TWH00418
20-954 HD325-6
0
P-43 Steering oil temperature caution lamp stays lighted up

I Cause I Remedy
it with chassis
viring harness After inspec-
_..__.. 105 (female) tion, repair or
and PLS (female) (31 reolace
ution lamp body in
ntact with chassis After inspec-
Does steering oil 1ChaSS’! xmd, or contact of
tion, repair or
temperature _ - Disconnect DP05 NO chassis ground with wiring
harness between caution replace
caution lamp and PLS.
lamp and PLS (male) (3)
light up? * Turn starting
- Disconnect DP05. switch OFF.
- Turn starting NO
switch ON.
Starting switch
Fuse box 11
Monitor Panel Steering oil

temperature lamp
TWH00418
HD325-6 20-955
0
P-44 Differential lock pilot lamp does not work, or monitor panel detects
Honilar Panel display
service code
TWH00404
Cause Remedy
YES See Trouble-

-
jhooting P-12
1
panel detect YES After inspec-
service code tion, repair or
2 (female) (10) and PLS
IA0131 or [A0181? _ replace
(female) (4)
_ DP05 (female) (10) _
YES
NO and chassis
3 Idefective center module qeplace
ground normal?
.20-30V Does differential

* Disconnect DP05 NG lock pilot
light up7 lamp [Iisconnection in wiring
-r, ifter inspec-
4YES larness between DP05
and PLS.
- Turn starting
. Disconnect DP05. Does differential
1female) (IO) and PLS
(female) (4)
ion, repair or
eplace
switch ON.
. Connect DPO5 lock pilot lamp
(female) (10) and NO light up?
chassis ground. -I -C So to A
* Turn starting switch * Connect PLS (3) NO ,
and chassis ground.
ON.
*Turn starting switch ON.
5 YES Uter inspec-
- [Iefective warning lamp ion, repair or
eplace
From AjFH- [Iisconnection in wiring
tjarness between PLS
Uter inspec-
_ (female) (1) and fuse II-
ion, repair or
.20-30V NO ( 12), or between fuse II-
,eplace
* Disconnect PLS. ( 12) and starting switch
*Turn starting I 4cc
switch ON.

Starting switch
Fuse box 11
(BT2)
Monitor panel Differential
I I
Y
I PILS ;M4,'
lock Pilot lamp
DP05 (04012) I J LD
Differential
m-3
lock Pilot lamp
I I TWH00419
20-956 HD325-6
0
P-45 Differential lock pilot lamp stays lighted up

Cause Remedy
Short circuit with chassis After inspec_

(IO) and PLS (female) (4)
YES between PLS
- chassis ground? with chassis ground, or After inspec-
Does differential contact of chassis ground tion, repair or
lock pilot lamp -
- Disconnect DP05 NO with wiring harness between replace
and PLS. pilot lamp and PLS (male) 14)
light up?
- Turn starting
_ Defective center module Replace
-Turn starting NO
switch ON.
Startins switch-
TWH00419
HD3256 20-957
0
P-46 High beam display does not light up

-f Before carrying out troubleshooting, check that all the connectors related to the wiring harnesses
Cause Remedy
YES - Isee Trouble-

rhooting P-l
1
Is voltage After inspec-
between DPll _ YES
harness between DPI 1 tion, clean or
(14) and chassis 2 replace
(female) (14) and R06
ground normal?
~ Does Hi beam of (female) (8)
- Turn starting left and right
switch ON. YES
NO head lamps light So to A
3
* High beam switch up?
ON: ~ Is voltage between
20 - 30 v * Turn Hi beam R06 (female) (3) Defective contact or
switch ON. NO and chassis disconnection in wiring After inspec-
* High beam switch 4 YEI
OFF: * Turn starting ground normal? harness between R06 tion, clean or
switch ON. - Is voltage (female) (3) and CM replace
Max. 1 V
*20-30V between CM (2) (female) (2)
- Turn starting and chassis Defective contact or discon-
switch ON. nection in wiring harness After inspec-
NO ground normal?
* Remove head lamp between CM (male) (2) and tion, clean or
(Hi) relay. *20-30V NC combination switch, or
* Disconnect R06. *Turn starting switch defective combination switch
*Turn Hi beam ON.
switch ON. *Turn Hi beam switch
Defective head lamp (Hi)
ON. relay, or defective contact or
After inspec-
6 YES disconnection in wiring
harness between DPll tion, clean or
(female) (14) and R06
YES between R06 (female) (8) or JO3 (7)
(female) (2) and
Defective contact or After inspec-
chassis ground?
disconnection in wiring tion, clean or
5-- harness between R06 ifernallel
~ * Remove head lamp NO replace
Is voltage between (2) and chassis ground
(Hi) relay.
From * ~06 (female) (1) _ . Turn starting switch OFF.
and chassis * Disconnect R06.
ground normal?
Defective contact or discor After inspec-
nection in wiring harness
tion, clean or
between R06 (female) (1)
replace
and CM (female) (6)
Defective contact or discon-
nection in wiring harness After inspec-
between CM (male1(6) and tion, clean or
*Turn Hi beam -20 30 v NO combinationswitch,or replace
switch ON. * Turn starting switch defectivecombinationswitch
ON.
* Turn Hi beam switch ON.
20-958 HD325-6
0
Head lamp
relay (Hi)
I
Combination
Monitor Panel
Inside cab
HD325-6 20-959
0
P-47 Turn signal lamp (right) does not light up

between the modules are properly inset-ted.
Remedy
I 2, ,YES - See Trouble-

shooting P-l
Is resistance be-
YES tween DPll ifemale)
1 (15) and chassis
~ ground normal? disconnection in wiring After inspec-
Do front and rear ~ ~ harness between DPll tion, clean or
turn signal lamps - ’ Max. 5 R NO (female) (15) and R09 replace
work properly? * Turn starting switch OFF. (female) (3)
* Disconnect DPll.
See Trouble-
* Actuate turn . Ground R09 (female) (3) to chassis. - shooting for
signal lamp. NO turn signal Ial
- Turn starting
switch ON.
Combination
Right turn
Left turn
Hazard lamp
TWH00421
20-960 HD325-6
0
P-48 Turn signal lamp (left) does not light up

Cause Remedy
2 YES See Trouble-

shooting P-l
YES Is resiStanCe be-
tween DPll (female1
1 (16) and chassis Defective contact or
- ground normal? disconnection in wiring After inspec-
Do front and rear p - harness between DPI 1 tion, clean or
turn signal lamps - ’ Max. 5 R NO (female) (16) and R09 replace
*Turn starting switch OFF.
work properly? (female) (I)
* Disconnect DPI 1.
~ * Ground R09 (female) II) to chassis. See Trouble-
* Actuate turn - shooting for
signal lamp. NO turn signal Iam1
- Turn starting
switch ON.

Monitor Panel Combination
switch
DPll (04068) CM 68)
Right turn .a
Left turn -m
Hazard lamp
.^I^., D3Q
ICldl
‘lLJ To hazar d
I ,I_L
I I ’ -‘SW’LC” L-II
-_-_-
Left
signal
turn
lamp
CN-10
_
Riaht . turn
._
CN-35 signal lamp
Inside cab i Outside cab
TWH0042 1
HD325-6 20-96 1
0
P-49 Lamp check switch does not work

Cause Remedy
YES - See Trouble-

shooting P-54
1
---I
Is there continuity
between DPI 1 After inspec-
harness between DPII
(female) (3) and tion, repair or
(female) (3) and CKl
chassis ground? replace
(female) (1)
- Turn starting
switch OFF.
Defective lamp bulb
- Disconnect DPl l.N check switch
Replace
-Turn lamp bulb
check switch ON.
. Turn lamp bulb ._- chassis ground? harness between CKI tion, repair or
check switch ON. - Turn starting (female) (2) and chassis replace
switch OFF. ground
- Disconnect CKl.
Monitor Panel
1 I CKl
DPll (04Oi6) (KES~ 2)
Caution &
@ 3 4b Bu I b check
Pilot switch
swi tch
3 6
TWH00422
20-962 HD325-6
0
P-50 Exhaust brake switch does not work

Cause Remedy
- See Trouble-
shooting P-54
Is there continuity; ‘_
YES Iisconnection in wiring
After inspec-
ES larness between DPll
tion, repair or
female) (5) and EXH
replace
female) (2)
4 YE:
lr
Defective exhaust brake
iwitch Replace
Is there continuity
brake switch ON. *Turn starting
switch OFF. Iisconnection in wiring
After inspec-
-Turn exhaust larness between EXH
tion, repair or
brake switch ON. -Turn starting NO female) (4) and chassis
replace
switch OFF. ground
- Disconnect EXH.
See Trouble-
shooting P-13
Monitor Panel
Exhaust
brake switch
TWH00423
HD325-6 20-963
0
P-51 Mode change switch (1) does not work

Cause Remedy
YES See Trouble-

-
shooting P-54
1
Is there continuity Disconnection in wiring After inspec-
between DPll _ YES
harness between DPI 1 tion, repair or
(female) (6) and 2 (female) (6) and MS1 1 replace
chassis ground?
~ Is there continuity
-Turn starting _ between MS11 _
switch OFF. NO and chassis 3 YES Defective mode change
Replace
- Disconnect DPll. ground? Is there continuity switch (1)
- Turn mode change Turn _ between MS12
switch (I) ON. switch OFF. NO and chassis
- Turn mode change ground?
harness between MS12 tion, repair or
switch (1) ON. * Turn starting NO replace
and chassis ground
switch OFF.
* Disconnect MS11
and MS12.
Monitor Panel
DPll (04Oi6)
Mode change MS11
switch (1) Mode change
switch (1)
MS12
TWH00424
20-964 HD325-6
0
P-52 Mode change switch (2) does not work

-l
I Cause Remedy
YES - See Trouble-

shooting P-54
1
Is there continuity Disconnection in wiring After inspec-
between DPI 1 _ YES
harness between DPI 1 ion, repair or
(female) (7) and 21
I
(female) (7) and MS21 ‘eplace
chassis ground?
Defective mode change

qeplace
switch (2)
Disconnection in wiring Vter inspec-

harness between MS22 ion, repair or
h (2) ON. * Turn starting and chassis ground .eplace
switch OFF.
* Disconnect MS21
and MS22.
Mode change
swi t ch (2)
TWH00425
HD3256 20-965
0
P-53 KPH/MPH speedometer unit selector does not work

Cause Remedy
YES - See Trouble-

shooting P-54
After inspec-
between DPI 1 YES rarness between DPI 1
tion, repair or
(female) (8) and female) (8) and CNP15
replace
female) 11)
Is there continuity; 1
* Turn starting L between CNP15 _
switch OFF. NO (1) and chassis 3 YES lefective MPH selection
Replace
- Disconnect DPI 1. ground? Is there continuity onnector
* Install MPH - Turn starting between CNP15
selection connector. NO (female) (2) and Gsconnection in wiring
switch OFF. After inspec-
- Install MPH chassis ground? larness between CNP15
tion, repair or
selection connector. . Turn starting NO female) (2) and DP05
replace
switch OFF. female) (12)
* Disconnect CNP15.
Monitor Panel
1
DPll (04016) P15 (M2)
KPH/MPH change MPH

select ion
I connector
DP05 (04012)
(Connected for MPH dis Play)
TWH00426
20-966 HD325-6
0
P-54 Defective operation of all switch inputs

Cause Remedy
2 YES
YESI l-
1 YES
lgj$qG+f3
Defective LH module Replace
1
1
f
wiring harnesses
between modules
- Lamp bulb check NO and chassis
tl 4 YE:
normal? (Check A- Defective LH module Replace
9, A-10, B-8, B-9, C switch ON: Varies
10, C-11, C-18, C- between 0.05 and * Turn starting
19, C-25, C-26, C- 0.11 v switch ON. ~1 ~ju~~~~a,7 1,
31, C-32, C-36, C- * Lamp bulb check * Fixed at max. 1 V
37, c-40, c-41, c- switch OFF: Varies Defective center module Replace
or min. 4.8 regard- * Turn startina NO
43, c-44, c-45, c- between 0.18 and less of whether switch ON.-
0.30 v lamp bulb check - Disconnect DPlO. Defective wiring harness
- See Item P-l switch is ON or OFF. . Min. 4.8 V After inspec-
between modules where
tion, repair or
hIO there is improper
replace
continuity
1- Fa& II -

TWH00392
HD325-6 20-967
0
Monitor Panel dlsrlav Monitor Panel display
P-55 Monitor panel detects service codes or

TWH00427 TWH00428
Cause Remedy
YES
-1 Defective PMC Replace
check on network
wiring harnesses in
Table 1 normal? I:Xsconnection in wiring After inspec-
-t tarness where there is tion, repair or
NO
ilmproper continuity replace
For details of
controller cor- * Disconnect DP05
adjusting, see
TESTING AND
ADJUSTING,
[:Defective model selection SETTING ROTAR
c)f shift controller SWITCH (MODEL
NO DATA, NETWORk
DATA) WHEN
REPLACING
TRANSMISSION
CONTROLLER.
Table 1
1 No. 1Monitor panel end 1 PMCend 1 Judgment I

1 1 1 DP05 (female) (3) 1PMC5 (female) (1) 1 Continuitv = Normal 1
2 DP05 (female) (4) PMC5 (female) (2) Continuity = Normal
3 DP05 (female) (5) PMC5 (female) (3) Continuity = Normal
4 DP05 (female) (3) PMC5 (female) (3) No continuity = Normal
5 DP05 (female) (4) PMC5 (female) (3) No continuity = Normal
TMD ISI 61 AT’24 (04012)
I I TWH00429
20-968 HD325-6
0
Moniior Panel display
P-56 Monitor panel detects service code

TWH00430
Cause Remedy
YES Defective engine

Replace
controller
wiring harnesses in
Table 1 normal? Disconnection in wiring After inspec-
harness where there is tion, repair or
Is model selec- - Turn starting NO replace
improper continuity
switch OFF.
For details of
controller cor- - Disconnect DP05
adjusting, see
and EC4.
TESTING AND
ADJUSTING,
Defective model selection SETTING ROTAA

SWITCH (MODEL
NO of shift controller
DATA, NETWORI
DATA) WHEN
REPLACING
TRANSMISSION
CONTROLLER.
Table 1
Engine
NO. Monitor panel end Judgment
controller end
1 ; 1DP05(female)C3) 1 EC4Wmald6) 1 Cb;~;Zb~~~i_;]

DP05 (female) (4) EC4 (female) (12)
DP05 (female) 6) EC4 (female) (10)
DP05 (female) (3) EC4 (female) (10) No continuity = Normal
DP05 (female) (4) EC4 (female) (10) No continuity = Normal
Ymitlr rrnc,
1
OPO5 ~04012)
TWH00429
HD325-6 20-969
0
TROUBLESHOOTING P-57,58,59
Hanitor ml display

TWH00431
t The monitor panel saves trouble data for problems detected as [A0131, fA0141, [A0151, W0161, IA0181,
or [A0191 together as service code [A01 11.
or If [A013], [A014], [A0151, IA0161, [A0181, or IA0191 are currently being detected, carry out repairs
according to the respective troubleshooting.
*_ If [A013], [A014], [A0151, [A0161, [A0181, or (A0191 are not currently being detected, the system has
been reset so the condition is normal.
Monitor meI display

TWH00432
Cause Remedy
’ Defective center module Replace
DATA) WHEN
REPLACING
TRANSMISSION
CONTROLLER.
llonitor Panel display

TWH00433
The monitor panel saves trouble data for problems detected as [AOOII, fA0021, or IA0031 together as
failure code [AOOOI.
If [AOOI], [A002], or [A0031 are currently being detected, carry out repairs according to the respective
troubleshooting.
If [AOOI], [A002], or [A0031 are not currently being detected, the system has been reset so the condi-
tion is normal.
20-970 HD325-6
0
TROUBLESHOOTING OF ABS/ASR SYSTEM
(OW
Troubleshooting flowchart ................................................................................................................... 20-I 002

For machines with ABS installed independently ......................................................................... 20-1002
For machines with ABS/ASR installed .......................................................................................... 20-1003
Method of deleting ECU trouble data from memory ......................................................................... 20-1004
Procedure for deleting trouble data from memory ..................................................................... 20-1004
Method of troubleshooting using self-diagnostic function of ECU .................................................. 20-I 005
INDEX (troubleshooting code) ....................................................................................................... 20-1006
System check sheet for using system checker ................................................................................... 20-1008
Troubleshooting
W-l Warning lamp does not light up.. ................................................................................... 20-1016
l-l ASR information switch does not go out ...................................................................... 20-1017
ASR-1 Failure in ASR control valve (only machines with ABS/ASR installed). ...................... 20-1018
ASR-2 ........................................................................................................................................... 20-1019
ABS-1 Failure inside ECU ............................................................................................................ 20-I 020
ABS-2 Failure in front right pressure control valve.. ............................................................... .20-1021
ABS-3 Failure in front left pressure control valve .................................................................... 20-I 022
ABS4 Failure in rear left pressure control valve.. ................................................................... .20-1023
ABS-5 Failure in rear right pressure control valve ................................................................... 20-1024
ABS-6 Failure in front right wheel speed sensor.. .................................................................... 20-1025
ABS-10 Abnormality in front right wheel speed sensor output.. .............................................. 20-I 025
ABS-7 Failure in front left wheel speed sensor ........................................................................ 20-1026
ABS-11 Abnormality in front left wheel speed sensor output.. ................................................. 20-1026
ABS-8 Failure in rear left wheel speed sensor.. ........................................................................ 20-1027
ABS-12 Abnormality in rear left wheel speed sensor output.. ................................................. .20-1027
ABS-9 Failure in rear right wheel speed sensor ....................................................................... 20-1028
ABS-13 Abnormality in rear right wheel speed sensor output ................................................. 20-1028
ABS-14 Failure in valve relay (VR2) ............................................................................................. 20-1029
ABS-15 Failure in valve relay (VRI) ............................................................................................. 20-1030
ABS-16 Failure in valve relay (VR2) ............................................................................................. 20-I 031
ABS-14Failure in valve relay (VRI) ............................................................................................. 20-I 032
ABS-18 Abnormality in power source voltage ........................................................................... 20-1033
HD325-6 20-1001
0
TROUBLESHOOTING ROUBLESHOOTING FLOWCHART
TROUBLESHOOTING FLOWCHART
When carrying out troubleshooting, use the flowchart in Fig. 1 or Fig. 2.
<For machines with ABS installed independently>
Starting switch
Repair * 4
ON + LOCK
t I
Check for blown

bulb in warning
lamp [check for Does not light up
disconnection, -
short circuit in
wiring between
lamp and ECU1
See troubleshooting
code W-l
Start machine, accelerate

to travel speed of at least
10 km/h Troubleshooting
I Carry out
troubleshooting
Normal
Delete trouble data from
IFor details, see Method

of deleting trouble data
Check completed
Fig. 1 Troubleshooting flowchart for machines with ABS installed independently
20- 1002 HD3256

0
TROUBLESHOOTING ROUBLESHOOTING FLOWCHART
<For machines with ABS/ASR installedz- Start troubleshooting
I
ABS/ASR main switch
ON
I I
Starting switch
Repair
ON + LOCK
I I I
A
short circuit in
blown bulb in
Repair
A
Lights up + goes out
See
troubleshooting
code INDEX W-l I-1
Troubleshooting
t Does not light up
Carry out
troubleshooting
t A
1 Lights up I
Start machine,
accelerate to travel
speed of at least 10
Goes out
Normal
Delete trouble data from
memory
[For details, see Method
of deleting trouble data
from memory1
Fig. 2 Troubleshooting flowchart for machines with ABS/ASR installed
HD325-6 20-1003
0
TROUBLESHOOTING METHOD OF DELETING ECU TROUBLE DATA FROM MEMORY
METHOD OF DELETING ECU TROUBLE DATA FROM MEMORY

To delete the trouble data, follow the procedure given in the timing chart for deleting trouble data from
memory (Fig. 3).
ON
Starting switch and
AEWASR main switch
t Min. 3 set --f
Troubleshooting
switch
Fig. 3 Timing chart for deleting trouble data from memory
*Procedure for deleting trouble data from memory>

(1) Check that the ABS/ASR main switch and starting switch are OFF, then turn the troubleshooting
switch ON.
(2) Turn the starting switch and ABS/ASR main switch ON (either switch can be turned on first). There is
no need to start the engine.
(3) Keep in this condition for at least 3 seconds, then turn the troubleshooting switch OFF.
(4) Turn the ABS/ASR main switch and starting switch OFF.
(5) Carry outthe troubleshooting operation again and check that the number of flashes indicates that the
system is normal.
(6) If the number of flashes indicates that the system is normal, the machine can be used as normal.
However, before starting to use the machine, check that the troubleshooting switch is OFF and that
the troubleshooting lamp is also OFF.
(7) If the number of flashes in the No. 1 block (see Fig. 4) is not 2 (machines with ABS installed indepen-
dently) or 4 (machines with ABWASR installed), check that the pressure controls valves and ASR
control valves for each wheel are correctly wired, then delete the data from memory again.
20-1004 HD3256
0
METHOD OF TROUBLESHOOTING USING
TROUBLESHOOTING SELF-DIAGNOSTIC FUNCTION OF ECU
METHOD OF TROUBLESHOOTING USING SELF-DIAGNOSTIC

FUNCTION OF ECU
(1) Stop the machine at a safe place, apply the parking brake, and stop the engine.
(2) Check that the troubleshooting switch is OFF, then turn the ABS/ASR main switch ON.
(3) Turn the starting switch ON. There is no need to start the engine.
(4) Turn the troubleshooting switch ON for at least 1 second, then turn it OFF again.
(5) When the troubleshooting switch is turned OFF, the troubleshooting lamp will flash, so count the
number of flashes as shown in the procedure in Fig. 4. If you fail to count the number of flashes,
wait for the flashing of the troubleshooting lamp to stop, then repeat the procedure for Step (4) to
start the flashing again.
(6) After completing the counting of the number of flashes, turn the ABS/ASR main switch and starting
switch OFF.
(7) Use the number of flashes to judge the location of the failure from Tables 1 and 2, check the appli-
cable place with the INDEX (troubleshooting code), then carry out repairs.
(8) After completing repairs, check that the troubleshooting switch is OFF, then turn the ABS/ASR main
switch ON.
(9) Drive the machine at a speed of less than 10 km/h and check that the warning lamps go OFF.
(10) After checking that the warning lamps go OFF, stop the machine again and apply the parking brake.
If the warning lamps do not go out, there is still some failure, so repeat Steps (1) - (7) above to carry
out troubleshooting again.
(11) After the warning lamps go OFF, delete the data according the method of deleting the trouble data
of ECU, and then check that the number of flashing times of the troubleshooting lamp indicates that
the system is normal. If the system is normal, it can be used for ordinary purpose.
Fig. 4 Flashing interval for troubleshooting lamp
Note 1 : Flashes 2 times when ABS is installed independently

Flashes 4 times when ABS/ASR is installed
Note 2 : 2nd block: Indicates a failure mode in the left front or right rear system.
• When normal: Flashes 1 time.
• When abnormal: Flashes by the number of times corresponding to the failure mode.
Note 3 : 3rd block: Indicates a failure mode in the right front or left rear system.
• When normal: Flashes 1 time.
• When abnormal: Flashes by the number of times corresponding to the failure mode.
HD325-6 20-1005
C
INDEX (troubleshooting code)

• Machines with ABS installed independently
Number of flashing times INDEX
Failure mode
1st block 2nd block 3rd block (Troubleshooting code)
2 1 1 System is normal
2 9 9 Source voltage system ABS – 18

Failure mode
2 2 fl Controller system ABS – 1
2 10 fl Left front ABS valve system ABS – 3
2 11 fl Right rear ABS valve system ABS – 5
2 6 fl Left front wheel speed sensor system ABS – 7
2 7 fl Right rear wheel speed sensor system ABS – 9
2 3 fl Left front wheel speed sensor output system ABS – 11
2 4 fl Right rear wheel speed sensor output system ABS – 13
2 9 fl Valve relay 1 system ABS – 15

Failure mode
2 fl 2 Controller system ABS – 1
2 fl 10 Right front ABS valve system ABS – 2
2 fl 11 Left rear ABS valve system ABS – 4
2 fl 6 Right front wheel speed sensor system ABS – 6
2 fl 7 Left rear wheel speed sensor system ABS – 8
2 fl 3 Right front wheel speed sensor output system ABS – 10
2 fl 4 Left rear wheel speed sensor output system ABS – 12
2 fl 9 Valve relay 2 system ABS – 14
In the columns marked with fl, “1” is displayed when normal and “Failure mode in each block” is dis-
played when abnormal.
(Explanation 1) When only the “left front ABS valve system” has a failure (The right front and left rear
systems are normal).
Number of flashing times
1st block 2nd block 3rd block
2 10 1
(Explanation 2) When the “left front ABS valve system” and the “right front wheel speed sensor system”
have failures simultaneously.
2 10 6
(Explanation 3) When only the “source voltage system” has a failure or when the “valve relay 1 system”
and “valve relay 2 system” have failures simultaneously.
2 9 9
20-1006 HD325-6
C
• Machines with ABS/ASR installed

Failure mode
4 1 1 System is normal
4 9 9 Source voltage system ABS – 18

Failure mode
4 2 fl Controller system ABS – 1
4 10 fl Left front ABS valve system ABS – 3
4 11 fl Right rear ABS valve system ABS – 5
4 6 fl Left front wheel speed sensor system ABS – 7
4 7 fl Right rear wheel speed sensor system ABS – 9
4 3 fl Left front wheel speed sensor output system ABS – 11
4 4 fl Right rear wheel speed sensor output system ABS – 13
4 14 fl ASR valve system ASR – 1

Failure mode
4 fl 2 Controller system ABS – 1
4 fl 10 Right front ABS valve system ABS – 2
4 fl 11 Left rear ABS valve system ABS – 4
4 fl 6 Right front wheel speed sensor system ABS – 6
4 fl 7 Left rear wheel speed sensor system ABS – 8
4 fl 3 Right front wheel speed sensor output system ABS – 10
4 fl 4 Left rear wheel speed sensor output system ABS – 12
4 fl 14 ASR valve system ASR – 1
In the columns marked with fl, “1” is displayed when normal and “Failure mode in each block” is dis-
played when abnormal.
(Explanation 1) When only the “left front ABS valve system” has a failure (The right front and left rear
systems are normal).
4 10 1
(Explanation 2) When the “left front ABS valve system” and the “right front wheel speed sensor system”
have failures simultaneously.
4 10 6
(Explanation 3) When only the “source voltage system” has a failure or when the “valve relay 1 system”
and “valve relay 2 system” have failures simultaneously.
4 9 9
HD325-6 20-1007
C
TROUBLESHOOTING SYSTEM CHECK SHEET FOR USING SYSTEM CHECKER
SYSTEM CHECK SHEET FOR USING SYSTEM CHECKER

Order of Terminal for System checker, brake operation
Order of inspection connecting system
inspection required for inspection
checker for tester
1 Controller ground A c@+Chassis
2 Controller power source
Actuate power relay

3 Relay resistance Rlt@-+R2
Press check switch RI (Note 2)
Actuate power relay

4 Power relay 1
Press check switch RI
Actuate power relay

5 Power relay 2
Press check switch R2
Actuate power relay

6 Warning lamp control
Press check switches RI and R2 at same time
Connect A terminal and terminal D2 of

7 ASR information lamp D2t Lead +$,
checker with tester lead wire
8 Warning lamp line Dl+t@ L
9 ASR engine control terminal DF + +@I+ E3
10 Wheel speed sensor resistance

IL Front left wheel DF+t@+DF- Press wheel selector switch 1L
IR Front right wheel DF+t@-+DF- Press wheel selector switch 1R
2L Rear left wheel DF+t@+DF- Press wheel selector switch 2L
2R Rear right wheel DF+t@+DF- Press wheel selector switch 2R
Wheel speed sensor

11 insulation resistance
IL Front left wheel Press wheel selector switch 1L
1R Front right wheel Press wheel selector switch 1R
2L Rear left wheel DF-+-@+A Press wheel selector switch 2L
2R Rear right wheel DF-+@+A Press wheel selector switch 2R
dote 1 : lurn the startlng switch U-l- also when measuring. Alter measuring, turn it ON and carry out the
next inspection.
Note 2 : Remove fuse 2 before carrying out inspection. After the inspection, return it to the correct position.
20-1008 HD3256
0
Key for “Terminal for connecting system checker for tester” column
@ Measure resistance @ Measure DC voltage Lead: Connected with lead wire
260 - 360 Q
ABS-10
OFF 950 - 1450 n
ABS8
2L
ABS-12
ABS-9
2R
ABS-13
ABS-7
IL
ABS-11
ABS-6
IR
ABS-10
OFF >3ow
ABS-8
2L
ABS-12
ABS-9
2R
ABS-13
HD325-6 20- 1009

0

checker for tester
3esistance inside pressure
12 Iold valve
IL Front left wheel EV+-@-t?s, Press wheel selector switch 1L
IR Front right wheel EV+@+zl, Press wheel selector switch IR
2L Rear left wheel EVt@+-tC, Press wheel selector switch 2L
2R Rear right wheel Press wheel selector switch 2R
Resistance inside pressure

13 exhaust valve
IL Front left wheel Press wheel selector switch 1L
IR Front right wheel Press wheel selector switch 1R
2L Rear left wheel AV+@+zl, Press wheel selector switch 2L
1. Press wheel selector switch IL

Control valve function 2. Press valve actuation check switch EV
(Note 3) (Note 4)
3. Depress brake pedal fully.
Front left wheel pressure
hold function 4. Return valve actuation check switch
EV.
5. Continue to depress brake pedal.
6. Press valve actuation check switch AV
Front left wheel pressure (Note 4)
exhaust function 7. Return valve actuation check switch AV
8. Release brake pedal.
14
1. Press wheel selector switch 1R

2. Press valve actuation check switch EV
Front right wheel pressure (Note 4)
hold function 3. Depress brake pedal fully.
4. Return valve actuation check switch
EV.
6. Press valve actuation evaluation
switch AV (Note 4)
Front right wheel pressure
7. Return valve actuation check switch
exhaust function
AV
Note 3 : When inspecting the control valve function, jack up the wheel to be inspected.
Note 4 : The actuation time for each hold or exhaust valve (time of operating EV or AV switch) should
be a maximum of 4 seconds each time. Operating for longer than this may cause damage to
the coil inside the control valve.
20-1010 HD3256
0
ABSJASR main Actual mea-

Specified value
switch
OFF
14-21Q
OFF
l Front left wheel rotates freely
ABS-3
l Brake is applied to front left wheel
l Front left wheel rotates freely

ON
l Front right wheel rotates freely
ABS-2
l Brake is applied to front right wheel
l Front right wheel rotates freely
HD325-6 20-1011
0

checker for tester
1. Press wheel selector switch 2L

Control valve function
(Note 4)
(Note 3)
3. Depress brake pedal fully.
Rear left wheel pressure 4. Return valve actuation check switch
hold function EV.
6. Press valve actuation check switch AV
(Note 4)
Rear left wheel pressure 7. Return valve actuation check switch
exhaust function AV
15
1. Press wheel selector switch 2R

(Note 4)
Rear right wheel pressure 3. Depress brake pedal fully.
hold function 4. Return valve actuation check switch
EV.
6. Press valve actuation evaluation
switch AV (Note 4)
Rear right wheel pressure 7. Return valve actuation check switch
exhaust function AV
Wheel speed sensor

16
function (Note 5)
IL Front left wheel Assemble system

Press wheel selector switch 1L
checker
Front right wheel Assemble system

IR Press wheel selector switch 1R
checker
2L Rear left wheel Assemble system Press wheel selector switch 2L

checker
Assemble system
checker
dote 3 : When inspecting the control valve function, jack up the wheel to be inspected.
Jote 4 : The actuation time for each hold or exhaust valve (time of operating EV or AV switch) should
be a maximum of 4 seconds each time. Operating for longer than this may cause damage to
the coil inside the control valve.
Note 5 : When inspecting the wheel speed sensor function, jack up the wheel to be inspected in the
same way as when inspecting the control valve function.
During the inspection, when inspecting the left (right) wheel, never rotate the right (left)
wheel at the same time.
Rotate the wheel at a constant speed as far as possible. Rotate so that the wheel speed
sensor output check LED UDF (assembled in the system checker) lights up (it must not flash),
and read the value indicated on the meter at that point.
20-1012 HD325-6
0
ABSIASR main Actual mea-

Specified va’lue Pass/fail INDEX
switch sured value
l Rear left wheel rotates freely
ABS-4
l Brake is applied to rear left wheel
l Rear left wheel rotates freely
ON
l Rear right wheel rotates freely
ABS-5
l Brake is applied to rear right wheel
l Rear right wheel rotates freely
IL ABS-7
ABS-11
> 10 ABS6
IR
ON Variation from minimum value should ABS-10
be a maximum of 25%
ABS-8
2L
ABS-12
ABS-9
2R ABS-13
HD325-6 20-1013
0

checker for tester
Resistance of ASR valve
Rear left wheel ASRc@+ A Press wheel selector switch 2L

17
Rear right wheel ASRt@+ A Press wheel selector switch 2R
Do not depress the brake pedal
18 ASR valve function (Note 6) Press the 2L button
Press the ASR button

Rear left wheel
Return the ASR button
Do not depress the brake pedal
Press the 2R button

Rear right wheel
Press the ASR button
Return the ASR button
Note 6 : After carrying out inspection of the ASR valve function above, jack up the rear wheels.
During the inspection, when inspecting the left (right) wheel, never rotate the right (left)
wheel at the same time.
20-1014 HD3256
0
@I Measure resistance @ Measure DC voltage Lead: Connected with lead wire
ABS/ASR main Actual mea-

Specified value Pass/fail INDEX
switch sured value
2L
OFF
42-52Q ASR-1
2R
Brake is applied to rear left wheel
Rear left wheel rotates freely

ON ASR-1
Brake is applied to rear right wheel
Rear right wheel rotates freely
HD325-6 20-1015
0
TROUBLESHOOTING w -1
W-l Warning lamp does not light up

* Check that fuses FBX (10) (1 - 7) and (2 - 8) are not blown. If they are blown, check for a short circuit
with the ground inside the controller and in the wiring harness between the fuse and the controller.
* When the ABS/ASR main switch is ON.
* When the starting switch is ON. Cause Remedy

t
YE Is resistance
between ECU (26) -
and (9) normal?
Blown warning lamp bulb , R eplace
* 2 - 4.5 R NO
harness between ECU
1 YES (female) (9) - SW3, SW4 - Repair or replace
FBX (21, FBX (8) - CNl,
I I
Is voltage ECU (female) (27) - CN2,
between ECU (9) JO6 - battery relay, JO7 -
and (27) normal? circuit breaker f+)
yEgjj$$yiiP fsM$ive ABS/ASR main
.21-29v
1 Defective WR2 relay Rleplace

NO
N
Defective WR 1 relay FIeplace
CN2 ~ JO6 _To battery

v relay
WRl Warning IamP relay
WR2 Warning IamD relay
Warning lamp
To circuit
breaker
TWH00713
20-1016 HD325-6
0
TROUBLESHOOTING I-1
I-1 ASR information switch does not go out
Cause .Remedy __
I YES
Is resistance
between ECU (27) -
and (28) normal? Short circuit in wiring
harness between ECU Repair or replace
l2-4.5a NO (female) (28) and AL1
control ler ECU AL1 AL2 FBX

JO7 ,To circuit
breaker
I IV/+ 1
Cl JO6 _To bat terv
relay
TWH00714
HD3256 20-1017
0
TROUBLESHOOTING ASR-1
ASR-1 Failure in ASR control valve (only machines with ABS/ASR

installed)
Cause Remedy
YES
between ECU (2)
harness between ECU (2) -
- (27) and ECU
SVR (female) (9). ECU (20) Repair or replace
- SVR (female) (10). ECU
(27) - SVR (female) (13)
-45-5222
Iefective contact or
jisconnection in wiring
Repair or replace
Jarness between SVR
male) (9) - VK (female)
1). SVR (male) (IO) - VTC
female) (2). SVR (male)
13) - VTC (female) (4)
Defective valve
controller ECU SVR VTC ASR control valve
CN2 ,JO6 _ To ba t terv

U
relay
TWH00715
20-1018 HD325-6
0
TROUBLESHOOTING ASR-2
ASR-2
Cause Remedy
I YES
Defective system checker Repair or replace
Is resistance
between ECU (12) -
and (14) normal? Defective contact or
Repair or replace
-So NO harness between ECU
(12) and (14)
controller ECU
I \ I
)P
12
14
I I I
TWH00716
HD3256 20-1019
0
TROUBLESHOOTING ABS-1
ABS-1 Failure inside ECU

* Check that fuses FBX (IO) (2 - 8) are not blown.
Ir When the battery is normal.
Replace
between ECU (9) Defective contact or

and (27) normal? disconnection in wiring
harness between ECU
(female) (IO) - SW3, SW4 Repair or replace
.21-29v NO - FBX (2), FBX (8) - CNl,
l Turn starting ECU (female) (27) - CN2,
switch ON. JO6 - battery relay, JO7 -
* Turn ABSIASR circuit breaker (+)
main switch ON. Defective ABS/ASR main
switch
20- 1020 HD325-6

0
ABS-2 Failure in front right pressure control valve
Cause Remedy
YES
I
1
Is resistance
between ECU (6) _
YI Repair or replace
- (27) and ECU
(7) - (27) normal? 2
l 14-21 Q Is resistance
between SVF Defective contact or
- (male) (8) - (10) - disconnection in wiring
YES Repair or replace
NO and SVF (male) 3 ~ harness between SVF
(7) - (10) normal? Is resistance (male) (7) -VFR (female)
between VFR (I), SVF (male) (8) - VFR
-14-21 Q (female) (2). SVF (male)
- (male) (2) - (4) -
NO and VFR (male) (10) -VFR (female) (4)
(1) - (4) normal?
-14-21 a Defective valve Replace
NO
Front right Pressure

controller ECU SVF VFR control valve
CN2 r\ JO6 _ To battery

, u relay
TWHOO71B
HD3256 20-l 021

0
TROUBLESHOOTING ABS3
ABS-3 Failure in front left pressure control valve
Cause Remedy
YES
1
Is resistance disconnection in wiring
between ECU
harness between ECU (23)
(23) - (27) and - YES Repair or replace
- SVF (female) (6). ECU
ECU (24) - (27)
2 (24) - SVF (female) (5).
normal?
ECU (27) - SVF (female) (91
. 14-21 Q Is resistance
between SVF Defective contact or
- (male) (6) - (9) - disconnection in wiring Repair or replace
NO and SVF (male) harness between SVF
(5) - (9) normal? Is resistance (male) (6) - VFL (female)
.14-21Q between VFL (2). SVF (male) (5) -VFL
- (male) (2) - (4) - (female) (1). SVF (male)
NO and VFL (male) (9) - VFL (female) (4)
(1) - (4) normal?
-14-21 Q Defective valve
NO
Front left Pressure

controller ECU VFL control valve
CN2, JO6 _ To ba t terv

v relay
TWH00719
20- 1022 HD325-6

0
TROUBLESHOOTING ABS4
ABS-4 Failure in rear left pressure control valve
Cause Remedy
Defective controller Xeplace

1
Is resistance
between ECU
(21) - (27) and - YIES 3epair or replace
- SVR (female) (6). ECU (221
ECU (22) - (27)
normal? 2 - SVR (female) (5). ECU (27)
- SVR (female) (11)
.14-21a Is resistance
between SVR Defective contact or
- (male) (5) - (11) - disconnection in wiring
NO and SVR (male)
(6) - (11) normal?
aYES harness between SVR
[male) (5) -VRL (female)
3epair or replacf
[I), SVR (male) (6) -VRL

-14-21 Q
(male)
II (female) (2), SVR (male)
(11) -VRL (female) (4)
(2) - (4) normal?
.14-21Q Defective valve Replace
NO
Rear left Pressure

controller ECU SVR VRL control valve
I I I I I I
CN2 JO6 To battery

V relay
TWH00720
HD325-6 20-1023
0
ABS-5 Failure in rear right pressure control valve
Replace
1
Is resistance disconnection in wiring
between ECU (4) _ harness between ECU (4) -
YES Repair or replace
- (27) and ECU SVR (female) (8). ECU (5) -
(5) - (27) normal? SVR (female) (7). ECU (27)
2
- SVR (female) (12)
l 14-21 Q Is resistance
between SVR Defective contact or
- (male) (7) - (12) - YES disconnection in wiring Repair or replace
NO and SVR (male) 3p harness between SVR
(8) - (12) normal? ~Is resistance (male) (7) - VRR (female)
between VRR 11). SVR (male) (8) -VRR
-14-21 Q - (female) (2). SVR (male)
-(male)(l)-(4) -
NO and VRR (male) (12) -VRR (female) (4)
(2) - (4) normal?
-14-21 G P Defective valve Replace
NO
Rear right Pressu re

controller ECU SVR VRR control valve
CN2, JO6 _ To bat t cry

v
relay
TWH0072 1
20-1024 HD3256
0
TROUBLESHOOTING ABS-6, ABS-1 0
ABS-6 Failure in front right wheel speed sensor
ABS-10 Abnormality in front right wheel speed sensor output
Cause I Remedy
For ABS-6
4v&S
I , Defective controller Replace
Is width of
YES variation in
sensor output
normal?
For ABS-10 3
Defective rotor Repair or replace
l Use system checker.NC
Is
* Variatron from
Is sensor output
- minimum value
normal? should be within
1
2 25% 5VES
Defective sensor Replace
l Use system
YE! resistance checker. Is sensor mount
between ECU (34) NG normal?
. >lOKQ
and (27) normal?
Push in until
Defective sensor mount sensor contacts
* >30KQ * Check that tip of NO rotor
BTurn starting sensor is in
switch ON. contact with rotor. Short circuit with chassis
YES between ECU (34) - SVF
Repair or replace
[female) (3), ECU (17) -
“I7 SVF (female) (4)
between SVF Short circuit with chassis
n ground in wiring harness
between SVF (male) (3) - Repair or replace
SFR (female) (1). SVF
* >30KQ [male) (4) - SFR (female)
(2)

. >30Kn NCI
YES larness between ECU (17)
Repair or replace
8 - SVF (female) (4). ECU
34) - SVF (female) (3)
Is resistance
. between SVF Defective contact or
N (male) (3) and (4) - g YES disconnection in wiring
normal? harness between SVF Repair or replace
Is resistance [male) (4) - SFR (female)
l950-1450n _ between SFR [2), SVF (male) (3) - SFR
NO (male) (1) and (2) [female) (1)
normal?
Iefective sensor Replace
* 950 - 1450 a NO
Front right wheel

control Ier ECU SVF SFR speed sensor
CN2, JO6 _ To battery

w
relay
TWH00722
HD325-6 20- 1025

0
TROUBLESHOOTING ABS-7, ASS-1 1
ABS-7 Failure in front left wheel speed sensor
ABS-11 Abnormality in front left wheel speed sensor output
Cause Remedy
F:nr ARS-7
-I Iefective controller Replace
4YES
il Iefective controller Replace
YE S_
u
For ABS-11 3
normal?
*Variation
I IL IIefective
Use system checker-NC 1
rotor Repair or replace
l from
Is sensor output
- minimum value
25% 5YES , Defective sensor Replace
* Use system
YES checker. Is sensor mount
between ECU (32) . >lOKn NG normal?
and (27) normal?
Push in until
>30KQ *Check
sensor is in
kiI IDefective sensor mount sensor contacts
rotor
Turn starting
,around in wiring harness
YES Ibetween ECU (15) - SVF Repair or replace
I[female) (2). ECU (32) -
SVF (female) (1)

; !around in wiring harness
between ECU (15)
Ibetween SVF (male) (1) - Repair or replace
and (32) normal? SFL (female) (1). SVF
I[gale)(2) - SFL (female)
I
IIefective sensor
*>30Kn Na 1
IIefective contact or
,jisconnection in wiring
Iiarness between ECU (15) Repair or replace
- SVF (female) (21, ECU
i132)- SVF (female) (1)
IDefective contact or
,disconnection in wiring
Iharness between SVF Repair or replace
I(male) (1) - SFL (female)
I[I), SVF (male) (2) - SFL
I(female) (2)
-I Iefective sensor
l 950 - 1450 a NO
Front left wheel

control Ier ECU SF L speed sensor
CN2 A JO6 _ To battery

” re tav
TWH00723
20- 1026 HD325-6

0
TROUBLESHOOTING ’ ABS-8, ABS-12
ABS-8 Failure in rear left wheel speed sensor
ABS-12 Abnormality in rear left wheel speed sensor output
Cause Remedy
or ABS-8

YE
YE
For ABS-12 IL Defective rotor Repair or replace

m * Use system checker.NC
* Variation from
1
Is sensor output
minimum value
I1 25% BYES
r I Defective sensor Replace
H
* Use system Ii-
I.
YE! j
1
checker. Is sensor mount
between ECU (35)
and (27) normal?
. ,lOKQ n normal?
Push in until
Defective sensor mount sensor contacts
’ 30 KQ * Check that tip of NO rotor
Turn starting sensor is in
YES between ECU (18) - SVR
Repair or replace
(female) (2), ECU (35) -
SVR (female) (1)
Is resistance
between SVR Short circuit with chassis
(male) (1) and 7 YES ground in wiring harness
chassis normal? between SVR (male) (1) -
between ECU (18) Repair or replace
and (35) normal? SRL (female) (1). SVR
. >30KI1 &ale) (2) - SRL (female)
N jE[

* >30KSL NO
Repair or replace
- SVR (female) (2). ECU
(35) - SVR (female) (I)
harness between SVR Repair or replace
(male) (1) - SRL (female)
(l), SVR (male) (2) SRL
(female) (2)
.* Nyl0.1ii(li sensor Replace
Rear left whee I

controller ECU SVR SRL speed sen or
I I I
CN2 A JO6 _ To battery
v relay
TWH00724
HD325-6 20- 1027

0
TROUBLESHOOTING ABS-9, ABS-13
ABS-9 Failure in rear right wheel speed sensor
ABS-13 Abnormality in rear right wheel speed sensor output
Cause Remedy
For ABS-9
4YES
, Defective controller
YE Is width of
YES variation in
sensor output
normal?
For ABS-13 3
Defective rotor Repair or replace
* Use system checker.NC
* Variatron from
Is sensor output - minimum value
2 25% SYEF
Replace
+Use system
YES Is resistance checker.
between ECU (33)
* >lOK.Q
and (27) normal?
I Push in until
I Defective sensor mount sensor contacts
’ >3oKQ * Check that tip of NC rotor
5Turn starting sensor is in
YES between ECU (16) - SVR Repair or replace
(female) (4), ECU (33) -
SVR (female) (3)

r ground in wiring harness
between ECU (16) between SVR (male) (3) - Repair or replace
~ SRR (female) (1). SVR
and (33) normal?
{n$e) (4) - SRR (female)
I I Defective sensor Replace

* >30KQ &
YES harness between ECU (16) Repair or replace
- SVR (female) (41, ECU
133) - SVR (female) (3)
harness between SVR Repair or replace
(male) (3) - SRR (female)
(1). SVR (male) (4) SRR
(female) (2)
Defective sensor
* 950 - 1450 a NO
,I Rear right wheel

controller ECU SVR ShK speed sensor
bI”)L .I””
_ To battery
u relay
TWH00726
20- 1028 HD325-6
0
ABS-14 Failure in valve relay (VR2)

* Check that no fuses are blown.
Cause Remedy
YES
between ECU (8) Defective controller qeplace
and (25) normal?
t Defective contact or
*260-360Q harness between ECU (8)
* Remove fuse 121. 4 YEI - VR2 (female) (3), ECU
(8) - WR2 (female) (3). 3epair or replace
VR2 (female) (2) - WR2
between WR2 (female) (2), FBX (4) - VRi
YES (male) (85) and
I (female) (21, FBX (4) -
.130-180Q WR2 (female) (2)
- Remove fuses 121
and [41. Defective WR2 relay Replace
I Defective VR2 relay Replace

NO
controller ECU VR2 Valve relay 2
VR1 Valve relay

3
WR2 Warning iamP relay 2
WR1 Warning lamp relay
FBX
To circuit
breaker
TWH00726
HD325-6 20- 1029

0
ABS-15 Failure in valve relay O/RI)

Ir Check that no fuses are blown.
Cause Remedy
lefective controller leplace
VIES
between ECU (8) jefective controller (eplace
and (25) normal?
jefective contact or
2
.260-360&I larness between ECU-
* Remove fuse [21. 4 YES 25) -VRl (female) (3).
Is resistance epair or replace
I
Ilr kti (25) - tiR1 (female)
between ECU Is resistance 3), VRl (female) (2) -
I-
N (25) and FBX (3) between WRl YRl (female) (2). FBX (3)
normal? YEc (male) (85) and
1
.VRl (female) (2). FBX (31
(86) normal? WRI (female) (2)
.130-18OL2 3
* Remove fuses [21 *305*15a
and 131. Is resistance
jefective WRl relay Ieplace
‘I ,between VRI
NO
NO
*305*15n
befective VRI relay
NO
controller ECU VR2 Valve relay 2

I
WR2 Warning lamp relay 2
WR1 Warning lamp relay
I FBX
To circuit
20-1030 HD325-6
0
ABS-16 Failure in valve relay (VR2)

YES ? YES
defective wiring harness Repair or replace
defective wiring harness Repair or replace
disconnection in
YE (female) (1) - CN2,

(male) (30) and
-c Iefective controller Replace
D
between WR2 --c Iefective VR2 relay Replace

(male) (30) and
I Defective WR2 relay Replace

NO
Back relay
Back relay
Warning lamp
relay
G-1
3 Warning lamp
0, relay
-
I F
24 II
I- Warning lamp (3W1
--FL--PoHer SUPPI Y
TWH00727
HD3256 20-1031
0
Cause Remedy
ABS-17 Failure in valve relay (VRI)
YES ”
Defective wiring harness ;epair or replace
1Is there short
circuit in wiring
harness between
ECU (19) - VRI
. (female) (I), VRI 4 YES
(female) (4) - VRI Defective wiring harness lepair or replace
(female) (2), VRI
!fFmale) (4) - FBX disconnection in
2
Is resistance N
vE5 between VRI (female) (I) - CN2,
(male) (30) and
(87a) normal? Defective controller
Na
.no
1
Is resistance
between WRl _ Defective VRI relay &place
(male) (30) and
(87a) normal?
Defective WRI relay leplace
Back relay
Back relay
Warnine lama
relay
control I
Warnine lama
relay
Warnine lams (3W)
ASR scare lams (3W)
Monitor switch
ON/OFF switch
TWH00727
FBX
20- 1032 HD3256

0
ABS-18 qbnormality in power source voltage

I Cause 1 Remedy 1
1
Is voltage harness between ECU (9)
between ECU (9) - - CNI, CNl -circuit
2 YES
and (27) normal? breaker (+)Defective
Is resistance contact or disconnection
l21-29v between ECU in wiring harness
,,,c (27) and chassis -
* Turn starting
normal? Defective contact or
switch ON.
Turn ABS/ASR disconnection in wiring
l
*L3D NO harness between ECU (27)
main switch ON. *Turn starting - CN2, CN2 - battery relay
switch ON.
controller 'ECU ABS/ASR main switch FBX
SW3 \sw2 2 8 CNl,J07 -To circuit

v
breaker
10A
CN2,J06 _ To battery
w
relay
TWH00728
HD3256 20- 1033

0
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL .................... 30- 3 CYLINDER HEAD

PRECAUTIONS WHEN CARRYING OUT Removal ...................................................... 30-31
OPERATION ................................................ 30- 4 Installation .................................................. 30-35
SPECIAL TOOL LIST ..................................... 30- 7 ENGINE
SKETCHES OF SPECIAL TOOLS .................. 30-10 Removal ...................................................... 30-38
STARTING MOTOR Installation .................................................. 30-41
Removal and Installation ........................... 30-18 RADIATOR, TORQUE CONVERTER
ALTERNATOR OIL COOLER
Removal and Installation ........................... 30-19 Removal ...................................................... 30-43
ENGINE OIL COOLER Installation .................................................. 30-46
Removal ...................................................... 30-20 RADIATOR, FRONT DRIVE COOLER (HD325-6W)
Installation ............................................... 30-20-1 Removal ................................................... 30-46-1
FUEL INJECTION PUMP Installation ............................................... 30-46-2
Removal ...................................................... 30-21 FRONT DRIVE OIL COOLER (HD325-6W)
Installation .................................................. 30-22 Removal and Installation ........................ 30-46-3
FUEL SUPPLY PUMP OUTPUT SHAFT
Removal ................................................... 30-22-1 Removal ...................................................... 30-47
Installation ............................................... 30-22-3 Installation .................................................. 30-48
AIR COMPRESSOR Disassembly ............................................... 30-49
Removal ................................................... 30-22-4 Assembly .................................................... 30-50
Installation ............................................... 30-22-5 TORQUE CONVERTER, TRANSMISSION
AIR CONDITIONER COMPRESSOR (HD325, 405-6)
Removal ...................................................... 30-23 Removal ...................................................... 30-52
Installation .................................................. 30-24 Installation .................................................. 30-54
AIR CONDITIONER CONDENSER TORQUE CONVERTER, TRANSMISSION
Removal and Installation ........................... 30-25 (HD325-6W)
WATER PUMP Removal ................................................... 30-55-1
Removal ...................................................... 30-26 Installation ............................................... 30-55-3
Installation ............................................... 30-26-1 TORQUE CONVERTER VALVE
AFTERCOOLER Removal and Installation ........................... 30-56
Removal ...................................................... 30-27 Disassembly and Assembly ...................... 30-57
Installation ............................................... 30-27-1 TORQUE CONVERTER, TRANSMISSION
EXHAUST BRAKE CYLINDER Disconnection ............................................. 30-58
Removal and Installation ........................... 30-28 Connection .................................................. 30-59
TURBOCHARGER TORQUE CONVERTER
Removal and Installation ........................... 30-29 Disassembly ............................................... 30-60
NOZZLE HOLDER Assembly .................................................... 30-65
Removal and Installation ........................... 30-30 PTO (HD325, 405-6)
FUEL INJECTOR Disassembly ............................................... 30-70
Removal ................................................... 30-30-1 Assembly .................................................... 30-71
Installation ............................................... 30-30-2
HD325-6 30-1
9
PTO (HD325-6W) PARKING BRAKE PAD
Disassembly ............................................ 30-72-1 Removal .................................................... 30-168
Assembly ................................................. 30-72-2 Installation ................................................ 30-169
TRANSMISSION PARKING BRAKE CALIPER
Disassembly ............................................... 30-73 Removal and Installation ......................... 30-170
Assembly .................................................... 30-91 Disassembly and Assembly .................... 30-171
TRANSMISSION CONTROL VALVE FRONT SUSPENSION CYLINDER
(ECMV ASSEMBLY) (HD325, 405-6)
Removal and Installation ......................... 30-109 Removal .................................................... 30-172
Disassembly ............................................. 30-110 Installation ................................................ 30-173
Assembly .................................................. 30-111 FRONT SUSPENSION CYLINDER
DIFFERENTIAL (HD325-6W)
Removal and Installation ......................... 30-112 Removal ................................................. 30-173-1
Disassembly (Standard) .......................... 30-113 Installation ............................................. 30-173-2
Disassembly (with differential lock) ....... 30-118 Disassembly ............................................. 30-174
DIFFERENTIAL GEAR Assembly .................................................. 30-175
Assembly (Standard) ............................... 30-123 VARIABLE DAMPING SELECTOR VALVE
Assembly (with differential lock) ............ 30-133 Disassembly ............................................. 30-176
FRONT WHEEL (HD325, 405-6) Assembly .................................................. 30-177
Removal and Installation ......................... 30-145 REAR SUSPENSION CYLINDER
FRONT WHEEL (HD325-6W) Removal and Installation ......................... 30-178
Removal and Installation ...................... 30-145-1 Disassembly ............................................. 30-179
REAR WHEEL Assembly .................................................. 30-180
Removal .................................................... 30-146 AIR GOVERNOR
Installation ................................................ 30-147 Removal and Installation ......................... 30-181
FRONT BRAKE CALIPER PAD Disassembly and Assembly .................... 30-182
Removal and Installation ......................... 30-148 BRAKE VALVE
FRONT BRAKE CALIPER Removal and Installation ......................... 30-183
Removal and Installation ......................... 30-149 Disassembly ............................................. 30-184
Disassembly ............................................. 30-150 Assembly .................................................. 30-186
Assembly ............................................... 30-150-1 PARKING BRAKE CHAMBER
FRONT WHEEL HUB Removal and Installation ......................... 30-188
Disassembly ............................................. 30-151 Disassembly ............................................. 30-189
Assembly .................................................. 30-153 Assembly .................................................. 30-190
FRONT FINAL DRIVE CLUTCH, CARRIER FRONT BRAKE CHAMBER (HD325, 405-6)
(HD325-6W) Removal and Installation ......................... 30-192
Disassembly .......................................... 30-155-1 REAR BRAKE CHAMBER
Assembly ............................................... 30-155-5 Removal and Installation ......................... 30-193
FRONT FINAL DRIVE, BRAKE (HD325-6W) FRONT BRAKE CHAMBER
Disassembly ........................................ 30-155-10 Disassembly ............................................. 30-194
Assembly ............................................. 30-155-15 Assembly .................................................. 30-196
FRONT DRIVE SHAFT (HD325-6W) REAR BRAKE CHAMBER
Disassembly ........................................ 30-155-22 Disassembly ............................................. 30-198
Assembly ............................................. 30-155-26 Assembly .................................................. 30-202
REAR FINAL DRIVE CARRIER SLACK ADJUSTER
Removal .................................................... 30-156 Removal and Installation ......................... 30-205
Installation ................................................ 30-157 Disassembly and Assembly .................... 30-206
Disassembly ............................................. 30-158 TRANSMISSION LUBRICATION, RETARDER
Assembly .................................................. 30-159 BRAKE PUMP (HD325, 405-6)
REAR FINAL DRIVE Removal and Installation ......................... 30-207
Disassembly ............................................. 30-160 TRANSMISSION LUBRICATION, RETARDER
Assembly .................................................. 30-162 BRAKE PUMP (HD325-6W)
REAR BRAKE Removal and Installation ......................... 30-208
Removal and Installation ......................... 30-164 BRAKE COOLING PUMP (HD325, 405-6)
Disassembly ............................................. 30-165 Removal and Installation ...................... 30-208-1
Assembly .................................................. 30-166
30-2 HD325-6
9
BRAKE COOLING PUMP (HD325-6W)
Removal and Installation ...................... 30-208-2
HOIST, STEERING PUMP
Removal and Installation ......................... 30-209
FRONT DRIVE PUMP (HD325-6W)
Removal ................................................. 30-209-1
Installation ............................................. 30-209-2
EMERGENCY STEERING MOTOR PUMP
TRAVEL MOTOR (HD325-6W)
Removal ................................................. 30-210-1
Installation ............................................. 30-210-2
TRAVEL MOTOR (HD325-6W)
Disassembly and ASSEMBLY .............. 30-210-3
STEERING VALVE
Disassembly ............................................. 30-212
Assembly .................................................. 30-216
DEMAND VALVE
Disassembly and Assembly .................... 30-223
RELIEF VALVE ASSEMBLY
Disassembly and Assembly .................... 30-224
HOIST VALVE
Disassembly ............................................. 30-226
Assembly .................................................. 30-227
STEERING CYLINDER
Disassembly ............................................. 30-229
Assembly .................................................. 30-231
HOIST CYLINDER
Disassembly ............................................. 30-234
Assembly .................................................. 30-236
BODY ASSEMBLY
Removal .................................................... 30-240
Installation ................................................ 30-241
FRONT DRIVE CONTROLLER (HD325-6W)
HD325-6 30-2-1
9
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
METHOD OF USING MANUAL

1. When removing or installing unit assemblies
@ When removing or installing a unit assembly, the order of work and techniques used are given
for the removal operation; the order of work for the installation operation is not given.
@ Any special techniques applying only to the installation procedure are marked Ix, and the
same mark is placed after the relevant step in the removal procedure to indicate which step in
the installation procedure it applies to.
(Example)
REMOVAL OF 0000 ASSEMBLY . . . .. . . . . . . . . . . Title of operation
. . .. . . . . . . . . . . .. .. . .. . . . .. . . . . . .. . . . . .. . .. . . .. . . .. . . . . . . .. . . . . . . . . . .. . Precautions related to safety when carrying out

the operation
1. xXxX(1) .. .. . . .. . . . . .. . . . . .. . . . . .._.......................... Step in operation
* . .. . . . . . . . . .. . .. .. . . .. . . . . . . .. . . .. . .. .. . . .. .. .. . . . .. . .. . .. . . .. . . .. . Technique or important point to remember
when removing XXXX (1).
2. A A A A (2): .. . . . . .. . . . . . .. . .. . . .. .. . . .. . . . .. . . . . . .. . .. . . . .. m Indicates that a technique is listed for use
during installation
3. 0 0 0 jJ assembly (3)
:
u .......‘.. ............................. ................. ............ Quantity of oil or water drained
INSTALLATION OF 0000 ASSEMBLY .. . . . Title of operation

Carry out installation in the reverse order to removal.
‘@ . ._. ............... ........... ................ ..... ..... .. .... Technique used during installation
when
. . . . . . .. . . . . .. . . . .. . .. .. . .. . .. .. . . . .. .. . . .. . . . . .. . . .. . .. . . . . . .. . . . . Technique or important point to remember
installing A A A A (2).
. Adding water, oil .... ............... .............. Step in operation
* .... ......................._..........._.................... Point to remember when adding water or oil
................ .................. ............ ... .... .... Quantity when filling with oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units
are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow
these precautions when carrying out the operation.
3. Listing of special tools

@ For details of the description, part number, and quantity of any tools (Al, etc.) that appear in
the operation procedure, see the SPECIAL TOOLS LIST given in this manual.
HD325-6 30-3
0
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[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
. If the coolant contains antifreeze, dispose of it correctly.
. After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from
entering.
. When draining oil, prepare a container of adequate size to catch the oil.
. Confirm the match marks showing the installation position, and make match marks in the neces-
sary places before removal to prevent any mistake when assembling.
. To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors. Do not pull the wires.
. Fit wires and hoses with tags to show their installation position to prevent any mistake when
installing.
. Check the number and thickness of the shims, and keep in a safe place.
. When raising components, be sure to use lifting equipment of ample strength.
. When using forcing screws to remove any components, tighten the forcing screws uniformly in
turn.
. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt
from entering after removal.
* Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
Nominal Sleeve nut (elbow end)

Plug (nut end) Use the two items below as a set
number
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut),07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
I) Hoses and tubes using sleeve nuts
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
2) Split flange type hoses and tubes

3) If the part is not under hydraulic pressure, the following corks can be used.
I
I
Taper 1/s
0
a P
t
I
DEW00401
HD325-6
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
2. Precautions when carrying out installation work

. Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
. Install the hoses without twisting or interference.
. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
. Bend the cotter pins and lock plates securely.
. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2 - 3 drops of adhesive.
. 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.
. Clean all parts, and correct any damage, dents, burrs, or rust.
. Coat rotating parts and sliding parts with engine oil.
. When press fitting parts, coat the surface with anti-friction compound (LM-P).
. After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then
connect securely.
. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and
align the direction of the hook.
. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one
side.
* 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 idling.
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.
* When using the machine for the first time after repair or long storage, follow the same
procedure.
3. Precautions when completing the operation

. If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
the engine to circulate the water through the system. Then check the water level again.
. If the hydraulic equipment has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again.
. If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
* For details, see TESTING AND ADJUSTING, Bleeding air.
. Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
HD325-6 30-5
0
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

fl Tools with part number 79cT-ccc-cccc can not be supplied (they are items to be locally manu-
factured).
fl Necessity: : .......... Cannot be substituted, should always be installed (used)
b : .......... Extremely useful if available, can be substituted with commercially avail-
able part.
New/remodel: N : .......... Tools with new part numbers, newly developed for this model.
R : .......... Tools with upgraded part numbers, remodeled from items already available
for other models.
Blank: .... Tools already available for other models, used without any modification
fl Tools marked c in the Sketch column are tools introduced in special sketches (See SKETCHES OF
SPECIAL TOOLS).
Nece- New/ Ske-
Component Symbol Part No. Part Name ssity Q’ty model
re-
tch Nature of work, remarks
796-514-2110 Weight 1 Removal of nozzle holder
Disassembly, assembly 1 assembly
of engine 01011-51090 Bolt 1
2 790-331-1110 Wrench Tightening of cylinder head
1 assembly
A 795-471-1700 Remover 1
Removing fuel supply 795-471-1520 • Block 1

pump 3
795-471-1530 • Bolt 1
01435-01085 • Bolt 2
790-201-2840 Spacer 1 c
791-600-1120 Bolt 1
Removal, installation of 01580-01613 Nut 1

output shaft assembly B 1
01643-31645 Washer 1
790-101-2102 Puller 1
790-101-1102 Pump (30t) 1
Centering engine and torpue
1 790-413-1110 Centering tool 1 converter
790-501-5000 Unit repair stand
(100V) 1
or
Unit repair stand
790-501-5200 (110V–120V or 220–240V) 1 Torque converter, PTO repair
2 stand
Disassembly, assembly 790-901-2110 Bracket 1
of torque converter C
P.T.O. assembly 793-310-2141 Plate 1 c
Removal, installation of round
3 790-102-1871 Nut wrench 1 nut of PTO gear bearing
Removal, installation of holding
4 792-103-5110 Wrench 1 round nut of pump lock bearing
Lock of front drive pump,
5 791-342-1310 Wrench 1 removal of holding nut
Disassembly, assembly Check operation of clutch,
of transmission assembly D 1 799-301-1600 Oil leak tester kit (A) 1 piston
790-501-5000 Unit repair stand
(100V) 1
or
Unit repair stand
Disassembly, assembly 790-501-5200 (110V–120V or 220–240V) 1
of differential assembly H 1 Differential repair stand
790-901-4110 Bracket 1
790-901-3430 Plate 1 c
HD325-6 30-7
(14)
Nece- New/ Ske-

re-
2 792-525-2100 Nut runner 1 Removal, installation of
differential bevel pinion nut
3 Power wrench and locknut
790-102-1100 (No. 16) 1
4 791-103-0901 Wrench 1 Side bearing adjustment nut
5 Wrench Tightening of pinion gear

797-101-1171 1 round nut
6 792-525-1220 Adapter 1
Disassembly, assembly 7 792-525-1000 Depth micrometer 1 Adjusting bearing preload

of differential assembly H
8 792-103-0901 Wrench 1
790-102-1100 Power wrench 1

Removal, installation of
790-102-1110 Lever 1 bearing cap bolt
fl Use comercially available
9 790-102-1120 Bolt 1 socket (width across flats:
46 mm, insertion angle
01580-02419 Nut 1 38.1 mm)
Kit Part No. 790-103-1130
01644-12408 Washer 1
1 792T-488-1110 Fixture 3 N c
791-585-1510 Installer 1
2 Installation of floating seal
792-530-1700 Push tool 1
Disassembly, assembly
of front drive, final 3 792-103-1201 Fixture 3 c
drive, wheel brake J
assembly 792-520-2121 Installer 1 Installation of floating seal
(small seal)
791-580-1600 Push tool 1
4
792-520-2110 Installer 1 Installation of floating seal
(large seal)
791-580-1600 Push tool 1
Disasembly, assembly Centering of steering valve
1 790-452-1200 Pilot ring tool 1 upper cover
of steering valve T
assembly 2 790-452-1100 Installer set 1
792-103-4102 Push tool 1 c

Press fitting of suspension
1 792-101-5421 Grip 1 cylinder coil bushing
Disassembly, assembly 01010-51240 Bolt 1
of front, rear suspen- Q
sion cylinder assembly 792-610-1000 Suspension tool 1
2 • 792-610-1100 Pump assembly 1 Charging suspension cylinder
with oil, gas
• 792-610-1200 Charging tool 1
Cylinder repair Removal, installation of
1 790-502-1003 1 cylinder round head
stand
Disassembly, assembly 790-101-1102 Pump 1 (Hoist cylinder)
of hoist cylinder, 2
steering cylinder U 790-102-3802 Wrench assembly 1
assembly 790-102-2303 (Steering cylinder)
3 or Wrench assembly 1
790-330-1100
30-8 HD325-6
9
Nece- New/ Ske-

re-
Removal, installation of nylon
4 790-302-1270 Socket 1 nut (steering)
790-201-1881 Push tool 1
Press fitting of No. 1 coil
5 790-101-5021 Grip 1 bushing (hoist cylinder)
Kit Part No. 790-201-1700
01010-50816 Bolt 1
790-201-1841 Push tool 1
Press fitting of No. 2 coil
6 790-101-5021 Grip 1 bushing (hoist cylinder)
Kit Part No. 790-201-1700
01010-50816 Bolt 1
790-201-1690 Plate 1
Press fitting of No. 1 gland
7 790-101-5021 Grip 1 dust seal (hoist cylinder)
Kit Part No. 790-201-1500
01010-50816 Bolt 1
790-201-1650 Plate 1
Disassembly, assembly Press fitting of No. 2 gland
of hoist cylinder, U 8 790-101-5021 Grip 1 dust seal (hoist cylinder)
steering cylinder Kit Part No. 790-201-1500
assembly 01010-50816 Bolt 1
790-201-1570 Plate 1
Press fitting of dust seal
9 790-101-5021 Grip 1 (steering cylinder)
Kit Part No. 790-201-1500
01010-50816 Bolt 1
790-720-1000 Expander 1
Installation of piston, wear
10 796-720-1680 Ring 1 ring
(No. 1 hoist cylinder)
07281-01589 Clamp 1
796-720-1670 Ring 1 Installation of piston, wear
11 ring
07281-01279 Clamp 1 (No. 2 hoist cylinder)
796-720-1640 Ring 1 Installation of piston, wear

12 ring
07281-00909 Clamp 1 (steering cylinder)
Removal of dump body V 1 790-441-1320 Hook 4 c

799-703-1200 Service tool kit 1
Vacuum pump
799-703-1100 (100V) 1
Collection, re-use of Vacuum pump Collection, charging with
new freon gas X 1 799-703-1110 (220V) freon gas
Vacuum pump
799-703-1120 (240V)
799-703-1400 Gas leak tester 1
HD325-6 30-9
9
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these
sketches.
B-l. Spacer
566FO6701
OPT : MATERIAL TO BE STKM16A
790-201-2840 A
30-10 HD325-6
0
C-2. Plate
9-15 DRILLS
5-20 DRILLS
299 299
w
242 182.5
k
121.5 , 35
43
247.5
I- 247.5
I II
300 300
t-
335 335
r - e
t=9
566FO6702
HEAT TREATMENT MATERIAL

SS4OOP
PART NAME O’TY
PLATE 1
PART NO.
793-310-2141 A
HD325-6 30-11
0
H-l. Plate
6-23DRILLS
6 - 27DRI LLS
I I I ‘- 644 .‘I1 I Ik
t=16
566FO6703
/ HEAT TREATMENT / MATERIAL

1 SS4OOP
PART NAME O’TY
I PLATE
PART NO.
1
790-901-3430 A
30-l 2 HD325-6
0
H-4. Wrench
c Z
25 240
255 145
-4
545
e h
566FO6704
HD325-6 30-13
0
J-l. Fixture
-
+I
2
9 -
I
I
1
22
566FO6705
1 HEAT TREATMENT 1 MATERIA i-

1 SS400F -
PART NAME O’TY
FIXTURE 3
PART NO.
1 792T-488-1110 A
30-14 HD325-6
0
J-3. Fixture
566FO6706
) HEAT TREATMENT 1 MATERIAL

1 SS4lF
PART NAME O’TY
FIXTURE 3
PART NO.
792-103-1201 A
HD325-6 30-15
0
Q-l. Push tool
r
vvv
rw
zi -
L
-a
-
\
“t
4
.- I-
6 96
m
566FO6707
)
SYM. PART NAME MATERIAL Q’TY/SEl
30-16 HD325-6
0
V-l. Hook
I 566FO6708
HEAT TREATMENT MATERIAL

SEE DWG
PART NAME O’TY
HOOK 4
PART NO.
790-441-1320 A
HD325-6 30-17
0
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
REMOVAL OF STARTING
MOTOR ASSEMBLY
¤ Disconnect the cable from the negative (–) ter- HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
minal of the battery. HD405-6 Serial No.: 1055 – 2000
1. Disconnect wiring connector (1).
2. Disconnect wiring (2).
3. Remove mounting bolts (3), then remove start-

ing motor assembly (4).
INSTALLATION OF STARTING
MOTOR ASSEMBLY HD325-6W Serial No.: 6001 and up
• Carry out installation in reverse order to removal.
30-18 HD325-6
9
DISASSEMBLY AND ASSEMBLY ALTERNATOR
REMOVAL OF ALTERNATOR
ASSEMBLY
¤ Disconnect the cable from the negative (–) ter- HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
minal of the battery. HD405-6 Serial No.: 1055 – 2000
1. Disconnect 3 wires (1).
2. Remove bolt (2), then remove cover (3).
3. Loosen locknuts (4) and lock bolt (5).
4. Loosen bottom locknuts completely, then gradu-

ally tighten top locknuts and remove belt (6).
5. Remove lock bolt (5), then lower adjustment bolt

(7) towards frame.
6. Remove locknut (8), then remove bolt (9). HD325-6 Serial No.: 6001 and up
fl Note that the length of spacers (1) is differ- HD325-6W Serial No.: 6001 and up
ent.
7. Remove alternator assembly (11). 1
INSTALLATION OF
ALTERNATOR ASSEMBLY
• Carry out installation in the reverse order to re-

moval.
1
fl Adjust the fan belt tension.
For details, see STANDARD TABLE FOR EN-
GINE RELATED PARTS.
HD325-6 30-19
9
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER
REMOVAL OF ENGINE OIL COOLER ASSEMBLY

HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
1. Drain water
= Coolant: 106 ¬
2. Remove turbocharger return tube (1).
3. Remove turbocharger lubrication return tube

(1).
4. Remove piping (3) and (4).
5. Remove cover (5).
6. Remove cooler assembly (6).

1. Drain water
= Coolant: 89 ¬
2. Remove tube (1).
3. Remove piping (2).
5. Remove core assembly (4).
30-20 HD325-6
9
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER
INSTALLATION OF ENGINE OIL

COOLER ASSEMBLY
moval.
• Refilling with water

fl Refill with water to the specified level, and
run the engine to circulate the water
through the system. Then check the water
level again.
fl Check if the water level in the reservoir tank
changes.
HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
- Coolant: 106 ¬

- Coolant: 89 ¬
HD325-6 30-20-1
9
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000

moval.
1
9 Sleeve nut:
23.52 ± 0.98 Nm {2.4 ± 0.1 kgm}
2
9 Coupling bolt:
61.25 ± 2.45 Nm {6.25 ± 0.25 kgm}
3
• Adjust the fuel injection timing.
For details, see TESTING AND ADJUSTAIG.
30-22 HD325-6
9
DISASSEMBLY AND ASSEMBLY FUEL SUPPLY PUMP
REMOVAL OF FUEL SUPPLY

PUMP
1. Align 1.6 TOP stamp line a of damper (2) with

pointer (1).
2. Remove breather tube (3).
3. Remove plugs (4) (2 places, at the upper and

lower part), then check that the stamp line is
aligned with the fuel supply pump drive gear
and forcing tap hole. 1
4. Remove cover (5). Remove gear mounting nut

and washer (6) and (7) with care not to fall them
in the engine. 2
5. Set gear forcing jig A3.
6. Tool bolt A3 must be mounted at the gear forcing

tap hole (2 places).
7. Remove fuel hose (9), then remove fuel tube (10),

fuel supply tube (11), oil tube (12) , and overflow
tube (13). 3
fl Install masking at the joints and the joint por-
tions of piping to keep dust and debris out.
8. Remove harness connectors (14) and (15).

fl Install masking the connector parts to keep
dust and debris out.
HD325-6 30-22-1
C
9. Loosen bolts (16) and nuts (17) of the bracket and

fuel supply pump mounting bolts (18) (4 places
on the front and rear side).
10. Clockwise rotate tool bolt A3 to pull out the fuel

supply pump drive gear.
fl There is key (19) inside. Be careful not to drop
it.
11. Remove bolts (16) and nuts (17) loosened at Step

9, then remove fuel supply pump assembly (20).
30-22-2 HD325-6
C
SUPPLY PUMP

moval.
• General bolts and nuts conform to KES04.123.1.
• Unspecified joint bolts conform to D07206 –
XXXXX.
1
9 Plug: 14.7 – 19.6 Nm {1.5 – 2.0 kgm}
2
• Installing the fuel supply pump drive gear
9 Nut: 176.5 – 196.1 Nm {18 – 20 kgm}
3
• Fuel filter side
9 Joint bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}

• Fuel supply pump tube
fl Place the cap with its slit toward the cylinder
block side.
• Supply pump side
9 Tube: 39.2 – 49.0 Nm {4 – 5 kgm}

• Common rail side
9 Tube: 49.0 – 58.8 Nm {5 – 6 kgm}
• Air clamp
9 Mounting bolt, upper side:
4.9 ± 1 Nm {0.5 ± 0.1 kgm} (M6)
9 Mounting bolt, lower side:

9.8 – 1.0 Nm {1.0 – 0.1 kgm} (M6)
fl Other clamps conform to KES
HD325-6 30-22-3
9
DISASSEMBLY AND ASSEMBLY AIR COMPRESSOR
INSTALLATION OF AIR
COMPRESSOR ASSEMBLY
HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000

moval.
9 Joint bolt: 56.4 ± 7.4 Nm {5.75 ± 0.75 kgm}

fl Refill with water to the specified level, and run
the engine to circulate the water through the
system. Then check the level again.
- : 106 ¬


moval.
9 Joint bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
9 Clamp: 4.4 ± 0.49 Nm {45 ± 5 kgm}
9 Tube: 24.5 –59 Nm {2.5 – 6 kgm}
HD325-6 30-22-5
9
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
REMOVAL OF AIR
CONDITIONER COMPRESSOR
ASSEMBLY
HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
¤ Using tool X1, collect air conditioner freon gas.
1. Disconnect connector (1).

fl Disconnect the ground connection from the
air conditioner compressor.
2. Disconnect 2 hoses (2). 1
3. Loosen hibge bolt (3) and adjustment bolt (4), and

remove belt (5). 2
4. Remove air conditioner compressor assembly (6).

¤ Using tool X1, reclaim air conditioner CFC gas.

fl Disconnect the grounding cable from the air
compressor.
2. Disconnect 2 hoses (2). 1
3. Remove bolt (3), then remove cover (4).
4. Loosen locknut (5) and lock bolt (6). 2
5. Loosen the locknut at the lower side completely.

While loosening the locknut at the upper side
gradually, remove belt (7).
6. Remove lock bolt (6), then put down adjustment

bolt (8) to the frame side.
7. Remove air compressor assembly (9).
HD325-6 30-23
9
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
INSTALLATION OF AIR
CONDITIONER COMPRESSOR
ASSEMBLY
HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000

moval.
1
9 Mounting bolt a b :
30.5 ± 4.5 Nm {3.1 ± 0.5 kgm}
2
fl Adjusting the tension of the air conditioner
compressor belt
1) Check that deflection of the belt is approx.
10 mm when pressed with a thumb
(approx. 6 kg) at a point midway between
the air compressor pulley and the drive
pulley.
2) After completing adjustment, tighten bolts
(3) and (4).
• Using tool X1, charge with air conditioner freon

gas.


moval.
1
9 Mounting bolts a and b :
30.5 ± 4.5 Nm {3.1 ± 0.5 kgm}
2
fl Adjusting tension of air compressor belt
1) Press the middle point between the air
compressor pulley and drive pulley with
your thumb (approx. 58.8 N {6 kgm}), and
then check that there is deflection of
approx. 10 mm .
2) After completing adjustment, tighten lock
bolt (6) and locknut (5).
• Using tool X1, fill with air conditioner CFC gas.
30-24 HD325-6
9
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
REMOVAL OF AIR
HD325-6, HD405-6
CONDITIONER CONDENSER
ASSEMBLY
¤ Using tool X1, recover the freon gas from the
air conditioner.
1. Remove radiator mask.
2. Disconnect hoses (1) and (2).
3. Remove air conditioner condenser assembly (3).
HD325-6W
INSTALLATION OF AIR
CONDITIONER CONDENSER
ASSEMBLY
moval.
• Using tool X1, charge the air conditioner with
freon gas.
HD325-6 30-25
2
DISASSEMBLY AND ASSEMBLY WATER PUMP
REMOVAL OF WATER PUMP ASSEMBLY

HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
1. Remove alternator assembly (1).

• For details, see REMOVAL OF ALTERNATOR
ASSEMBLY.
2. Drain cooling water.

= : 106 ¬
3. Remove turbocharger lubrication tube (2).
4. Disconnect ground connection, then remove af-

ter cooler piping (3).
5. Disconnect wiring connector, then remove en-

gine oil cooler tube (4).
6. Remove water pump piping (5).
7. Remove pulley (6).
8. Remove water pump assembly (7).

fl Remove 4 bolts (8).

1. Remove alternator assembly (1). 1

• For details, see REMOVAL OF ALTERNATOR
ASSEMBLY.

= : 89 ¬
3. Disconnect the grounding cable (2), then re-

move aftercooler piping (3).
4. Disconnect the wiring clamp, then remove wa-

ter pump piping (4).
5. Remove pulley (5).
6. Remove water pump assembly (8).

fl Remove one mounting bolt (6) and 3
mounting bolts (7).
30-26 HD325-6
9
DISASSEMBLY AND ASSEMBLY WATER PUMP
INSTALLATION OF WATER
PUMP ASSEMBLY
HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000

moval.
1
fl Adjust the fan belt tension.
For details, see STANDARD VALUE TABLE FOR
ENGINE RELATED PARTS.

level again.
- : 106 ¬


moval.
1
• Adjust the fan belt tension.
For details, see STANDARD VALUE TABLE
FOR ENGINE RELATED PARTS.

level again.
- : 89 ¬
HD325-6 30-26-1
3
DISASSEMBLY AND ASSEMBLY AFTERCOOLER
REMOVAL OF AFTERCOOLER ASSEMBLY

HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
1. Referring to REMOVAL OF RADIATOR AND

TORQUE CONVERTER COOLER ASSEMBLY, re-
move the radiator guard.
2. Loosen hose clamp (1) on the turbocharger side

and hose clamp (2) on the upper side of the
aftercooler, on the side of tube (3).
3. Remove U-bolts (4) and (5) securing the tube,

then remove tube (3).
4. Loosen hose clamp (6) on the engine side and

hose clamp (7) on the lower side of the
aftercooler, on the side of tube (8).
5. Remove U-bolts (9) and (10) securing the tube,

then remove tube (8).
6. Hang aftercooler (11) temporarily and remove

bolt (12), then hang and remove the aftercooler.
HD325-6 30-27
9

1. Referring to “REMOVAL OF RADIATOR-TORQUE

CONVERTER ASSEMBLY”, remove the radiator
guard.
2. Loosen the clamps of joint hose (1) at the turbo-

charger side and joint hose (2) at the aftercooler
inlet. 1
3. Remove U-bolts (3) and (4), then remove tube (5)

between the turbocharger and aftercooler.
4. Loosen joint hose (6) at the engine side and hose

(7) at the aftercooler side. 2
5. Remove U-bolts (8) and (9), then remove tube (10)

between the engine and aftercooler outlet.
6. Lift aftercooler assembly (11) temporarily, then

remove mounting bolts (12). Lift the aftercooler,
then remove the aftercooler core.
30-27-1 HD325-6
9
INSTALLATION OF
AFTERCOOLER ASSEMBLY
HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000

moval.


moval.
fl When assembling air intake piping, assemble
it so that coma A at the tube end may come
directly above the aftercooler.
fl Where you use two clamps, install them at

places displaced 180° as shown in the figure.
9 Hose clamp:
9.8 – 0.5 Nm {1 – 0.05 kgm}
fl Protrusion of the screw end with regard to
tightening torque must be as follows.
Portion a of the screw end: 5.1 mm

places displaced 180° as shown in the figure.
9 Hose clamp:
9.8 – 0.5 Nm {1 – 0.05 kgm}
fl Protrusion of the screw end in relation to tight-
ening torque must be as follows.
Portion a of screw end: 5.1 mm
HD325-6 30-27-2
9
DISASSEMBLY AND ASSEMBLY EXHAUST BRAKE CYLINDER
REMOVAL OF EXHAUST BRAKE

CYLINDER ASSEMBLY
HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
1. Disconnect hose (1).
2. Remove nut (2).
3. Remove mounting bolt (3), then remove cylinder

assembly (4).

1. Remove joint bolt (1). 1
2. Remove tube (2).
3. Remove mounting bolts (3), then remove cylin-

der assembly (4).
INSTALLATION OF EXHAUST
BRAKE CYLINDER ASSEMBLY
HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000

moval.


moval.
1
9 joint bolt : 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
30-28 HD325-6
9
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
REMOVAL OF TURBOCHARGER
ASSEMBLY
HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
1. Loosen clamp and move hose (1) towards tube.
2. Remove mounting bolts, then remove intake con-

nector (2).
3. Remove cooling water inlet tube (3). 1
4. Disconnect lubrication oil inlet tube (4).
5. Remove bolt (5) and disconnect connection of

exhaust brake and turbocharger.
6. Remove intake hose (6).
7. Remove cooling water outlet tube (7). 2
8. Remove lubrication oil outlet tube (8).
9. Remove mounting bolt (9), then remove turbo-

charger assembly (10).

1. Loosen the clamp, then displace hose (1) to the

tube side.
2. Remove the mounting bolts, then remove air in-

take connector (2).
3. Remove tube (3). 1
4. Remove bolts (4), then disconnect the exhaust

brake from turbocharger.
5. Remove air intake hose (5). 2
6. Remove tube (6).
7. Remove mounting nut (7), then remove turbo-

charger assembly (8). 3
HD325-6 30-29
9
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
INSTALLATION OF
TURBOCHARGER ASSEMBLY
HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000

moval.
1
9 Cooling water inlet tube joint bolt :
29.7 ± 5.0 Nm {3.0 ± 0.5 kgm}
2
9 Cooling water outlet tube joint bolt :
29.7 ± 5.0 Nm {3.0 ± 0.5 kgm}


moval.
1
9 Tube joint bolt:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
9 Clamp: 8.8 ± 0.5 Nm {90 ± 5 kgm}
9 Nut: 44.1 – 53.9 Nm {4.5 – 5.5}
30-29-1 HD325-6
9
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
REMOVAL OF NOZZLE HOLDER ASSEMBLY

HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
1. Remove engine hood assembly.

• For details, see REMOVAL OF ENGINE HOOD
ASSEMBLY.
2. Disconnect wirihg connector, then remove win-

dow washer tank.
3. Loosen hose clamp, then remove intake connec-

tor (1). (No.6 only)
4. Disconnect delivery tube (2). 1
5. Remove cover (3). 2
6. Loosen locknut (4). 3
7. Remove connector (5). 4
8. Remove flange (6). 5
9. Use tool A1, or screw in bolt (Thread dia. = 10

mm, Pitch = 1.5 mm), then using a bar, remove
nozzle holder (7).
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY

moval.
1
9 Sleeve nut: 23.52 ± 0.98 Nm {2.4 ± 0.1 kgm}
2
9 Mounting bolt:
4.90 ± 0.98 Nm {0.5 ± 0.1 kgm}
3
9 Locknut: 36.75 ± 2.45 Nm {3.75 ± 0.25 kgm}
4
9 Connector:
36.75 ± 2.45 Nm {3.75 ± 0.25 kgm}
5
9 Mounting bolt:
66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}
30-30 HD325-6
9
DISASSEMBLY AND ASSEMBLY FUEL INJECTOR
REMOVAL OF FUEL INJECTOR

1. Open the engine hood.

2. Disconnect the wiring connector, then remove the
window washer tank.
3. Remove cover (1). (Only No. 3 – No. 6)
4. Remove exhaust brake tube (2). (Only No. 4) 1
5. Remove tube (3). (Only No. 5) 2
6. Remove cover (4). 3
7. Rocker arm
Remove 3 mounting bolts, then remove rocker
arm (5). 4
fl When installing the rocker arm, loosen lock-
nut (7) and then, loosen adjust screw (8) a few
turns so that an excessive force may not be
applied to push rod (6).
8. Fuel injector assembly 5

fl When removing the fuel system harness, in-
sert flat-head screwdriver 1 into stepped por-
tion a and move it in the X direction while
pressing stopper b. Then, disconnect connec-
tor c with a single motion.
d: Fuel injector harness side
1) Remove 2 nuts (10) at the solenoid valve at

the upper part of fuel injector (9), then pull
out spring clamp (11).
2) Remove the bolts of clamp (12), then remove
one mounting bolt (15) of holder (14) of con-
nector (with an o-ring) (13) (by using an hex-
agonal wrench).
3) Remove holder (14), press connector (13) in-
side, and then remove it.
HD325-6 30-30-1
9
4) Loosen the bolts of holder (16) of fuel injector

(9), then remove fuel injector (9).
5) Place a small L-shape bar under connection

(17) of fuel injector (9). Pull out fuel injector
(9) slowly by applying leverage.
fl Never hold the solenoid valve at the up-
per part of the injector with a pair of pli-
ers.
fl Precautions when removing only the in-
jector only for replacing the injector or
nozzle tip.
Before starting a series of mentioned in-
jector removal steps, find a clamp near
the injector from high-pressure tube
clamps No. 1 to No. 6, then loosen bolts
which mount it to the air intake manifold.
Also, remove the sleeve of high-pressure
tube at the injector side, and pull out the
injector with care so that the sleeve end
may not touch the concaved portion of the
injector.
INJECTOR
• Carry out installation in reverse order to removal.
1
3 Joint bolt: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
30-30-2 HD325-6
9
2
3 Joint bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3
3 Mounting bolt:
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
4
Install the rocker arm, then tighten it with bolts.
fl Check that the ball portion of the adjust screw
is firmly placed in the socket of the push rod.
Tighten the mounting bolts.
3 Mounting bolt:
93 – 103 Nm {9.5 – 10.5 kgm}
fl After tightening the locknut, referring to “Ad-
justing valve clearance”, adjust valve clear-
ance.
3 Locknut: 53 – 64.7 Nm {5.4 – 6.6 kgm}
5
fl When installing the high-pressure tube, visu-
ally check if there is a dent like a vertical slit
flaw b or spot flaw c at the taper seal portion
of the connection (portion a: 2 mm from the
end) or a bump (deformation) large enough
to catch your nail at portion d (the end por-
tion of taper seal portion: 2 mm from the end),
which may cause fuel leak. If any, replace the
high-pressure tube.
fl Check that there is no dust and debris in the
injector sleeve.
1) Install a gasket and O-ring to the fuel injector
and apply engine oil (SAENo. 30).
2) Insert holder (16) of fuel injector (9). Place
the injector connection toward the fuel high-
pressure tube insertion hole, then insert the
injector and the holder at the same time.
HD325-6 30-30-3
9
3) Attach a spherical washer to bolts (18), then

tighten holder (16) with it temporarily. Place
high-pressure tube sleeve (19) through the
fuel high-pressure tube insertion portion, then
align it with injection (20) and tighten it tem-
porarily. Firmly tighten holder (16) with bolts
(18).
fl Apply engine oil to the spherical surface
of the spherical washer. (To improve the
spherical washer’s stability.)
fl After tightening the holder, remove the
high-pressure sleeve. In the same man-
ner as above, install each injector in suc-
cession.
3 Holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
Fuel injector harness assembly

fl It is difficult to insert the connector from in-
side with the O-ring of the connector attached.
1) Remove O-ring (22) from harness connector
(21), then let the harness connector out from
inside the connector insertion port. Attach O-
ring (22) and apply engine oil (SAE30). Install
connector holder (23) and press it inside.
Using mounting bolts (15), tighten connector
holder.
2) Install harness terminal (25) to injector termi-
nal (24), then tighten 2 nuts (10). Tighten har-
ness holder clamp (27) with bolts (28).
fl Take in the slack of the harness and press
it to the injector main unit.
3 Terminal nut:
1.8 – 2.2 Nm {0.18 – 0.22 kgm}
30-30-4 HD325-6
9
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
REMOVAL OF CYLINDER HEAD

ASSEMBLY
HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
¤ Raise the body and lock with the safety pin.

¤ Disconnect the cable from the negative (–) ter-
minal of the battery.

= Engine cooling water : 110 ¬
2. Remove turbocharger fire-prevention cover.

(HD325-6W only)
3. Loosen hose clamp and remove hose (1) between

aftercooler and intake manifold.
4. Loosen hose clamp and remove hose (2) between

turbocharger and aftercooler.
5. Remove mounting bolts, then remove connector

(3).
6. Disconnect turbocharger lubrication inlet tube (4).
7. Remove turbocharger cooling water inlet tube (5).

1
8. Remove bracket (6).
9. Disconnect aeration hose (7).
10. Disconnect wiring and hose, then remove washer

tank (8).
11. Disconnect exhaust brake hose (9). 2
12. Remove heater hose clamps (10).
13. Disconnect turbocharger cooling water outlet tube

(11). 3
14. Loosen clamp and remove hose (12).
15. Disconnect turbocharger lubrication outlet tube

(13).
16. Disconnect heater relay wiring (14) (3 places).
17. Remove wiring clamps (15) and (16).
18. Remove clamp and remove tube (17) between air

compressor and air tank.
HD325-6 30-31
9
19. Remove boost compensator tube (18).
20. Remove clamps (19) (2 places), then remove 6

delivery tubes (20). m
21. Remove tube (21) between air compressor and

intake manifold.
22. Disconnect hose (22) between air compressor and

corrosion resistor at air compressor end.
23. Remove engine oil pressure switch wiring clamp

(23).
24. Sling intake manifold assembly (241, remove

mounting bolts, then lift off. m
r+ kg intake manifold assembly: 50 kg
25. Sling turbocharger and exhaust brake cylinder as

an assembly, then remove turbocharger and ex-
haust brake cylinder assembly (26). m
&I kg Turbocharger, exhaust brake cylinder

assembly: 35 kg
27. Remove exhaust manifold assemblies (28). m
30-32 HD325-6
0
28. Disconnect aeration tube (29).
29. Remove spill pipe (30).
30. Remove head cover (31).
31. Loosen locknut (32).
32. Remove connector (33).
33. Remove flange (34).
32
34. Remove nozzle holder assembly (35).
‘35
566FO6346
35. Remove rocker arm assembly (36). I

* Loosen the locknut, then loosen screw 2 - 3
turns.
36. Remove push rod (37).
37. Remove crosshead (38).
HD325-6
38. Remove rocker arm housing (39).
Y r7 CEH00702
39. Remove cylinder head assembly (40). m
+I kg Cylinder head assembly: 30 kg (1 set)
30-34 HD325-6
0

¤ Raise the body, then lock it with a safety pin.

¤ Disconnect the negative (–) terminal of the bat-
tery.
1. Drain water.
6 : 89 ¬
2. Loosen the hose clamp, then remove hose (1) be-
tween the aftercooler and air intake manifold.
3. Loosen the hose clamp, then remove hose (2) be-
tween the turbocharger and aftercooler.
4. Remove the mounting bolts, then remove con-
nector (3).
5. Remove the mounting bolts, then remove cover
(4).
6. Remove tube (5). 1
7. Remove the mounting bolts, then remove bracket
(6).
9. Disconnect the wiring and hose, then remove
washer tank (8).
10. Remove exhaust brake tube (9). 2
11. Remove harness clamp (10).
12. Remove hose clamp (11).
13. Remove the clamp, then remove tube (12) be-
tween the air compressor and air tank.
14. Remove tube (13) between the corrosion resister
and exhaust manifold. 3
15. Loosen the lamp, then remove hose (14).
16. Disconnect tube (15).

17. Remove oil tube mounting clamp (16), then re-
move 2 tubes.
18. Disconnect heater relay wiring (17) at 3 places.
19. Remove wiring clamp (18).
20. Remove reservoir tank hose mounting clamp (19).
HD325-6 30-34-1
9
21. Remove clamps (20) at 6 places, then remove 6

delivery tubes (21). 4
22. Remove tube (22) between the air compressor and

corrosion resister. 5
23. Lift air intake manifold assembly (23) temporarily,

then remove the mounting bolts. 6
0 Air intake manifold assembly: 50 kg
24. Lift turbocharger-exhaust brake assembly (24)

temporarily, then remove mounting bolts (25).
7
0 Exhaust manifold assembly: 35 kg

26. Remove exhaust manifold assembly (27). 8
30-34-2 HD325-6
9
27. Disconnect tube (28). 9
28. Disconnect tube (29). 0
29. Remove head cover (30). A
30. Remove the rocker arm.

fl Referring to “REMOVAL OF FUEL INJECTION
ASSEMBLY”, remove the rocker arm.
31. Remove the fuel injection assembly.

fl Referring to “REMOVAL OF FUEL INJECTION
ASSEMBLY’, remove the fuel injection assem-
bly.
32. Remove push rod (31).
33. Remove crosshead (32). B
34. Remove mounting bolts (33), then remove cylin-

der head assembly (34). C
0 Cylinder head assembly: 21.2 kg (1 unit)
HD325-6 30-34-3
9
INSTALLATION OF CYLINDER
HEAD ASSEMBLY
HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000

moval.
1
9 Turbocharger cooling water inlet tube :
29.7 ± 5.0 Nm {3.0 ± 0.5 kgm}
2
9 Air tube : 56.4 ± 7.4 Nm {5.8 ± 0.8 kgm}
3
9 Turbocharger cooling water outlet tube :
29.7 ± 5.0 Nm {3.0 ± 0.5 kgm}
4
9 Sleeve nut: 23.52 ± 0.98 Nm {2.4 ± 0.1 kgm}
5
fl Tighten in the order shown in the diagram
below.
9 Intake manifold mounting bolt:

• The first time:
29.4 ± 4.9 Nm {3.0 ± 0.5 kgm}
• The second time:
66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}
6
9 Turbocharger mounting bolt:
49.0 ± 4.9 Nm {5.0 ± 0.5 kgm}
7
fl After tightening in the order (1) – (3) in the
diagram below, tighten (4) – (24).
9 Exhaust manifold mounting bolt:

• The first time:
29.4 ± 4.9 Nm {3.0 ± 0.5 kgm}
• The second time:
66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}
HD325-6 30-35
9
QKI Joint bolt:

11.27 i 1.47 Nm (1.15 * 0.15 kgm}
m
m Joint bolt: 8.82 i 0.98 Nm IO.9 i 0.1 kgm}
B Mouting bolt:
4.9 + 0.98 Nm IO.5 ? 0.1 kgm)
m
B Locknut:
36.75 k 2.45 Nm (3.75 _+0.25 kgm}
m
m Connector:
36.75 f 2.45 Nm I3.75 k 0.25 kgm}
m
m Mouting bolt:
66.15 & 7.35 Nm 16.75 + 0.75 kgm)
Clean the oil hole in the mounting bolt, then

install.
Check thet the ball of the adjustment screw is
fitted properly into the socket of the push rod.
Adjust the valve clearance.
Adjusting valve clearance.
m Rocker arm assemble mounting bolt:

98.0 + 4.9 Nm {IO k 0.5 kgm}
B Locknut: 48.02 f 2.94 Nm I4.9 f 0.3 kgm}
m
* Adjust the crosshead as follows.
i) Loosen the locknut, and turn back the ad-
justment screw.
ii) Hold the top surface of the crosshead
lightly, and screw in the adjustment screw.
iii) After the adjustment screw contacts the
valve stem, screw it in a further 20”.
iv) Tighten the locknut to hold it at this posi-
tion.
Locknut: 58.8 f 5.88 Nm IS.0 f 0.6 kgm}
30-36 HD325-6
0
Check that there is no dust on the cylinder

head mounting surface or inside the cylinder.
Check that the grommet does not come out
when installing the gasket.
Coat the bolt threads and seat surfaces com-
pletely with molybdenum disulphide (LM-P).
621OF301
Screw in the cylinder head mounting bolts 2
- 3 turns by hand, then tighten as shown in
the diagram.
& Mounting bolt:

Anti-friction compound(LM-P)
m Cylinder head mounting bolt:
l The first time :147.1 + 9.8 Nm I15 f 1 kgm}

l The second time:
215.7 f 4.9 Nm I22 f 0.5 kgm)
l The third time: I 566FO6353
1) When using tool A2
Use an angle tightening wrench and
tighten 90” + “0””
Put mark on the bolt
2) When not using tool A2 and cylinder head
Make marks on the bolt and head with a

felt pen, then taghten the bolt 90” + to”
* Tighten bolt 0 to
66.15 + 7.35 Nm (6.75 + 0.75 kgm1
* Aftertightening, make one punch markon the
bolt.head to indicate the number of times that
DWH00104
the bolt has been used.
l If any bolt has 5 punch marks, do not re-
use it. Replace it with a new bolt.
. Charging air conditioner with gas.
l Refilling with water

* Refill with water to the specified level, and
level again.
%z 106 Q
DWH00105
HD325-6 30-37
0


moval.
1
3 Joint bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
2
3 Joint bolt: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3
3 Joint bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
4
3 Clamp: 9.8 ± 1 Nm {1.0 ± 0.1 kgm}
5
3 Joint bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
6
fl Regarding the order of tightening, conform
to the right figure.
3 Air intake manifold mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
7
3 Turbocharger mounting bolt and nut:
44.1 – 49 Nm {4.5 – 5 kgm}
8
fl After tightening the bolts in order of 1 to 3
as shown in the right figure, tighten them in
order of 4 – N.
3 Exhaust manifold mounting bolt:
56 – 74 Nm {6 – 7.5 kgm}
30-37-1 HD325-6
9
9
3 Joint bolt: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
0
3 Joint bolt: 8 – 9.8 Nm {0.8 – 1.0 kgm}
A
3 Mounting bolt:
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
B
fl Adjust the crosshead by following the steps
below.
i) Loosen the locknut, then loosen the ad-
just screw.
ii) Lightly press the upper surface of the
crosshead, screw in the adjust screw.
iii) After checking that the adjust screw
touches the valve stem, screw it in 20˚
more.
iv) Tighten the locknut at this position.
3 Lock nut: 53 – 64.7 Nm {5.4 – 6.6 kgm}
C
fl Check that there are no dust and foreign mat-
ter on the cylinder head mounting surface and
in the cylinder.
fl When installing the gasket, check that there
is no peeling on the grommet.
1) Before tightening the cylinder head mounting
bolts, check the following.
fl If the under-head length of bolt exceeds the
specified use-limit length or the number of
bolt tightening (number of tightening
punches) exceeds five times, replace it with-
out reusing.
i) Measure the under-head length of all
mounting bolts a, then check that it is
within the use-limit length.
ii) Use-limit length of bolt
Short bolt: Under 170.8 mm
Long bolt: Under 205.8 mm
HD325-6 30-37-2
9
DISASSEMBLY AND ASSEMBLY ENGINE
REMOVAL OF ENGINE
ASSEMBLY
HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000
¤ Stop the machine on level ground, and put

blocks under the wheels.
¤ Raise the dump body and lock with the safety
pin.
¤ Disconnect the cable from the negative (–) ter-
fl Close the fuel supply valve.
• Remove radiator assembly.

For details, see REMOVAL OF REDIATOR,
TORQUE CONVERTER OIL COOLER ASSEMBLY.
• Top of engine
1. Remove rod (1).

fl Check the installed dimensions, then remove.
2. Remove tube (2).
3. Remove washer tank (3).

fl Remove washer tank together with the mount-
ing bracket.
5. Disconnect heater relay wiring (5).
6. Disconnect exhaust brake tube (6).
• Left side of engine
7. Remove accelerator rod (7).

8. Disconnect stop motor cable (8).

9. Remove hoses (9), (10), and (11), and engine oil

pressure sensor wiring (12).
30-38 HD325-6
9
10. Disconnect oil pressure hose (13).
. Rear of engine
11. Remove protection covers (14) and (15).
12. Remove bracket (16), then remove exhaust pipe

(17), and disconnect connctor (18).
13. Disconnect front drive shaft assembbly (19). m
HD325-6
14. Disconnect wiring (20) from engine block.
16. Disconnect fuel return tube (22).
. Right side of engine
17. Disconnect starting motor wiring connector (23).
18. Disconnect starting motor wiring (24).
19. Disconnect ground connection (25).
20. Disconnect alternator wiring (26).
. -
21. Remove engine assembly. u
I) Remove mounting bolt (front) (27).
2) Remove mounting bolts (rear) (28).
YW A CEH00707
30-40 HD325-6
0
3) Lift off engine assembly (29).

0 1,700 kg
fl When raising the engine assembly, use the
lengths of the wires shown in Fig. a on right
for reference to maintain the balance.
HD325-6 30-41
9

¤ Park a vehicle on flat ground, then chock the

wheels.
¤ Raise the body and lock it with a safety pin.
¤ Disconnect the negative (–) terminal of the bat-
tery.
fl Close the fuel supply valve.
• Radiator assembly
Referring to “REMOVAL OF RADIATOR ASSEM-
BLY”, remove the radiator assembly.
• Upper side of the engine

1. Remove rod (1).
fl Check mounting dimensions, then remove the
rod.
2. Remove clamp (2).
3. Remove washer tank (3).
fl The washer tank must be removed together
with the mounting bracket as one unit.
• Left side of the engine

5. Disconnect two connectors at the body side (5).
6. Disconnect engine speed sensor connector (6).
7. Disconnect heater relay wiring (7).
8. Remove heater relay wiring clamp (8).

9. Disconnect air compressor hose (9).
10. Disconnect exhaust brake air tube (10).
11. Remove reservoir tank drain hose mounting
clamp (11).
30-41-1 HD325-6
9
12. Disconnect fuel hoses (12) and (13).

13. Disconnect air compressor hose (14).
14. Disconnect air compressor connector (15).
15. Disconnect 2 air compressor hoses (16).
• Rear side of the engine

16. Disconnect heater hose (17).
17. Disconnect hose clamp (18).
18. Disconnect fuel return hose (19).
19. Remove bracket (20), then disconnect exhaust

pipe (21). 1
20. Disconnect front drive shaft assembly (22). 2
HD325-6 30-41-2
9
21. Remove fuel hose clamps (23) (4 places).
22. Disconnect starting wiring connector (24).
23. Disconnect starting wiring (25).
24. Disconnect alternator wiring (26).
25. Disconnect grounding cable (27).
26. Engine assembly 3

1) Remove mounting bolts (front side) (28).
fl Note that the part numbers of the cush-
ions change to front (29) and rear (31) af-
ter removing them.
2) Remove mounting bolts (rear side) (30).
fl Note that the part numbers of the cush-
ions change to front (29) and rear (31) af-
ter removing them.
30-41-3 HD325-6
9
3) Lift engine assembly (32), then remove it.

0 Engine assembly: 1,630 kg
fl When lifting the engine assembly, refer to the

length of each wire in Fig. a to keep it in bal-
ance.
HD325-6 30-41-4
9
INSTALLATION OF ENGINE
ASSEMBLY
HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000

moval.
• Install the radiator assemby.

For details, see INSTALLATION OF RADIATOR,
1
8 Drive shaft (front) mounting bolt:
Thread tightener (LT-2)
9 Drive shaft (front) mounting bolt:

106.25 ± 12.25 Nm {11.25 ± 1.25 kgm}
2
9 Engine mounting bolt (front):
926.10 ± 102.9 Nm {94.5 ± 10.5 kgm}
9 Engine mounting bolt (rear):

384.65 ± 41.65 Nm {39.25 ± 4.25 kgm}
fl When installing the engine assembly, assemble

cushions (27a) and (28a).
fl See the procedure for centering the engine as-
sembly and torque converter, transmission as-
sembly.

Refill with water to the specified level and run the
engine to circulate the water through the system.
Then check the water level again.
- 110 ¬
• Refilling with oil

Refill with water to the specified level and run the
engine to circulate the oil through the system.
Then check the oil level again.
- 36 ¬
30-42 HD325-6
9


moval.
• Referring to “INSTALLATION OF RADIATOR AS-
SEMBLY”, install the radiator assembly.
1
fl When assembling a band, assemble it with 0
mm of dimensions in Fig. a or with the speci-
fied bolt and nut tightening torque.
3 Bolt and nut: 24.5 – 31.4 Nm {2.5 – 3.2 kgm}
2
2 Drive shaft (front side) mounting bolt:
Adhesive (LT-2)
3 Drive shaft (front side) mounting bolt:
98.10 – 123 Nm {10 – 12.5 kgm}
3
3 Engine mounting bolt:
662 – 829 Nm {67.5 – 84.5 kgm}
fl When installing the engine assembly, as-

semble cushions (29) and (31).
fl Refer to the procedures for centering between
the engine assembly and torque converter
transmission assembly.
• Water supply
Supply water up to the specified level. Start the
engine to circulate coolant, then check the level
again.
5 : 106 ¬
• Lubrication
Supply oil up to the specified level. Start the en-
gine to circulate oil, then check the level again.
5 : 37 ¬
HD325-6 30-42-1
9
DISASSEMBLY AND ASSEMBLY RADIATOR, TORQUE CONVERTER OIL COOLER
21. Disconnect radiator outlet tube (19).
22. Disconnect oil cooler tubes (20) and (21).
23. Disconnect bypass tube (22).
24. Remove nut of radiator top mount (23) at radia-

tor end. 6
fl Before removing the nut, check dimension a
in the diagram on the right for both the left
and right sides.
25. Remove radiator bottom mount (24).

fl Sling the radiator, and remove the mounting
bolts.
26. Lift off radiator assembly (25).

0 Radiator assembly: 300 kg
HD325-6 30-45
2
DISASSEMBLY AND ASSEMBLY RADIATOR AND TORQUE CONVERTER COOLER

¤ Using tool X1, reclaim air conditioner CFC gas.

• Support the underguard with a transmission jack
or the like, then remove the mounting bolts at the
front side.
1. Drain water.
2. Lift engine hood (1), then remove it.

0 Engine hood: 46 kg
3. Disconnect the air conditioner hose and wiring

clamp (2).
4. Disconnect horn connectors (3).

fl 2 places
5. Disconnect air conditioner hose (4) at the receiver

tank side. 1
6. Disconnect air conditioner hose (5) at the receiver

tank side. 2
7. Disconnect air conditioner switch connector (6).
8. Disconnect air conditioner drain tube clamp (7).
9. Disconnect air conditioner hose (8) at the com-

pressor side. 3
30-45-1 HD325-6
9
10. Remove shims (9) for the radiator guard. 4

fl Check the number of shims on the right and
left.
11. Lift the radiator guard assembly (10), then remove

it.
0 Radiator guard assembly: 100 kg
12. Remove tube (11) between the turbocharger and

aftercooler. 5
13. Remove tube (12) between the aftercooler and

inlet manifold. 6
14. Disconnect radiator inlet hose (13). 7
15. Disconnect water level sensor connector (14).
16. Disconnect aeration hose (15). 8
17. Disconnect reservoir hose (16).
18. Disconnect heater hose (17).

fl Disconnect the hose clamp at the same time.
19. Disconnect make-up line hose (18). 9
20. Remove fan guard (19).
HD325-6 30-45-2
9
21. Disconnect radiator outlet hose (20). 0
22. Disconnect oil cooler tube (21).
23. Disconnect bypass hose (22). A
24. Remove the nut of mount (23) at the upper part

of the radiator at the radiator side. B
fl Before removing it, check dimension a on the
right and left shown in the right figure.
25. Remove mount (24) at the lower part of the radia-

tor.
fl Lift the radiator temporarily, then remove the
mounting bolts.
26. Lift radiator assembly (25), then remove it.

30-45-3 HD325-6
9
DISASSEMBLY AND ASSEMBLY RADIATOR, TORQUE CONVERTER OIL COOLER ASSEMBLY
INSTALLATION OF RADIATOR,
TORQUE CONVERTER OIL
COOLER ASSEMBLY
HD325-6 Serial No.: 5680 – 6000
HD325-6W Serial No.: 5706 – 6000
HD405-6 Serial No.: 1055 – 2000

moval.
1
fl Install the hoses without twisting or interfer-
ence.
9 Hose sleeve nut :
13.23 ± 1.47 Nm {1.35 ± 0.15 kgm}
2
ence.
9 Hose sleeve nut :
13.23 ± 1.47 Nm {1.35 ± 0.15 kgm}
3
ence.
9 Hose sleeve nut :
22.05 ± 2.45 Nm {2.25 ± 0.25 kgm}
4
• Check the number of shims and install.
5
9 Hose clamp :
33.3 ± 4.90] Nm {34 ± 0.5 kgm}
6
• When installing, set to dimension a (measured
during removal operation).
• Using tool X1, charge with air conditioner

freon gas.

Add water to the specified level.
• Run the engine to circulate the water through

the system. Then check the water level again.
30-46 HD325-6
9


moval.
1
fl Install the hose without twisting.
3 Hose sleeve nut:
12 – 15 Nm {1.2 – 1.5 kgm}
2
3 Hose sleeve nut:
12 – 15 Nm {1.2 – 1.5 kgm}
3
3 Hose sleeve nut:
20 – 25 Nm {2.0 – 2.5 kgm}
4
• Check the number of shims, then install them.
5
places displaced 180˚ as shown in the figure.
3 Hose clamp:
9.8 ± 0.5 Nm {1 ± 0.05 kgm}
fl Protrusion of the screw end with regard to

tightening torque must be as follows.
6
places displaced 180˚ as shown in the figure.
3 Hose clamp: 9.8 ± 0.5 Nm {1 kgm}
fl Protrusion of the screw end in relation to tight-
ening torque must be as follows.
HD325-6 30-46-1
9
7
fl Install the hose clamp at the place shown in
the figure.
fl The length of the hose insertion portion b
must be as follows.
1) Radiator side: 85 mm
2) Engine side: 75 mm
8
the figure.
must be as follows.
Length of hose insertion portion b: 25 mm
3 Hose clamp:
3.33 ± 0.5 Nm {34 ± 5 kgm}
9
the figure.
must be as follows.
3 Hose clamp: 4.41 Nm {45 ± 5 kgm}
0
the figure.
must be as follows.
A
the figure.
must be as follows.
B
• Using tool X1, fill with air conditioner CFC gas.
• Water supply
Supply water up to the specified level. Start
the engine to circulate coolant, then check the
level again.
30-46-2 HD325-6
9
DISASSEMBLY AND ASSEMBLY RADIATOR, FRONT DRIVE COOLER
REMOVAL OF RADIATOR, FRONT

DRIVE COOLER ASSEMBLY
HD325-6W
¤ Using tool X1, collect the freon gas from the air
conditioner.
• Support the underguard with transmission jack,

and remove the front mounting bolts.
• Drain the oil from the front drive oil tank.

6 Front drive oil tank : 36 ¬
• Drain coolant.
1. Remove radiator guard.

For details, see REMOVAL OF RADIATOR,
2. Remove 3 hose clamps, and disconnect 2 cooler

hoses (1).
3. Remove nut of radiator top mount (2) at radiator

end. 1
fl Before removing, check dimension a on both
the left and right (shown in the diagram on
the right).
4. Remove radiator bottom mount (3).

fl Sling the radiator and remove the mount
bolts.
5. Lift off radiator assembly (4).

HD325-6 30-46-3
9
DISASSEMBLY AND ASSEMBLY RADIATOR, FRONT DRIVE COOLER
INSTALLATION OF RADIATOR,
FRONT DRIVE COOLER
ASSEMBLY
HD325-6W
1
• Align to dimension a (checked before removing),
then install.
• Using too X1, charge the air conditioner with freon

gas.

Add water to the specified level, and run the en-
gine to circulate the water through the system.
Then check the water level again.
30-46-4 HD325-6
9
DISASSEMBLY AND ASSEMBLY FRONT DRIVE OIL COOLER
REMOVAL OF FRONT DRIVE

OIL COOLER ASSEMBLY
HD325-6W
1. Drain oil from front drive oil tank.
6 Oil tank : 36 ¬
2. Remove radiator guard.

For details, see REMOVAL OF RADIATOR,
4. Sling the front drive oil cooler assembly (4) and

remove the mount bolts (3).
INSTALLATION OF FRONT
DRIVE OIL COOLER ASSEMBLY
HD325-6W
moval.
6 Oil tank : 36 ¬
• Refilling with oil (front drive tank)

Add oil to the front drive oil tank to the specified
level, and run the engine to circulate the oil
through the system. Then check the oil level
again.
5 Front drive oil tank : 36 ¬
HD325-6 30-46-5
9
DISASSEMBLY AND ASSEMBLY OUTPUT SHAFT
REMOVAL OF OUTPUT SHAFT

ASSEMBLY
AL Stop the machine on level
ground, and put
A Raise the dump body and lock with the safety

pin.
1. Drain oil from transmission case. (HD325-6W only)
- : Transmission case: 90.4?
2. Using transmission jack 0, open undercover (1).

(HD325-6W only) 566FO6720
3. Remove brake pump assembly (21, then remove

tube (3). For details, see REMOVAL OF BRAKE
COOLING PUMP ASSEMBLY. (HD325-6W only)
4. Remove 4 hose clamps (4).
5. Remove guide bracket, and lift off drive shaft as-

sembly (5). a
6. Remove coupling (6). m
7. Remove oil seal gauge (7). m
566F06382A 11 566FO6383P
8. Remove snap ring (8).
9. Lift off cover (9). m
&I kg Cover : 35 kg
* Use forcing screw @ and guide bolts @ to

remove.
566FO6384A
HD325-6
10. Lift off output shaft assembly (IO). m

el kg Output shaft assembly: 60 kg
* Use forcing screw @ or guide bolts @ to re-

move.
11. Remove bearing (IO).
F56103264B-K
30-47-l HD325-6
0
INSTALLATION OF OUTPUT
SHAFT ASSEMBLY
l Carry out installation in the reverse order to re-
moval.
l For details of filling with ENS grease, see DISAS-

SEMBLY, ASSEMBLY OF OUTPUT SHAFT AS-
SEMBLY.
,=Q= Drive shaft mounting bolt:

m Drive shaft mounting bolt:

110.3 f 12.3 NmIl1.25 f 1.25 kgm)
a
& Spline: ENS grease
* Before using ENS grease, remove all other

grease completely. Do not mix ENS grease
with other grease. (Use different grease guns
for each type of grease.)
ENS grease Part No.:
427-12-11871 (2 kg can)
a Bearing cover mounting bolt:

B Bearing cover mounting bolt:

110.3? 12.3 Nm III.25 + 1.25 kgm}
Raise the cover and set to the output shaft, use

tool A4 to press fit the inner bearing, then install
cover (9).
6 Output shaft mounting bolt:

m Output shaft mounting bolt:

110.3 + 12.3 Nm Ill.25 k 1.25 kgm}
Bearing: Coat whole surface of bearing inside

diameter and shaft outside diameter
with ENS grease.
30-48 HD325-6
0
DISASSEMBLY OF OUTPUT SHAFT ASSEMBLY
1
569FO52 14-1K
1. Oil cage assembly

Remove oil seal (I) from cage (2).
2. Cover assembly
Remove nearing (3) from cover (4).
3. Damper assembly (5)

I) To keep the balance when reassembling, mark
the set positions of flange (6), body assembly
(71, and outer body (9) before disassembling.
2) Remove body assembly (7) and rubber (8)
from outer body (9).
3) Remove bearing (IO) from flywheel.
HD325-6 30-49
0
-DISASSEMBLY AND ASSEMBLY OUTPUT SHAFT
ASSEMBLY OF OUTPUT SHAFT

ASSEMBLY
1. Using push tool, press fit bearing (IO) in flywheel.
& Flywheel hole portion, inside of bearing:
ENS grease
2. Assembly of damper assembly.

1) Coat mating surface of outer body (9) and one
side of flange (6) with adhesive, then as-
semble.
& Mating surface of flange:
Adhesive (LG-4)
& Mounting bolt: Thread tightener (LT-2)
m Mounting bolt:
66.2 + 7.4 Nm (6.75 + 0.75 kgm}
2) Install body assembly (7).

3) Assemble rubber (8).
* Before assembling, coat with grease.
& Outer body, body assembly, rubber:
Grease (G2-LI)
4) Install flange (6).

& Mating surface of flange:
Adhesive (LG-4)
Q3 Mounting bolt:
66.2 + 7.4 Nm (6.75 f 0.75 kgm}
It Align the marking position of the outer body, in-
ner body, inner body, and flange, ten assembly.
3. Install damper assembly (5) to flywheel.

Shaft spline of body assembly:
ENS grease
Mounting bolt: Thread tightener (LT-2)
Mounting bolt:
110.3 k 12.3 {I 1.25 k 1.25 kgm}
4. Press fit bearing (3) in cover (4).
& Bearing: ENS grease
5. Install cover assembly to flywheel
&I kg Cover assembly: 35 kg
30-50 tlD325-6
0
6. Assemble oil seal (I) in (2).

& Oil seal: ENS grease
7. install cage assembly to cover assembly.

a Mounting bolt: Thread tightener (LT-2)
m Mounting bolt:
113.3 + 12.3 Nm Ill.25 + 1.25 kgm}
l Procedure for filling with ENS grease

1) ENS grease Part No.: 427-12-11871
2) Places to fill with grease, amount of ENS
grease (total amount: approx. 225 g), and
places to coat with grease.
Fill 3 points in 20 mm width on circumference at labyrinth.
Coat all surfaces of bearina I 60% Dack (300)

_.> .L.‘I _ L._ I..
Inner ula. ano snaT1 outer ola.
\
R(dislocated view)
/ Ful I pack (359)
/ /Fillbetween
/ / grease IiD and
/
60% pack [3Os)
Coat all sDIine.

90% pack (25e)
ack (250) 0-B
7 Fu I I Dack (300)
DWHO0107
HD325-6 30-5 1
0
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION
REMOVAL OF TORQUE
CONVERTER, TRANSMISSION
ASSEMBLY
HD325-6, HD405-6
a Stop the machine on level ground, and put

(g, Raise the dump body and lock with the safety
pin.
1. Drain oil
I) Dr$n transmission oil.
,(. approx 90 Q
2) Drain hydraulic oil.
:
_ approx 129 Q
2. Remove protection covers (I) and (2).

Ir Disconnect clamps 0, @, and @ of hoses (3)
and (4).
3. Remove exhaust pipe (5).
4. Remove emergency pump piping (6).
5. Disconnect wiring of transmission oil tempera-

ture switch (7).
6. Hoses
Disconnect bake cooling hose (8), steering and
hoist hose (9), and hose (IO) between transmis-
sion and filter.
30-52 HD325-6
0
7. Disconnect front drive shaft assembly (1 l).m
566FO6393
Rear drive shaft assembly

1) Remove guard (12), and liftoff rear drive shaft
assembly (13). m
9. Hoses, tubes, block

I) Disconnect hose (14), and tubes (15) and (16).
2) Remove tubes (17) and block (18).

3) Loosen belt clamp, and remove tube (19).
HD325-6
IO. Wiring, connector

I) Remove cover (20), and disconnect connec-
tor (211, then disconnect clamp of wiring (22).
11. Toque converter, transmission assembly

I) Remove front mount (23).
2) Remove rear mount (24). m
+ Check the number and thickness of the
shims, and keep in a safe place.
3) Remove torque converter and transmission
assembly (25). a
&I kg Torque converter transmission assembly:

1,500 kg
INSTALLATION OF TORQUE
ASSEMBLY
HD325-6, HD405-6

-
moval.
23 24
566FO6399
m Mounting bolt:
110.3 + 12.3 Nm (II.25 + 1.25 kgm}

w Mounting bolt:
176.5 + 19.6 Nm {I8 f 2 kgm}
w Mounting bolt:
193.2 f 21.6 Nm I19.7 + 2.2 kgm}
See the procedure for centering the engine as-

sembly and torque converter, transmission as-
sem bly.
l Refilling with oil

Ir Refill with oil to the specified level and run
the engine to circulate the oil through the sys-
tem. Then check the oil level again.
Q Transmission oil: 90 e
Q Hydraulic oil: 129 e
30-54 HD325-6
0
DISASSEMBLY AND ASSEMBLY C TORQUE CONVERTER, TRANSMISSION
PROCEDURE FOR CENTERING

THE ENGINE ASSEMBLY AND
TORQUE CONVERTER,
TRANSMISSION ASSEMBLY
l When the engine assembly, torque converter,
transmission assembly or drive shaft have been
removed, use tool A3, and center as follows.
1. Install flange (I) and collar (2) to coupling (3) at

engine end, and secure flange and collarwith bolt
(4).
* Look at the match mark on the collar from
above and install so that it is on the center
line.
2. Install flange (5) at collar (6) to coupling (7) at

torque converter end.
3. Slide collar (6) at torque converter end, align with

match mark on collar (2)at engine end, push into
contact and use a steel tape measure to measure
the stepped difference at the top and bottom, and
left and right.
Ir Check that the largest stepped difference at
the top and bottom, and left and right is within
3 mm.
566FO6402
HD325-6 30-55
0
REMOVAL OF TORQUE
ASSEMBLY
HD325-6W
g Stop the machine on level ground, apply the

parking brake, and put blocks under the wheels.
A Raise the dump body and lock with the safety
pin.
1. Draining oil
1) Drain transmission oil. \
& Approx. 90 .JJ
2) Drain hydraulic oil.
- : Approx. 129 e
3) Drain front drive tank oil.
- : Approx. 36 e
2. Remove fire prevention covers (I) and (2).

-k Disconnect the clamps of hoses (3) and (4) at
positions 0, @, 0, and @I.
3. Disconnect 4 hoses (31) between front drive tank

and front drive pump, and 3 hoses (32) between
tank and motor.
4. Disconnect connector (34) and hose (33) (I each

on left and right) between front drive pump and
travel motor.
5. Remove exhaust pipe (5).
6. Remove emergency pump piping (6).
7. Disconnect wiring of transmission oil tempera-

ture switch (7).
566FO6390 566FO6391
8. Hoses
1) Disconnect brake cooling hose (8), steering
and hoist hoses (9), and hoses (IO) between
transmission and filter.
30-55-l HD325-6
0
9. Disconnect front drive shaft assembly (11). m
566FO6393
IO. Rear drive shaft assembly

1) Remove guard (12), then sling rear drive shaft
assembly (13), and disconnect. m
11. Hoses, tubes, block

1) Disconnect hose (14) and tubes (15) and (16).
2) Remove tube (17) and block (18).
3) Loosen belt clamp, and remove tube (19).
HD325-6
12. Wiring, connector

1) Remove cover (201, disconnect connectors
(211, then disconnect clamps of wiring (22).
13. Torque converter, transmission assembly

1) Remove front mount bolts (23).
2) Remove rear mount bolts (24). a
Ir Check the number and thickness of the
3) Remove torque converter and transmission
assembly (25). m
566Fb6397 566FO6398
&I kg Torque converter, transmission
assembly : 1,500 kg
ASSEMBLY
HD325-6W
. Carry out installation in the reverse order to re-
moval.
23 24
a
566FO6399
Mounting bolt:
110.3 rtr12.3 Nm Ill.25 + 1.25 kgm}
Mounting bolt:
176.5 k 19.6 Nm {I8 k 2 kgm}
Mounting bolt:
193.2 k 21.6 Nm I19.7 F 2.2 kgm}
I- -n-0 /56iFO6400
See the procedure for centering the engine as-

sembly with the torque converter and transmis-
sion assembly.
. Refilling with oil
-k Add oil to the specified level, and run the
engine to circulate the oil through the sys-
Transmission oil: 90 e
Hydraulic oil :I29 e
Front drive oil : 36 e
30-55-3 HD325-6
0
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER VALVE
REMOVAL OF TORQUE
CONVERTER VALVE
ASSEMBLY
g Raise the dump body and lock with the safety
pin.
2. Disconnect lockup solenoid valve wiring connec-

tor (2).
3. Remove tube (3).
4. Remove torque converter valve assembly (4). m
CONVERTER VALVE
ASSEMBLY
moval.
u
QKl Mountain bolt of torque converter valve
assembly: 49 k 4.9 Nm I5.0 f 0.5 kgm)
30-56 HD325-6
0
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER VALVE
DISASSEMBLY OF TORQUE
CONVERTER VALVE ASSEMBLY
1. Remove solenoid valve (2) from body (1).
2. Remove cover (31, then remove spring (4).
3. Remove cover (51, then remove valve (6) and (8),

spring (71, and torque converter relief valve (9).
4. Remove cover (IO), then remove shim (11) and

spring (12).
Ir Check the number and thickness of the shims,
and keep in a safe place.
5. Remove plate (13), then remove valves (14) and

(16), spring (151, and main relief valve (17).
6. Remove cover (181, then remove piston (191, shim

(201, springs (21) and (221, and spacer (23).
7. Remove cover (24), then remove piston (25),

valves (26) and (281, spring (271, and lockup valve L 566F0640E
(29).
ASSEMBLY OF TORQUE
* Clean all parts, and checkfor dirt or damage. Coat

the sliding surfaces of all parts with engine oil
before installing.
1. Fit piston (25) and O-ring and install cover (24).
2. Assemble valves (28) and (261, and spring (27) to

lockup valves (291, then assemble in body.
3. Assemble spacer (23) in body, then assemble shim

(20) and springs (21) and (22) to piston (191, as-
semble to body, then fit O-rig and install cover
(18).
4. Fit O-ring and install plate (13).
5. Assemblevalves (16) and (141, and spring (15) to

main relief valve (17), then assemble in body.
6. Assemble shim (11) and spring (12) to cover (IO),

then fit O-ring and install to body.
9 1
566FO6406
7. Fit O-ring and install cover (3) to body.
8. Assemble spring (4), valves (8) and (61, and spring

(7) to torque converter relief valve (91, then as-
semble to body.
9. Fit O-ring and install cover (5).
IO. Install solenoid valve (2) to body (I).
HD325-6 30-57
0
DISCONNECTION OF TORQUE
ASSEMBLY
1. Piping
Remove each tube and hose.
* After removing the tubes and hoses, set a
block or stand under the transmission assem-
bly.
566FO6407-1
2. Hydraulic pump assembly

Remove 3 hydraulic pump assemblies (2).
(4 assemblies on HD325-6W)
3. Trunnion
Remove trunnion (3).
u
566FO6725
4. Torque converter assembly m

1) Using 2 lever blocks, keep torque converter
assembly (4) horizontal.
2) Lift off torque converter assembly (4).
&l kg Torque converter assembly: 380 kg
I 566F06409A
30-58 HD325-6
0
CONNECTION OF TORQUE
ASSEMBLY.
l Carry out connection in the reverse order to dis-
connection.
?I Check installation of input shaft seal ring (1 I),

coat with grease (G2-LI), then make protru-
sion from shaft uniform.
2) Using 2 lever blocks, raise torque converter
assembly (4).
I
3) Adjust with 2 lever blocks so that torque con- 566FO6410
verter assembly is horizontal to transmission

input shaft.
4) Move torque converter assembly horizontally,
and assembly to transmission assembly.
+ Do not force the torque converter in. This
will damage the seal ring.
QK Mounting bolt:
110.3 + 12.3 Nm Ill.25 + 1.25 kgm}
tlD325-6 30-59
0
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
DISASSEMBLY OF TORQUE
CONVERTER ASSEMBLY
1. Control valve assembly
Remove control valve assembly (1).
I 566FO6411
2. PTO assembly
1) Settorque converter assembly (2) on tool Bl.
2) Remove input coupling (3).
566FO6412
3) Using eye bolts (ij, remove PTO assembly (4)

with forcing screw.
3. Turbine *clutch assembly

1) Remove 30 mounting bolts (5).
2) Using eye bots CiJ, remove turbine l clutch
assembly (6).
'566F0641E
30-60 HD325-6
0
4. Stator assembly
Remove assembly (7) with pulling up.
\
566FO6416
5. Pump assemblv
1) Using tool 63, remove nut (8).
566FO6417 (1 566FO6418
2) Using puller 0, remove inner race (9) and

pump assembly (IO).
566FO641 C
3) Remove mounting bolt, then remove retainer

(11) and guide (12).
11
566FO6420 566FO6421
HD325-6 30-61
0
4) Using push tool 0, remove bearing (13) from

guide. 8 a a\
566FO6422 566FO6423
6. Stator shaft
1) Remove mounting bolts, then remove stator
shaft (14).
566FO6424 11 566FO6425 1
2) Remove plug, then remove inner race (15)

with bar.
3) Remove seal ring (16).
566FO6426 566FO6427
DISASSEMBLY OF TURBINE. CLUTCH

ASSEMBLY
C4
7. Input shaft
1) Using forcing screw 0, remove input shaft
(17).
2) Using puller 0, remove bearing (18).
566FO6428 11 566FO6429
30-62 HD325-6
0
8. Turbine
1) Remove snap ring (19), then remove plate
(20).
566FO643C 566FO643’
2) Using forcing screw @, remove turbine (21).
566FO6432
9. Housing assembly ir
I) Remove mounting bolt, then lift off housing
assembly (22).
2) Remove piston (23) from housing assembly,
then remove seal ring (24).
566FO6433 566FO6434
3) Using push tool 0, remove bearing (25) from

housing.
4) Remove seal ring (26).
5) Remove Din (35).
I
566FO643: 566FO64361
HD325-6 30-63
0
10. Disc
Remove disc (28) from case (27).
566FO6437
DISASSEMBLY OF STATOR ASSEMBLY
11. Stator
Remove mounting molt, then remove stator (29).
12. Bushings
Remove bushings (31) and (32) from race (30).
* Be careful not to lose balls.
566FO6438 566FO6439
13. Raceefree wheel

Remove race (33) and free wheel (34) from race
(30).
3j 52 ‘34
566FO6440
30-64 HD325-6
0
ASSEMBLY OF TORQUE
CONVERTER ASSEMBLY.
ASSEMBLY OF STATOR ASSEMBLY
1. Race l free wheel

Install free wheel (34) and race (33) in race (30).
* Assemble the free wheel so that the arrow on
the end face of the gauge is at the input shaft
end.
* Coat the race sliding surface with engine oil
(E030-CD or EOIO-CD)
\ \.
32 34
2. Bushings 566FO6440
Install bushings (32) and (31) in race (30).
* Be careful not to forget assembling of balls.
3. Stator
lnstallstator (29).
& Mounting bolt: Adhesive (LT-2)
w Mounting bolt:
68.6 k 4.9 Nm I7 + 0.5 kgml
* Check the direction of rotation of the stator.
Dirredtion of rotation as seen from input end:
Clockwise: Free
Counterclockwise: Locked
I 566FO6439 I 566FO6438
ASSEMBLY OF TURBINE l CLUTCH AS-

SEMBLY
4. Tubine l case
Set turbine (21) and case (27) on push tool@.
* Use block to prevent from case (27) direct
contacting with turbine (21).
27
566FO6442
5. Disc
Install disc (28).
* Coat the disc sliding surface with engine oil
(E030 - CD or EOIO - CD).
566FO6443
HD325-6 30-65
0
6. Housing assembly
1) Install pin(35).
* Expand fit pin (35) to the housing.
2) Install seal rings (24) and (26) on piston (23)
and housing (22).
a Rings: Grease (G-LI)
566FO6444 566FO6445
3) install piston in housing assembly (22), then

install housing assembly on case (27).
6 Mounting bolt: Adhesive (LT-2)
w Mounting bolt:
112.8 k 9.8 Nm (11.5rtl.O kgm}
566FO6446
7. Bearing
1) Using push tool @I, press fit bearing (25).
25.
566FO6447
2) Fit plate (20), then install snap ring
566FO6431 566FO6430
30-66 HD325-6
0
8. Input shaft
1) Using push tool, press fit bearing (18) on in-
put shaft (17).
2) Install input shaft (17) on housing.
w Mounting bolt:
279.5 rt 29.4 Nm I28.5 k 3.0 kmg}
566FO6448
ASSEMBLY OF TORQUE CONVERTER

ASSEMBLY
9. Stator shaft
1) Install seal ring (16).
& Seal rings: Grease (G2-LI)
2) Using push tool, press fit inner race (15).
566FO6427
II
566FO6449
3) Set torque converter case on tool C2.
4) Install stator shaft (14) on case.

w Mounting bolt:
112.8 + 9.8Nm {I 1.5 & 1.0 kgm}
566FO6425 566FO6424
IO. Pump assembly

I) Using push tool @I, press fit bearing (13) in
guide (12).
13
566FO6450 566FO645’
HD325-6 30-67
0
2) Install guide (12) and retainer (I 1) with mount-

ing bolts.
6 Mounting bolt: Adhesive (LT-2)
w Mounting bolt:
68.6 k4.9 Nm I7.0 k 0.5 kmg}
I 566FO6421 566FO6420
3) Set pump assembly (IO) and inner race (9) on

mounting position.
4) Using push tool @I, press fit inner race (9).
* Apply a drop of engine oil (E030-CD or
EOIO-CD), and rotate the bearing.
I 566FO6452 11 566FO64531
5) Tighten nut (8) with tool B3.

m Nut: 465.8 i: 24.5 Nm t47.5 + 2.5 kgm}
A 4
566FO6417 566FO6454
11. Stator assembly

Install stator assembly (7).
\ .-
566FO6416
30-68 HD325-6
0
12. Turbine clutch assembly

l
Using eye bolts 0, set turbine assembly (6) on

mounting position, then tighten 30 mounting bolts
(5).
w Mounting bolt:
53.9 * 43.9 Nm I5.5 + 0.5kmgI
13. PTO assembly

I) Fit O-ring, using eye bolt: 0, install PTO as-
sembly (4).
\ 566FO6456
2) Fit O-ring, install input coupling (3), then in-

stall holder (35).
& Mounting: Adhesive (LT-2)
m Mounting bolt:
279.5 + 29.4 Nm (28.5 f 3.0 kgml
566FO6457
14. Control valve assembly

Fit gasket, then install control valve assembly (I).
w Mounting bolt:
49.0 f 4.9 Nm t5.0 f 0.5 kgm1
566FO6411
HD325-6
DISASSEMBLY AND ASSEMBLY PTO
DISASSEMBLY OF PTO
ASSEMBLY
HD325-6, HD405-6
1. Using tool C3, remove nut (1).
2. Using puller 0, 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).
* Disassemble in same way for all three pump
1 566F0645f CWHOlOlS
drive gears.
5. Remove cover (II), then remove oil seal (12).
6. Remove other race (14) from case (13).
566FO6460 11 566FO6461 1
566FO6462 566FO6463
\ /
566FO6465 566FO6464
30-70 HD325-6
0
ASSEMBLY OF PTO ASSEMBLY

HD325-6, HD405-6
1. Using push tool 0, press fit outer race (14) in case

(13).
2. Using push tool 0, install oil seal (12) in cover

(II).
566FO6466 566FO6467
3. Fit O-ring, then install cover (11).
l Assemble all three pump drive gears as follows. I 566FO6465
4. Install outer race (IO), plate (9), outer (8) and plate
(91, then install snap ring (6).
* The bearing form a set, so assemblythe same

production numbers, and match marks [Al
and [Al, [Bland [Bl.
566FO6468
5. Using push tool, press fit gear (2) and bearing (5).
I 566FO6469
l-ID3256
6. Set plate (4) in case (13).
566FO6470
7. Using block @ and push tool 0, press fit bearing

(3)
566F1105
8. Tighten nut (I) with tool C3.

w Nut: 353.1 IL 39.2 Nm I36.0 + 4.0 kgm]
Ir Bend lock washer securely.
566FO6471
30-72 HD325-6
0
DISASSEMBLY OF PTO
ASSEMBLY
HD325-6W
* Disassembly the four sets of pump drive gears in

the same way.
1. Using push tool C3 and C5 remove nut (I).

* Use tool C3 for the hoist, steering, brake cool-
ing, and transmission drive gears; use tool C5
for the front drive gear.
2. Using puller 0, remove gear (2) and bearing (3).
3. Remove plate (4) and bearing (5) from gear (2).
4. Remove snap ring (6), then remove plate (71, outer

race (8) and plate (9), and outer race (IO).
6
566FO6728
5. Remove cover (I I), then remove oil seal (12).
6. Remove outer race (14) from case (13).
566FO6465
HD325-6 30-72-l
ASSEMBLY OF PTO ASSEMBLY

HD325-6W
1. Using push tool 0, press fit outer race (14) to case

(13).
2. Using push tool 0, install oil seal (12) to cover

(II).
566FO646t 566FO6467
3. Fit O-ring and install cover (I 1).
566FO6365
. Assemble all four pump drive gears as follows.
4. Fit outer race (IO), plate (9), and outer race (8),
and plate (7), then install snap ring (6).
* The bearing are used in sets, so assembly the

manufacturing numbers, and match marks [Al
and [Al, [BI and LB1together.
566FO6468
5. Using push tool, press fit gear (2) and bearing (5).
566FO6469
30-72-2 HD325-6
0
DISASSEMBLY AND ASSEMBLY TRANSMISSION
DISASSEMBLY OF
TRANSMISSION ASSEMBLY
DI XONNECT TORQUE CONVERTER
A! SEMBLY
1. Lift off ECMV assembly (2) from transmission as-

sembly (I).
2. Sleeve
Using eye bolt 0, remove 5 sleeves (3).
/i’kY b 566FO6473
3. Remove intermediate shaft rotation sensor, torque

converter output shaft sensor cover, then remove
intermediate shaft rotation sensor (4) and torque
converter out put shaft sensor (5).
4. Speedometer sensor
Remove cover (6), then remove sensor (7).
HD325-6
AND ASSEMBLY TRANSMISSION
DISASSEMBLY
5. Speedometer gear assembly

1) Remove cover (8), then remove gear assem-
bly (9).
566FO6476 566FO6477
2) Remove plug (IO), and pull put collar (II).
6. Oil pan assembly

1) Set transmission assembly on block (Height
= 150 mm) facing input shaft top.
2) Lift off oil pan (12).
i = 566FO6479
DISASSEMBLY OF OIL PAN
I) Remove baffle plate (13).

2) Remove plug (14).
3) Remove block (15), then remove valves (16)
and (17).
4) Remove cover (18), then remove magnet as-
sembly (19).
HD325-6
30-74
0
7. Checking piston operation

Using tool Dl, check piston operation of No. 1, 2,
and 3 clutches.
* Air pressure: 0.3 - 0.6 Mpa (3 - 6 kg/cm9
8. No.1 clutch assembly

Sling shaft, then remove No. 1 clutch assembly
(20).
DISASSEMBLY OF No.1 CLUTCH ASSEMBLY
1) Input shaft assembly

i) Remove input shaft assembly (21).
+-
566FO64fE
ii) Disassemble input shaft assembly as fol-

lows.
(a) Remove snap ring (221, then remove
gear (23) from shaft (24).
CWH01022
HD325-6
(b) Remove bearing (25) from gear (23).
(c) Remove snap ring (27), then remove

bearing (28).
(d) Remove snap ring (29).
29
28
I J566FO6486 I I’
566FO6487
2) No. 1 housing piston

l
Remove housing (30) together with piston.
566FO6488
3) Discs plates
l spring
l
Remove discs (311, plates (32) and springs (33)

and (34).
4) Ring gear guide pins

l
i) Removen ring gear (35) and guide pins

(36).
si 566F1107A-K
30-76 HD325-6
0
ii) Remove snap ring (38).
iii) Remove inner race (39).
566FO6489
5) Plate
Remove bearing (40) from plate (37).
566FO6490
g. Lift off No. 2 clutch assembly (41).
I I
566FO6491
DISASSEMBLY OF No. 2 CLUTCH

ASSEMBLY
1) Housing assembly ,42

i) Remove housing (42).
566FO649i
HD325-6 30-77
0
ii) Remove cylinder (43), then remove pis- 1
ton (44) from housing (42).
iii) Remove seal (45) from piston (44).
566FO6493 566FO6494
iv) Remove seal rings (46) and (47), and bear-

ing (48) from housing (42).
48 42
v) Remove seal ring (49). 50
vi) Remove bearing (50) from housing (42).
566FO6495 566FO6496
2) Discs plates
l
Remove discs (51), plates (52) and spring (53).
3) Remove plates (54).
566FO6498
30-78 HD325-6
0
4) Remove drum (55).
566FO6499
5) Planetary gear
A56 II
i) Remove shafts (56)
Ir Be careful not to lose balls (57). / 57 60 51
o/5’
ii) Remove gear (58), bearing (59), and thrust
washer (60) from carrier (61). 60
566FO6500 60 566FO6501
iii) Remove bearing (62), seal ring (66), and

inner race (63) from carrier (61), then re-
move ring gear (64). 61 64 I
* When removing ringer (64) from car- \ 62
rier (61), use two of the four holes in
the ring gear on opposite sides, insert 63
round bar 0 (max. diameter: 08 mm),
compress snap ring (65), and pull out
the ring gear.
566FO6503
566FO6504
HD325-6
10. Transmission case assembly

Lift off transmission case assembly (67).
566FO6505
11. Trasmission case

1) Remove snap ring (68).
2) Remove collar (69).
3) Remove inner race (70) from collar.
566FO6506 566FO6507

6, and 7 cutch.

Lift off No. 3 clutch housing (71).
L 566FO6501
30-80 HD325-6
0
DISASSEMBLY OF No. 3 CLUTCH

ASSEMBLY
I) Housing assembly ,72

i) Remove housing assembly (72).
566FO6510
ii) Remove cylinder (73), then remove pis-

ton (74) from housing (72).
113)
iii) Remove seal ring (75) from piston (74).
566FO65ll j1 566FO6512
iv) Remove seal rings (76) and (77), and bear-

ing (78) from housing (72). 72
I
VI Remove seal ring (79).
vi) Remove bearing (80) from housing (72).
566FO6513 566FO6514
2) Drum, disc, plate, spring

Remove disc (82), plate (831, and spring (84)
from drum (81).
i2
566FO651!
HD325-6 30-81
0
14. No. 3 clutch ring gear

1) Remove ring gear (85).
2) Remove seal ring (86) and inner race (87) from j B
ring gear (85).
86
I 566FO6516 II 566FO6517
15. Tie bolt

Remove tie bolt (88).
16. No. 4 clutch plate

Remove plate (89).
566FO6518
17. No. 4 clutch discs, plates, springs

Remove discs (90), plates (911, and springs (92)
and (93).
566FO6519
18. No. 4 ring gear

Remove ring gear (94).
19. No. 4 piston, housing

Remove housing (95) together with piston (961,
then remove piston (96) from housing (95).
‘96
566FO6520 566FO6521
30-82 HD325-6
0
20. No. 5 clutch discs. plates . springs

and (100).
566FO6522
21. Guide pins

Remove guide pins (101).
566FO6523

566FO6524
23. No. 5 housing, piston

Using eyebolts, remove No. 5 housing (103) to-
gether with piston (104).
I 566FO6525
HD325-6 30-83
0
24. No. 6 clutch discs. plates. springs

and (108).
25. Sun gear

1) Remove snap ring (109).
2) Remove No. 4 sun gear (110) and No. 5 sun
gear (I 1 I).
* Remove seal ring (I 12) from No. 4 sun gear.
566FO6527 566F1112A-K
26. No. 4,5 carrier assembly

Lift off No. 4 and 5 carrier assembly (I 13).
30-84 HD325-6
0
DISASSEMBLY OF No. 4,5 CARRIER I I

ASSEMBLY
1) Planetary gear for reverse

i) Knockshaft (114) for reverse gear out to
ball end, and remove ball (115).
ii) Knock shaft (114) out from ball end, and
remove reverse gear (116), bearing (117),
collar (118), and thrust washer (119).
* Knock shaft (114) out to the No. 4 car-

rier end. Be careful not to lose ball
(115).
I 566FO6529
2) No. 4, 5 planetary gear

i) Knock shaft (120) out to ball end, and re- 128 126 125 128
move ball (121).
ii) Knock out shaft (120), then remove No. 4
planetary gear (122), bearing (123), thrust
washer (124), No. 5 planetary gear (125),
bearing (126), collar (127), and thrust 124 12
washer (128).
569FO5231 A-K
3) Bearing, ring gear

i) Remove bearing (129) from carrier.
ii) Remove ring gear (130).
”
I 566FO6530
HD325-6 30-85
0
* When removing ring gear (130) from carrier

(1131, use two of the four holes in the ring
gear on opposite sides, insert round bar 0
(max. diameter: 08 mm), compress snap ring
(1311, and pull out ring gear (130).
566FO653’
27. No. 6, 7 housing, No. 6, 7 piston

I) Lift off No. 6 and 7 housing (132), No. 6 pis-
ton (1331, and No. 7 piston (134).
2) Remove No. 6 piston (133) and No. 7 piston
(134) from housing (132).
-132
-
566FO6532
3) Remove seal rings (135) from pistons (133) I
and (134).
4) Remove seal ring (136) from housing (132).
I 566FO6533
28. Guide pin

Remove guide pin (137).
-131
29. No. 7 clutch discs, plates. springs
Remove discs (1381, plates (139), and springs (140)
and (141).
566FO6534
30-86 HD325-6
0

Using eyebolts, remove No. 6 and 7 carrier as-
sembly (142).
142
566FO6535
DISASSEMBLY OF No. 6,7 CARRIER

ASSEMBLY
145
1) Collar
F
Remove collar (143).
2) Remove inner races (145) and (146) from col- 143

lar (143).
566FO6536 11 566FO65371
3) Intermediate shaft, sun gear, bearing

i) Knock out intermediate shaft (147), and
remove intermediate shaft and bearing
(148).
566FO6538
566FO653!
HD325-6 30-87
0
ii) Remove sun gear (149) and snap ring

(1.50) from intermediate shaft (147).
iii) Remove inner race (151).
I 566FO6540
4) Bearing, seal ring

i) Remove seal ring (152).
ii) Remove bearing (153).
‘153
'152
I
566FO6541
5) No. 6 planetary gear j54

i) Remove snap ring (154).
ii) Pull out shaft (155), then remove No. 6

planetary gear (156), bearing (1571, thrust
washer (158), and ball (159).
566FO6541 ,
6) No. 7 planetary gear

155 159 158 157 156 l.58
* Follow Steps i) and ii) to disassemble.
\\//I
566FO6543
30-88 HD325-6
0
31. No. 7 ring gear

566FO6544
32. Worm, collar

Remove worm (162) and collar (163) from cage
(161).
566FO6545 566FO6546
33. Output shaft

1) Remove output shaft assembly (164) from
cage (161).
161
v 566FO6547
2) Set cage (165) on block, press output shaft

(166) with press, and pull out from bearing.
HD325-6 30-89
0
3) Disassembly of cage
i) Remove oil seal (167) from cage (165). 165 167
ii) Remove bearing (I 68) from cage (I 65).
566Fll lOA-K
iii) Remove bearing (169) from output shaft

(164).
566FO6549
4) Remove bearing (170) from cage (161).
II
566FO6550 566FO6551
30-90 HD325-6
0
ASSEMBLY OF TRANSMISSION
ASSEMBLY
Caution when assembling
* Clean all parts, and remove burr.
* Coat seal ring with grease (G2-LI) before install-
ing.
* Coat rotating surfaces and sliding surfaces with
engine oil before installing.
I. Output shaft assembly

I) Install bearing (170) in cage ( 161).
ii
566FO6550 - 566FO6551
2) Assemble output shaft assembly as follows.

i) Install bearing (169) in output shaft (164).
566FO6549
ii) Install bearing (168) in case (165).

iii) Install oil seal (167) in cage (165).
& Oil seal lip: Grease (G2-LI)
566Flll OA-K
HD325-6 30-91
0
iv) Set output shaft (166) on press, then press 1

inner race to install cage (165).
-166
566FO6552 J
3) Fit O-ring, install output shaft assembly (164) 164 1

in cage (161).
Mounting bolt: Adhesive (LT-2)
4) Turn over cage (1611, and assemble collar

(163) and worm (162).
566FO6545 566FO6546
2. No. 7 ring gear

Install ring gear (160).
Jr Install ring gear so that outer gear which is
cut faces top.
566FO6544
30-92 HD325-6
0
ASSEMBLY OF No. 6,7 CARRIER

ASSEMBLY
i) Assem.ble bearings (157) in gear (156), set
gear and thrust washers (‘158) on carrier.
ii) Knock in shaft (155), then assemble ball
(159) to install completely.
566FO6543

Assemble No. 6 planetary gear.
For details, refer to step 1) (No. 7 planetary
gear). t
-153
3) Inner race. snap ring (No. 7 side)
i) Install snap ring (154).
ii) Install bearings (153). ‘152
iii) Install seal ring (152).
566FO6542 566FO6541
4) Intermediate shaft. No. 6 sun gear

i) Install inner race (151) on intermediate
shaft (147).
ii) Install snap ring (150).
iii) Install intermediate shaft (147) on carrier

(142).
iv) Install sun gear (149).
v) Using push tool 0, install bearing (148).
566FO6553 566FO6554
HD325-6
5) Collar
i) Install inner races (145) and (146) on col-
I
lar (143).
566FO6537
ii) Install collar (143) on carrier (142).
u
566FO6536

Using eyebolts, install No. 6, 7 carrier assembly
(142). -
Ir Be careful not to fall piston.
,142
\v 566FO6535
4. Guide pins
Install guide pins (137).
5. No. 7 clutch discs plates l springsl
Install discs (138), plates (139) and springs (140)

and (141).
* There are four discs and three plates.
* Free length of spring (140): 58 mm
566FO6534
30-94
0
6. No. 6, 7 housing l No. 6,7 pistons

1) Assemble seal ring (135) to piston (133), then
assemble seal ring (136) to housing (132).
2) Assemble piston (133) in housing (132).
+ Install the seal ring so that the portion with
the groove faces the side taking the pres-
sure.
-
566FO6532
3) Using eyebolts, align with springs, then in-
stall housing (132).
* Knock in dowel pin with plastic hammer.
* Check that the spring is fitted securely into
the seat of the piston and housing.
I /+yF 134
,133
late
Sprint
isc
Piston
receiving
ti
Pin
DWH00109
I ” 136 DWHOOIIO
l Assembly of No. 4,5, carrier assembly

I) No. 4, 5, planetary gear 128 128 125 128
i) Assemble bearing (123) in No. 4 planetary
gear (122), then fit thrust washers (124)
to both sides, and set in carrier.
ii) Insert collar (127) between 2 bearings
(126), assemble in No. 5 planetary gear
(125), then fitthrustwashers (128) to both
sides, and set in carrier.
iii) Cool shaft (120) with dry ice and assemble
to carrier.
* Check that the positions for the holes 569F05231A-K
of the bearing, thrust washer, and car-
rier are aligned correctly, then as-
semble the shaft, being extremely
careful not to damage the bearing or
thrust washer.
* When assembling, align the hole in
the carrier with the hole for mounting
the ball.
iv) Fit ball (121) and install shaft (120) com-
pletely.
* Check that the gear rotates smoothly.
566FO6555
HD325-6
2) Planetary gear for reverse

i) Insert collar (118) between 2 bearings
(117), assemble in gear (I 161, then fit
thrustwashers (I 19) to both sides, and set
in carrier.
hY----
F56103372-1K
ii) Align with bearing and thrust washer, and

push in shaft (I 14).
iii) Knock shaft (114) out until ball hole can
be seen completely, then assemble ball
(115) and knock into carrier to install.
* When press fitting the shaft, align the
center of the bearing and shaft to pre-
vent the bearing cage from becoming
deformed. Do not hit the shaft when
assembling.
* Check that the gear rotates smoothly.
566FO6529
3) Bearing
Install bearing (129) in carrier (I 13).
566FO6556
4) No. 6 ring gear

Install snap ring (131) to carrier case (113),
then assemble ring gear (130).
* Keep the snap ring compressed and push 129
the ring gear in. 113 130
131
130
566FO6557 566FO6530
30-96 HD325-6
0

Using eyebolts, install No. 4, 5 carrier assembly
(I 13).
566FO6528
8. Sun gear
1) Install No. 5 sun gear (111) and No. 4 sun gear
(1 IO).
+ Install seal ring (112) on No. 4 sun gear.
2) Install snap ring (109).
566F1112A-K
9. No. 6 clutch discs l plates l springs

Install discs (1051, plates (106) and springs (107)
and (108).
* There are four discs and three plates.
* Free length of spring (107): 58 mm -109
10. No. 5 housing . No. 5 piston

1) Assemble seal ring, then install piston (104)
in housing.
+ Install seal ring with groove side facing
pressure receiving side.
2) Using eyebolts, align with springs, then in-
566FO652f
stall housing (103).
t Check that the spring is fitted securely into
late
,103
SPrine
isc
-104
Piston
f
Pin
DWH00109
566F0652E
HD325-6 30-97
0
11. No. 5 ring gear

* install ring gear so that inner gear which is
cut faces lower.
12. Guide pins

566FO6524 566FO6523
1
13. No. 5 clutch discs plate
l springs
l
Install discs (97), plates (98) and springs (99) and

(100).
* There are five discs and four plates.
* Free length of spring (99): 77 mm
98 I
566FO6522
14. No. 4 housing lNo. 4 piston

1) Assemble seal ring, then install piston (96) in
housing.
* Install seal ring with groove side facing
pressure receiving side.
2) Align spline, then install housing (95).
+ Check that the spring is fitted securely into
late
Sprina
566FO6521
isc
Piston
5
Din
,488
DWH00109
15. No. 4 ring gear

* Install ring gear so that outer gear which is
cut faces lower.
566FO6520
30-98 HD325-6
0
16. No. 4 clutch discs - plates l springs

Install discs (901, plates (91) and springs (92) and
(93).
Ir No. 4clutch discs and plates are differentfrom
No. 5, 6 and 7 clutch.
+C There are three discs and two plates.
k Free length of spring (92): 54 mm
17. No. 4 plate

Aligning with spring, install plate (89).
* Check that the spring is fitted securely into
the seat of the piston and plates.
566FO651!
DWH00109
18. Tie bolts

Install tie bolts (88). - -
566FO6518
m Tie bolt: 166.7 k 9.8 Nm I17 + 1 kgm)
19. Install inner race (87) and seal ring (86) to ring
gear (85).
85
566FO6517

566FO6516,
HD325-6 30-99
0
21. No. 3 clutch drum

Install drum (81).
No. 3 clutch discs l plates l springs

Install discs (82), plates (83) and springs (84).
* There are three discs, two plates and three
springs.
566FO6558
22. Housing assembly

a2
1) Assemble housing assembly as follows.
i) Install bearing (80) in housing (72). \ F3
ii) Install seal ring (79).
iii) Install bearing (78) in housing (72).
iv) Install seal ring (76) and (77).
v) Install seal ring (75) on piston (74).
* Install seal ring with groove side fac-
ing pressure receiving side. .a4
566FO6559
Piston
Press”
WI DWHOOIII
vi) Assemble piston (74) in housing (72), then

install cylinder (73). 566FO6514
566FO6513
HD325-6
2) Using eye bolts, align outer teeth of piston

with inner teeth of drum, then install housing
assembly (71).
m Mounting bolt:
107.9 ? 9.8 Nm (11 * 1.0 kgm)
566FO6509

Using tool Dl, check piston operation of No. 4,5,
6, and 7 clutch.
* Air pressure: 0.3 - 0.6 MPa (3 - 6 kg/cm*)
* Standard piston stroke:
Piston No. Stroke mm

No. 4 4
No. 5 7
No. 6 5
No. 7 5
1024
24. Transmission case ii

1) Install inner race (70) in collar (69).
2) Install collar (69) in transmission case.
3) Install snap ring (68).
4) Install O-ring at cage end.
I 566FO6507 11 566FO6506
5) Secure eyebolts with nuts, then install trans-

mission case (67).
566FO6505
HD325-6 30-101
0
ASSEMBLY OF No. 2 CLUTCH ASSEMBLY r
1) install snap ring (65) to carrier (61), then as-

61
semble ring gear (64).
65 61
* When assembling the ring gear, keep the snap
ring compressed and push the ring gear in.
64
2) Planetary gear
i) Assemble bearing (59) in gear (58), set
566FO6502 566FO6560
gear and thrust washers (60) on carrier. L
ii) Align bearing with thrust washer, then

push in shaft (56).
iii) Assemble ball (57) to install completely.
* If shaft comes off, punch from carrier
end.
+ Check that gear rotates smoothly.
60
59
566FO6500 60
iv) Install inner race (63), bearing (62) and

seal ring (66) in carrier (61).
64
-63
566FO6503 566FO6561
3) Assemble drum (55) to carrier assembly (61).

+ Set block @ under the carrier when as-
sembling the drum.
566FO6499 1) 566FO6562
30-102 HD325-6
0
4) Install plate (54).
‘54
566F0649E
5) Discs plates
l springs
l
Install discs (51), plates (52) and springs (53).

* There are two discs, three plates and four
springs.
6) Housing assembly
. Assemble housing assembly as follows. 42
i) Install bearing (49) in housing (42). 50
ii) Install seal ring (50).
iii) Install bearing (48) in housing (42).
iv) Install seal ring (46) and (47).
v) Install seal ring (45) on piston (44).
t Install seal ring with groove side fac-
ing pressure receiving side.
566FO6496 566FO6495
43
44 /
7v-l I DWH00135
42
566FO6494 566FO6493
vi) Assemble piston (44) in housing (421, then ;
install cylinder (43).
HD325-6 30-103
0
vii) Align outer teeth of piston with inner teeth

of drum, then install housing assembly
(42).
& Mounting bolt:Thread tightener (LT-2) 42
m Mounting bolt:
107.9 f 9.8 Nm (II+ 1 kgm)
'06492
7) Raise No. 2 clutch assembly (41) and install.
ASSEMBLY OF No. 1 CLUTCH ASSEMBLY
I) Plate
Install bearing (40) in plate (37).
2) Ring gear
i) Install inner race (39).
566FO6469
30-104 HD325-6
0
iii) Install ring gear (35) in plate (37).
I 566FO6563
3) Guide pins
4) Discs plates
l springsl
Install discs (311, plates (32) and springs (33)

and (34).
* There are three discs and two plates.
* Free length of spring : 54 mm
3i 566F1107A-K
5) Housing assembly
i) Install piston assembled seal ring in hous-
ing.
* Install seal ring with groove side fac-
ing pressure receiving side.
ii) Install housing assembly (30) in plate (37).
QCI Mounting bolt:

166.7 + 9.8 Nm (’17 2 1 kgm)
I - 566FO6564
6) Input shaft assembly

l Assemble input shaft assembly as follows.
i) Install snap ring (29), then install bearing
(28).
566FO6487 566FO6486
HD325-6 30-105
0
iii) Assemble bearing (25) on gear (23).

iv) Install gear (23) on shaft (24).
v) Install snap ring (22).
CWH010231 566FO6565
vi) Install input shaft assembly (21) on ring

gear of No. 1 clutch.
566FO6483
25. No. 1 clutch assembly

Slinging shaft, install No. 1 clutch assembly (20).
666FO6482

and 3 clutch. (However, about No. 2 and 3 clutch,
it is impossible to measure piston stroke, check
movement of discs or plates.)
+ Standard piston stroke of No. 1 clutch: 5 mm
30-106 HD325-6
0
ASSEMBLY OF OIL PAN ASSEMBLY
Assemble oil pan (12) as follows.
1) Assemble magnet assembly (191, then fit O-ring

and install cover (18).
2) Assemble valves (17) and (16), and fit O-rings,
then install block (15).
3) Install plug (14).
4) Install buffle plate (13).
27. Oil pan

Fit gasket, then install oil pan (12).
28. Speedometer gear assembly

1 @ 566FO6479
1) Set transmission assembly with oil pan fac-

ing bottom.
2) Insert collar (II), and install plug (10).
I 566FO6472
3) Fit O-ring, then install assembly (9) and cover

(8).
566FO6477 566FO6476
HD325-6 30- 107

0
29. Speedometer sensor (If equipped)

Fit O-ring, set sensor (7) in case, then install cover
(6).
CWHOiOlP
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.
I II I CWHOlOlt
31. Sleeves
Fit O-rings, then install 5 sleeves (3).
I / 566FO6473
32. Raise ECMV assembly (2) and install to transmis- u n n

sion assembly (I).
m Mounting bolt of ECMV assembly:

30.9 + 3.4 Nm (3.15 k 0.35 kgm)
30-108 HD325-6
0
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
REMOVAL OF TRANSMISSION CONTROL VALVE ASSEMBLY

(ECMV ASSEMBLY)
g .
Raise the dump body and lockwith the safety pin.
1. Remove cover.
2. Disconnect wiring connectors (I) and (2).
3. Remove ECMV assembly (3). mfi[
T5695120
INSTALLATION OF
TRANSMISSION CONTROL
VALVE ASSEMBLY
(ECMV ASSEMBLY)
moval.
Before removing the ECMV assembly, clean the

area around the valve thoroughly, and make sure
that no dirt or dust gets in.
w ECMV assembly mounting bolt:

30.9 k 3.4 Nm (3.15 + 0.35 kgm)
HD325-6 30-109
0
DISASSEMBLY OF TRANSMISSION CONTROL VALVE ASSEMBLY

(ECMV ASSEMBLY)
566FO6566
l Before removing the ECMV assem bly from the

transmission assembly, clean thoroughly
around the ECMV assembly to be removed
to prevent dirt or dust from getting into the
transmission assembly or ECMV assembly.
l Keep the disassembled parts in a safe place
to protect them from damage.
1. Remove plate (2) from valve body (I). 3. Pressure control valve
* When disassembling thefollowingvalves, 1) Removespring (ll),shim (12), piston (13),
check that the valves move smoothly. and valve (14).
* Check the number and thickness of
2. Flow detector valve shims (121, and keep in a safe place.
1) Using bolts (Thread dia. = 8 mm, Pitch = 2) Remove solenoid valve (15).
1.25 mm), pull out plug (3), then remove + Mask the solenoid valve to prevent
spring (41, valve (5), and spring (6). dirt or dust from entering from the
2) Pull out connectors (7) and (8) from mating surface of the solenoid valve.
bracket, then remove fill switch (9) and
bracket (IO).
30-110 HD325-6
0
ASSEMBLY OF TRANSMISSION CONTROL VALVE ASSEMBLY

(ECMV ASSEMBLY)
If the control portion has been disassembled or 3) Assemble spring (4), then fit O-ring to
parts have been replaced, always inspect the pres- plug (3), and install to body.
sure. 4) Install plate (2) to body.
Clean all parts, and checkfor dirt or damage. Coat B Mounting bolt:
the sliding surfaces of all parts with engine oil 30.9 f 3.4Nm (3.15 I0.35kgm)
before installing. (7) and (8) to bracket.
5) Install connectors
Pressure control valve

3. Inspecting ECMV oil pressure
1) Assemble valve (14) in body (I).
* Press from both ends of the body with
Inspection ECMV oil pressure.
your finger to check that the movement
of the valve is smooth.
4. Adjusting ECMV oil pressure
2) Fit O-ring to solenoid valve (15) and install to
If the results of the inspection show that
body. is not with the standard
the oil pressure
m Mounting bolt: value, adjust the pressure with shim. (12).
13.2 + 1.5 Nm (1.35 + 0.15 kgm)
3) Assemble piston (13) in body (14).

* Check that the piston moves smoothly.
4) Assemble shims (12) and spring (11) to valve
(14), then fit O-ring and install in body.
l Standard number of shims: 3
Adjust with the shim as follows:
l Standard shim thickness: 0.6 mm
(Thickness of one shim: 0.2 mm) To INCREASE pressure, INCREASE shim
thickness To DECREASE pressure,
DECREASE shim thickness
* Assemble the same shim thickness when reus-
Install the shim securely, and be careful not
ing all of the following parts: valve body (I ), spring
to drop them inside the valve.
(II), piston (13), valve (14), and solenoid valve
After adjusting the shims, check the oil
(15). If any of these parts have been replaced, as-
pressure again.
semble the standard shim thickness.
* When replacing solenoid valve (15), remove plate
(2) and check that spring (11) is assembled se-
curely.
2. Flow detector valve

I) Assemble valve (5) in body.
* Press from both ends of the body with
your finger to check that the movement
of the valve is smooth.
Shim
2) Assemble spring (6), then fit O-ring to body, Valve
and install fill switch (9) and bracket (IO).
w Mounting bolt:
DWH00112
30.9 f 3.4 Nm (3.15 ? 0.35 kgm)
HD325-6 30-111
0
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
REMOVAL OF DIFFERENTIAL
ASSEMBLY
1. Drain oil
:
w Final drive case: 13 e (each side)
:
w Differential case: 45 !Z
2. Remove cover (I).
3. Remove shaft (2).

Sr Fit eyebolts, and pull out with bar.
DWH00113
4. Remove tube (3) and hose (4). 566FO6568 L
7. Lift off drive shaft assembly (7). m
& kg Drive shaft assembly: 65 kg
8. Lift off differential and parking brake assembly

(8). m
&I k8 Differential and parking brake assembly:

750 kg
566FO657C 566FO6571
INSTALLATION OF DIFFERENTIAL
ASSEMBLY
moval.
& Drive shaft mounting bolt:

w Drive shaft mounting bolt:
176.5 + 19.6 Nm {I8 + 2 kgm}
566FO6572 566FO6573
6 Differential mounting bolt:

m Differential mounting bolt:
549.2 ? 58.8 Nm I56 + 6 kgm)

Add oil to the specified level, and run the engine
to circulate the oil through the system. Then check
the oil level again.
Q Final drive case: 13 e (each side)
Differential case: 45 e 566FO657f 5

Q
30-112 HD325-6
0
DISASSEMBLY OF
DIFFERENTIAL ASSEMBLY
1. Set differential assembly in tool HI.
2. Parking brake chamber assembly

Pump air into parking brake chamber to retract
rod, then pull out connecting pin (2) of slack ad-
juster (1) lever, and remove parking brake cham-
ber (3).
A If the air in the parking brake chamber is

released, the rod will suddenly extend,
so be careful not to get caught.
3. Caliper assembly
1) Remove plate (4) on one side, then remove
caliper (6) together with pad (5).
2) Remove plate on other side.
T5695126
3) Remove disc plate (7).

8 9
4. Coupling
Remove mounting bolts (81, then remove coupling
(IO) together with retainer (9) and O-ring.
5. Support
Remove support (I I).
6. Pinion, cage assembly

Screw in forcing screws, then lift off pinion and
cage assembly (12).
* Checkthe number and thickness oftheshims,
F56103416
HD325-6 30-113
0
DISASSEMBLY OF PINION ASSEMBLY

I/
1) Pinion assembly
Remove color (15) from pinion (14) .
\ 14
7
/////////// CDH00722
2) Pinion, bearing
i) Remove pinion assembly (14) from case
(16).
ii) Using puller, remove bearing (18), spacer
(17) pull out.
CEHO0098
I!
3) Bearing, outer race

20
Remove bearing (19), and using push tool,
remove outer races (20) and (21) from case
(16).
I CEH00099
7. Differential gear assembly

1) Remove lock (22).
2) Using tool H8, loosen adjustment nut (23) to
a point where it can be turned by hand.
CEH00723
30-114 HD325-6
0
3) Remove 4 nuts (25) of cap (24).

Torque wrench
4) Using tool H9 , raise differential gear assembly
(261, remove cap (24) and nut (23) then remove
gear assembly.
* Be careful not to drop the outer race.
26-
DISASSEMBLY OF DIFFERENTIAL GEAR 24

SUB ASSEMBLY
I) Bearing
i) Set gear assembly (26) on block (height:
approx. 200 mm).
I 7 CEH0072E
ii) Using puller 0, remove bearing (27).
HD325-6
2) Case
i) Remove mounting bolts, then remove
29
case (28).
ii) Remove washer (29).
CEH00172 CEH00173
3) Bevel gear (small), pinion

i) Remove bevel gear (small) (30).
ii) Remove pinion (31) together with cross
shaft (32).
I CEH00174
DISASSEMBLY OF PINION
I) Nut
Using tool H5, remove nut (33).
CEH00175
2) Sleeve, bearing
i) Using push tool 0, pull out sleeve (341,
and remove bearing (35).
CEH00176
30-116 HD325-6
0
ii) Remove inside circumference seat (36).

iii) Using push tool 0, remve bearing (37).
CEH00177 CEHOOi78
3) Outer race
Using push tool 0, remove outer races (38)
and (39), and outside circumference seat (40).
CEH00179
4) Bevel gear (small), washer

ii) Rmove washer (42).
I CEH00180 CEH00181
5) Bearing, bevel gear (large)

i) Using puller, remove bearing (43).
ii) Remove mounting bolts, then remve
bevel gear (large) (44) from case (45).
44
CEH0072
HD325-6 30-117
0
DISASSEMBLY OF
DIFFERENTIAL ASSEMBLY
(With differential lock)
1. Set differential assembly in tool HI.
2. Parking brake chamber assembly

Pump air into parking brake chamber to retract
rod, then pull out connecting pin (2) of slack ad-
juster (I) lever, and remove parking brake cham-
ber (3).
A If the air in the parking brake chamber is re-

CWH01025
leased, the rod will suddenly extend, so be
careful not to get caught.
3. Caliper assembly
I) Remove plate (4) on one side, then remove
caliper (6) together with pad (5).
2) Remove plate on other side.
I T5695126
3) Remove disc plate (7).
4. Coupling
Remove mounting bolts (81, then remove coupling 8 9
(IO) together with holder (9) and O-ring.
5. Support
Remove support (II).
6. Pinion, cage assembly

Screw in forcing screws, then lift off pinion and
cage assembly (12).
* Checkthe number and thickness of the shims,
F56103416
30-118 HD325-6
0
DISASSEMBLY OF PINION ASSEMBLY
1) Pinion assembly
Remove color (15) from pinion (14).
COH00722
2) Pinion, bearing
i) Remove pinion assembly (14) from case
(16).
ii) After pulling out spacer (171, use puller to
remove bearing (18).
CEH00165
3) Bearing, outer race

Remove bearing (19), and using push tool,
remove outer races (20) and (21) from case
(16).
CEH00099
l-0325-6 30-119
0
7. Differential gear case assembly

1) Remove differential lock pipe (6).
2) Loosen locknuts (7) and (8).
3) Using tool H8, loosen adjustment nut (9) to
a point where it can be turned by hand.
4) Loosen 4 nuts (I 1).
5) Raise differential case with wire, remove
bearing caps (12) and (13), and 2 nuts (9),
then remove gear case assembly.
* Be careful not to drop the outer race of the
bearing.
ii 13 ii
CDH00737 CEH0073t
DISSEMBLY OF DIFFERENTIAL GEAR CASE

ASSEMBLY
1) Case
i) Set gear case on block (height: approx.
200 mm).
ii) Remove 8 mounting bolts (13).
iii) Using wire, lift off case (14).
2) Piston
Using 2 eyebolts (M8, P=1.25), remove pis-
ton (15).
3) Bearing
Using puller, remove bearing (16).
4) Sleeve
Remove sleeve (17).
F56605024
5) Discs, plates
Remove discs (18) and plates (19).
6) Pins 20 23 22 21 18 19
Remove 4 pins (20).
7) Gear
Remove snap ring (21), then remove ring
(22) and gear (23).
I F56605025
30-120 HD325-6
0
8) Differential gear case 30 29 25

i) Turn over case assembly. \ / /
ii) Remove 8 mounting bolts (24) from case.
iii) Lift off case (25).
Ir Make match marks before removing.
9) Differential side gear
Remove differential side gear (26).
IO) Pinion gear, cross shaft
Remove pinion gear (27) together with cross
shaft (28) from case.
11) Bearing
Using puller, remove bearing (29).
12) Bevel gear
Remove bolt, then remove bevel gear (30).
F56605027
DISASSEMBLY OF PINION
I) Nut
Using tool H5, remove nut (33).
566FO6590
2) Sleeve, bearing
i) Using push tool 0, pull out sleeve (341,
and remove bearing (35).
566FO6591
tlD325-6 30-121
0
ii) Remove inside circumference seat (36).

iii) Using push tool 0, remove bearing (37).
-------------- 36
CEH00177 I/ CEH00178
3) Outer race
Using push tool @_I,remove outer races (38)
and (39), and outside circumference seat (40).
CEH00179
4) Bevel gear (small), washer

ii) Remove washer (42).
CEH0018() CEH00181
5) Bearing, bevel gear (large)

i) Using puller, remove bearing (43).
ii) Remove mounting bolts, then remove
bevel gear (large) (44) from case (45).
44
30- 122 HD325-6

0
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL GEAR
ASSEMBLY OF DIFFERENTIAL
GEAR ASSEMBLY
ASSEMBLY OF DIFFERENTIAL GEAR

ASSEMBLY
1) Bevel gear (large)

i) Set bevel gear (large) (44) on block (height:
approx. 200 mm).
ii) Set case (45) on gear, and tighten bolts.
CEH00727
w Mounting bolt:
548.8 f 58.8 Nm I56 + 6 kgm}
2) Bearing, washer
i) Shrink fit bearing (43) to case (45).
* Shrink-fitting temperature: At 100°C for
approx. 30 minutes
ii) Turn over case, and install washer (42).
3) Bevel gear (small)

Install bevel gear (small ) (41).
CEH00181 I CEHOOIW
ASSEMBLY OF PINION
1) Outer races, bearing Step an inside

diameter
i) Install outside circumference seat (40) to pin-
/
ion (31).
* When installing the outside circumference
seat (40), set it with the side that has a
step on the inside diameter facing the
bearing (large).
ii) Expand fit outer races (39) and (38).

* Dry ice cooling time: Approx. 5 minutes 566FO6597
38.
566FO6598 566FO6599
HD325-6
2) Sleeve, bearing
i) Shrink fit bearing (37) to sleeve (34).
* Shrink-fitting temperature: At 100°C
for approx. 10 minutes
ii) Install inside circumference seat (36).
36.
566FO6600
3) Pinion, bearing, nut

i) Install pinion (31) to sleeve (341, and shrink
I 35
fit bearing (35).

* Shrink-fitting temperature: At 100°C
for approx. 10 minutes
ii) Using tool H5, tighten nut (33).
& Nut: Thread tightener (LT-2)
m Nut: 548.8 k 58.8 Nm {56 f 6 kgm}
* After tightening the nut, rotate the pinion at

least five turns, and check that it rotates
smoothly. 566FO6601
m Starting torque:
1.27 f 1.27 Nm IO.13 + 0.13 kgm)
1. Pinion, cross shaft, bevel gear (small)

I) Assemble pinion (31) to cross shaft (32).
2) Align dowel pin of case with groove of sleeve
(34) and install.
* If the dowel pin is not fitted completely
into the groove in the sleeve, the cross
shaft will come up and the pinion will not
rotate smoothly, so check these two
points.
3) Install bevel gear (small) (30).
2. Case
1) Install washer (29) to case (28).
2) Align case (28) with position of number of
mating case (45) and install.
& Mounting bolt:

m Mounting bolt:
548.8 + 58.8 Nm I56 f 6 kgm)
566FO6588 566FO6587
30-124 HD325-6
0
3. Bearing
Shrink fit bearing (27).
j, Shrink-fitting temperature: 100°C for 30 min.
. ASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY
4. Differential qear 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.
‘23
CFH00779
5. Cap
1) Install cap (24) and temporarily tighten nuts
(25).
2) Usinng tool H9, tighten nuts (25).
m Nut: 1,667 2 245 Nm I170 +_25 kgm}
24
DWH00116
HD325-6 30-125
0
6. Adjusiting preload of bearing

1) Install tool H6 on both sides of cap (24).
2) Measure distance between tools H6 with tool
H7.
+ When measering, hold the micrometer
securely with one hand and put the probe
in contact with and parallel to the mea-
suring adapters.
* When doing this, leave the adjustment nut
loosened.
3) Add 0.45 + O.lmm to the measured value, and
set the scale of the micrometer.
(Take the dimension after setting as A. )
* The amount added is equal to the defor-
mation of the case before applying
preload and after applying prelad.
4) Tighten adjustment nut (23) from both sides

with tool H8 so that the distance between the
adapters is A. Be earful of the groove where
the lock enters.
* 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.
CWH01030
* Precautions when adjusting preload

If the adjustment nut is tightened too far and
the increase in bend exceeds the standard Use electric Iioht or
value, loosen the adjustment nut and return feeler oauoe to check
OSP
to the position before adjustment.
When doing this, rotate the bevel gear, and
tap the bearing cap and bevel gearwith a plas-
tic copper hammer. Check that there is no gap
at b, then adjust again.
DWHOOI 17
ASSEMBLY OF PINION ASSEMBLY
1) Outer reces
Install oute reces (21) and (20) in case (17).
* Outer race O.D. (21): 215 mm
Outer race O.D. (20): 180 mm
CFH00099
30- 126 HD325-6

0
2) Pinion
* Always use the pinion and bevel gear as
a set.
If the combination is wrong, the correct
tooth contact cannot be obtained.
Shrink-fit bearing (18) on pinion (14).
-k Shrink-fitting temperature:
Approx. 100°C for 30 min.
CEH00728
3) Pinion case
Stand pinion (14) upright and apacer (171,
install case (18).
CEH00103
4) Bearing
Rotate case (16) and install bearing (19).
* Never push with a press.
* Coat the bearing with engine oil.
CEH00104
CEH00105
HD325-6 30-127
0
7. Adjustment
1) nstall collar (15) to pinion assembly (141, then
install cage (13).
* When installing the cage, take care not to
break the O-ring and dust seal.
* Apply G2-LI to the seal lip.
* Apply LG-1 to the inside of the cage.
2) Install support (I l), coupling (IO), and retainer
(9) to pinion cage assembly (141, then tighten
mounting bolt (8) until it reaches the retainer.
&Mounting bolt: Adhesive (LT-2)
CEH00106
3) Place the pinion cage assembly on its side,
then rotate it by 20 - 30 turns and tighten
mounting bolt (8) gradually.
m Mounting bolt:
926.0 f 102.9Nm 194.5 i 10.5kgm)
CEH00107
4) Adjust so that the tangential force at the bolt

hole of the case will be 6.8kg when the bolt is
tightened to the specified torque.
* After the adjustment, confirm that the all
bearing rollers turn.
CEHOO 106
8. Pinion assembly
1) Install the O-ring and the removed shim, then
install pinion assembly (14) by using the hang-
ing bolts
2) Tighten three bolts.
3) Adjust the tooth contact, then tighten the all
bolts to the specified torque. nt ial caaa
m Mounting bolt:
276.36 i 34.3Nm I28.2 i 3.5kgm)
DEH00062
30-128 HD325-6
0
9. Adjusting tooth contact, backlash

Adjust backlash and tooth contact of bevel gear
at the same time.
I) Adjust backlash as follows.
i) Mobe bevel gear with adjustment nut (23).
When adjusting the bevel gear, do not
change the preload of the bearing. Always
turn the adjustment nuts at both ends the
sane amount in the same direction.
ii) Put dial @ at right angles in contact with

the reverse face of the tooth at the out-
side of the bevel gear. turn the adjustment
nut and adjust until to movement of the
gauge indicator is 0.3 or 0.4 mm.
* Adjust at 3 to 4 places. Keep the pin-
ion gear locked when measuring.
2) Adjust tooth contact as follws.

i) Adjust the position of the bevel pinion by
changing the shims between the differen-
tial case and bearing case.
* Use the shims removed during disas-
sem bly.
ii) Adjust tooth contact. !nt ial case
For details, see 3) Adjusting tooth contact.
HD325-6 30-129
0
3) Adjusting tooth contact of bevel gear and

bevel pinion FORWARD REVERSE Edge of
face of Dear face of eear tooth
Inspection
i) Coat the tooth face of the bevel pinion
lightly with red lead (minimum). Rotate
the bevel gear forward and backward and
inspect the pattern left on the teeth.
ii) The tooth contact pattern should cover
about 30 to 60% (a) of the length of the /
tooth, and should be located about 33% Small end
Bevel Dear
lb) from the small end. It should be in the
DWHOOllB
center of the tooth height. There should
be no strong contact at the top or bottom
of the tooth face, or at the small or big
ends.
* If the gears are adjusted to this pat-
tern, the tooth contact will be correct
when load is applied.
Adjustment II end
If the result of the inspection shows that the
correct tooth contact is not being obtained,
adjust again as follows.
i) If bevel pinion is too far from center line
of bevel gear. Contact is at the small end a. Width of contact
of the convex tooth face of the bevel gear b. Center of contact
DWH00119
and at the big end of the concave tooth
face.
-k Procedure for adjustment
Adjust the thickness of the shims at the
to move the bevel pinion in direction A,
nearer to the bevel gear. Using shims or (Tooth contact of gear)
the adjustment nut of the bevel gear bear-
ing 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.
ii) If bevel pinion is too close to center line
of bevel gear. Contact is at the small end
of the concave tooth face of the bevel gear
and the big end of the convex tooth face. DWH00120
* Procedure for adjustment
I
bevel pinion to move the bevel pinion in
direction ,A, away from the bevel gear.
Using shims or the adjustment nut of the
[Tooth contact of eear)
bevel gear bearing cage, move the bevel 4
gear in direction B by the same amount
that the bevel pinion has moved in direc-
tion A. Check the tooth contact pattern and
backlash.
When adjusting the bevel gear to the right

or left, do not change the preload of the
bearing. Always turn the adjustment nuts
at both ends the same amount in the DWH00121
same direction.
30-130 HD325-6
0
4) After adjusting tooth cantact and backlash,

install lock plate (22).
10. Support
11A I
After completing adjustment of the tooth contact
and backlash, coat support mounting bolts (1 IA)
with thread tightener and tihgten fully.
& Mounting bolt: Thead tightener (LT-2)
m Mounting bolt:
279.3 f 29.4 Nm I28.5 & 3 kgm}
* After tightening, rotate the bearing 20 - 30
turns again, and check again that the bearing
rotates smoothly.
T5695158 1
11. Caliper assembly

I) Install disc plate (7).
Q3 Mounting bolt:
548.8 + 58.8 Nm {56 + 6 kgm}
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.
* Make a clearance of 0.1 mm between the
plate and the caliper.
m Mounting bolt:
926.1 i. 98.1 Nm I926.1 I: 98.0 kgm)
T5695126
HD325-6 30-131
0
12. Spring cylinder assenbly

I) Install spring cylinder (31, and connect forked
portion of rod and lever of slack adjuster (I)
with pin (2).
* Pump air into the spring cylinder and re-
tract the rod.
CWH01025
2) Adjusting clearance of caliper pad

Rotate adjustment screw (50) of slack adjuster,
and measure clearance of caliper pad with
gauge 0.
t Spuring cylinder stroke: 50 mm
* Clearance of pad:
Both ends: 0.5 mm each
When moved to one end: 1.88 f 0.08 mm
\ 1 F56103449 1
30-132 HD325-6
0
ASSEMBLY OF DIFFERENTIAL
GEAR ASSEMBLY

ASSEMBLY
1) Bevel gear (large)

i) Set bevel gear (large) (44) on block (height:
approx. 200 mm).
ii) Set case (45) on gear, and tighten bolts.
6 Mounting bolt: 566FO6596
w Mounting bolt:
548.8 + 58.8 Nm I56 + 6 kgm) 42
2) Bearing, washer
i) Shrink fit bearing (43) to case (45).
fl Shrink-fitting temperature: At 100°C for
approx. 30 minutes
ii) Turn over case, and install washer (42).
’ 566FO6595
ASSEMBLY OF PINION
I) Outer races, bearing

Step an inside
i) Install outside circumference seat (40) to diameter
pinion (31). /
* When installing the outside circumfer-
ence seat (401, set it with the side that
has a step on the inside diameter fac-
ing the bearing (large).
31
ii) Expand fit outer races (39) and (38). 566FO6597
* Dry ice cooling time:
Approx. 5 minutes
566FO6598 566FO6595
HD325-6
3. Differential side gear

Install differential side gear (26).
4. Case 30 24 29 26 25
I) Install case (25).
* Check the match marks on the mating
surfaces before installing.
2) Install bolt (24).
m Mounting bolt:
548.8 + 58.8 Nm I56 k 6 kgm}
5. Gear, ring, snap ring

1) Turn over case, and set on block.
F56605031
2) Install gear (23) to differential side gear (52),
then assemble ring (22), ring (56), and snap
ring (21) securely.
* When installing ring (22), lift up side gear 51 20 23 22 5fi ?l 1.3
(52).
6. Pins, discs, plates

1) Install 4 pins (20) to case.
2) Assemble plate (19), disc (18), and plate in or-
der.
Ir Coat the surface of the discs and plates
with engine oil (EO-30).
7. Pinion, seal
F56605032
1) Install seal (54) to piston (15).
2) Install seal (55) to case (14).
t Be careful install the seal facing in the cor-
rect direction.
8. Case
1) Align case (14) with position of pin (20), and
install.
2) Install 8 bolts (13).
m Mounting bolt:
548.8 * 58.8 Nm (56 * 6 kgm}
HD325-6
9. Seal, sleeve
I) Install seal (56) to case (14).
2) Be careful not to damage seal (56) when in-
stalling sleeve (17).
10. Bearing, washer

1) Shrink fit bearing (16) to case (14).
-k Shrink-fitting temperature: Approx. 100°C
for 30 minutes.
F56605035
30-136 HD325-6
0

ASSEMBLY
11. Differential gear assembly

1) Align with groove of differential case (46) and
install nut (23).
2) Raise gear case assembly (261, assemble outer
race on bearing, then install in case.
12. Cap
1) Install cap (24) and temporarily tighten nuts
(25).
2) Using tool H9, tighten nuts (25).
w Nut: 1666.0 + 245 Nm I170 ? 25 kgm)

Torsue wrench
/
DWH00116
13. Adjusting preload of bearing

1) Install tool H6 on both sides of cap (24).
2) Measure distance between tools H6 with tool
H7.
* When measuring, hold the micrometer se-
curely with one hand and put the probe
in contact with and parallel to the mea-
suring adapters.
* When doing this, leave the adjustment nut
loosened.
3) Add 0.45 rfI 0.1 mm to the measured value,
and set the scale of the micrometer.
(Take the dimension after setting as A.)
* The amount added is equal to the defor-
mation of the case before applying
preload and after applying preload.
HD325-6 30-137
0
-DISASSEMBLY AND ASSEMBLY DIFFERENTIAL GEAR
4) Tighten adjustment nut (23) from both sides

with tool H8 so that the distance between the
adapters is A. Be careful of the groove where
the lock enters.
* 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.
CWH01030
* Precautions when adjusting preload
If the adjustment nut is tightened too far and the
increase in bend exceeds the standard value,
loosen the adjustment nut and return to the posi-
tion before adjustment.
se electric light or
When doing this, rotate the bevel gear, and tap I gaugeto check
the bearing cap and bevel gear with a plastic cop-
per hammer. Check that there is no gap at b, then
adjust again.
ASSEMBLY OF PINION ASSEMBLY DWH00117
1) Outer races
Install outer races (21) and (20) in case (17).
k Outer race O.D. (21): 215 mm
Outer race O.D. (20): 180 mm
2) Pinion
* Always use the pinion and bevel gear as
a set. If the combination is wrong, the
correct tooth contact cannot be obtained.
Shrink-fit bearing (18) on pinion (16).
Sr Shrink-fitting temperature: CEH00099
Approx. 100°C for 30 min.
30-138 HD325-6
0
3) Pinion case
Place pinion (14) on its end and insert spacer
(17), then install case (16).
4) Bearing
Turning case (16), install bearing (19).
t Never fit the bearing with a press.
t Apply engine oil to the bearing.
CEHOOl04
CEH00105
14. Adjustment
1) install collar (15) to pinion assembly (14), then
install cage (13).
k When installing the cage, take care not to
break the O-ring and dust seal.
Ir Apply G2-LI to the seal lip.
* Apply LG-1 to the inside of the cage.
,,,,,,,,,,,,,,11,1,,~~~~,
CEH00106
HD325-6 30-139
0
2) nstall support (1 I), coupling (IO), and retainer

(9) to pinion cage assembly (141, then tighten
mounting bolt (8) until it reaches the retainer.
& Mounting bolt: Adhesive (LT-2) -I1
3) Place the pinion cage assembly on its side, then

rotate it by 20 - 30 turns and tighten mount-
ing bolt (8) gradually.
w Mounting bolt:
926.0 ? 102.9Nm (94.5 + 10.5kgmI
i CEH00107
4) So adjust that the tangential force at the bolt

hole of the case will be 6.8kg when the bolt is
tightened to the specified torque.
* After the adjustment, confirm that the all
bearing rollers turn.
I U CEH00108
15. Pinion assembly

1) Install the O-ring and the removed shim, then
install pinion assembly (14) by using the hang-
ing bolts
2) Tighten three bolts.
3) Adjust the tooth contact, then tighten all bolts
to the specified torque. ffer.ential
w Mounting bolt:
276.36 + 34.3Nm (28.2 + 3.5kgmI
‘///////////. DEH00062
30-140 HD325-6
0
16. Adjustment of tooth contact and backlash

Adjust the backlash and tooth contact simulta-
neously.
1) Adjust the backlash according to the following
procedure.
i) Move the bevel gear with adjustment nuts
(23). At this time, turn both nuts by the
same angle in the same direction so that
the pre-load on the bearing will not be
changed.
ii) Apply dial gauge (3) vertically to the re-
versing tooth surface at the outer end of CDH0073E
the bevel gear. Turn the adjustment nuts
so thatthe gauge will indicate 0.3 - 0.4mm.
* Adjust the backlash at three - four
places with the pinion fixed.
2) Adjust the tooth contact according to the fol-

lowinn procedure.
Adjust the projection of the bevel pinion
with the shim between the differential
Case v
case and bearing cage.
+ Use the shim that was removed on
Shim
disassembling procedure. erential case
Adjustment of tooth contact
See ADJUSTMENT OF TOOTH CONTACT
OF BEVEL GEAR AND BEVEL PINION in
3).
i-I p DEH00063
HD3256 30-141
0
3) Adjusting tooth contact of bevel gear and

bevel pinion FORWARD REVERSE Edoe of
Inspection face of Bear face of Dear tooth
i) Coat the tooth face of the bevel pinion

lightly with red lead (minimum). Rotate
the bevel gear forward and backward and
inspect the pattern left on the teeth.
ii) The tooth contact pattern should cover
about 30 to 60% (a) of the length of the
tooth, and should be located about 33% -
/
(b) from the small end. It should be in the Small end
center of the tooth height. There should Bevel gear
be no strong contact at the top or bottom DWH00118
of the tooth face, or at the small or big
ends.
* If the gears are adjusted to this pat-
tern, the tooth contact will be correct
when load is applied.
Adjustment
If the result of the inspection shows that the
correct tooth contact is not being obtained,
adjust again as follows.
i) If bevel pinion is too far from center line
of the convex tooth face of the bevel gear
a. Width of contact
and at the big end of the concave tooth
face.
* Procedure for adjustment
I b. Center of contact
OWH00119

to move the bevel pinion in direction A,
nearer to the bevel gear. Using shims or
(Tooth contact of Pearl
the adjustment nut of the bevel gear bear- 4
ing 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.
ii) If bevel pinion is too close to center line
of the concave tooth face of the bevel gear
and the big end of the convex tooth face.
* Procedure for adjustment I DWH00120

bevel pinion to move the bevel pinion in
direction A, away from the bevel gear.
Using shims or the adjustment nut of the
[Tooth contact of pear)
bevel gear bearing cage, move the bevel 4
gear in direction B by the same amount
that the bevel pinion has moved in direc-
tion A. Check the tooth contact pattern and
backlash.
* When adjusting the bevel gear to the right

or left, do not change the preload of the
bearing. Always turn the adjustment nuts
at both ends the same amount in the same
direction.
I DWHOOlZl
30-142 HD325-6
0
4) After adjusting tooth contact and backlash, in-

stall lock plate (22).
5) Install differential lock pipe (6).
17. Support
After completing adjustment of the tooth contact
and backlash, coat support mounting bolts (1 IA)
with thread tightener and tighten fully. CDH00736
w Mounting bolt:
279.3 ? 29.4 Nm I28.5 f 3 kgm}
* After tightening, rotate the bearing 20 - 30

turns again, and check again that the bearing
rotates smoothly.
18. Caliper assembly

1) Install disc plate (7).
6 Mounting bolt: Thread tightener (LT-2)
m Mounting bolt:
548.8 + 58.8 Nm I56 ? 6 kgm}
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.
* Make a clearance of 0.1 mm between the
plate and the caliper.
Mounting bolt:
926.1 k 98 NmI94.5 + 10 kgm} I T5695126
HD325-6 30- 143

0
19. Spring cvlinder assembly

l&tail spring cylinder (31, and connect forked
portion of rod and lever of slack adjuster (I)
with pin (2).
* Pump air into the spring cylinder and re-
tract the rod.
Adjusting clearance of caliper pad

Rotate adjustment screw (50) of slackadjuster, CWH01025
and measure clearance of caliper pad with
gauge 0
* Spring cylinder stroke: 50 mm
* Clearance of pad:
Both ends: 0.5 mm each
When moved to one end: 1.88 f 0.08 mm
F56103449
30-144 HD325-6
0
DISASSEMBLY AND ASSEMBLY FRONT WHEEL
REMOVAL OF FRONT WHEEL ASSEMBLY

HD325-6, HD405-6
a Stop the machine on level ground, and put

blocks on both sides of the rear wheels.
a Put a hydraulic jack (30 ton) under the suspen-

sion cylinder, and jack up the front wheel assem-
bly.
1. Remove 12 wheel clamp nuts (1). m
2. Remove front wheel assembly (2). m
&I kg Front wheel assembly: 650 kg F56103527
* Use a forklift truck (5 ton).

* When removing, be careful not to damage
the air valve of the inside wheel assembly.
g After removing the wheel assembly, stand it in

a safe place and use blocks to prevent it from
falling over.
WHEEL ASSEMBLY
HD325-6, HD405-6
. Carry out installation in the reverse order to
removal.
u
* Follow the order for tightening the wheel
clamp nuts and install uniformaly.
sr Tighten fully after lowering the machine to
the ground.
m Wheel clamp nut:

When coating thread with LM-G:
926.7 + 103 Nm (94.5 ? 10.5kgm)
When not coating thread with LM-G:
1,201.4 + 122.6 Nm (122.5 + 12.5 kgm)
* When the thread is coated with LM-G (mo-

566F06018A-K
lybdenum disulphide lubricant), the tighten-
ing torque is different, so check the torque
value carefully before tightening.
/12
* Align the notched groove of the wheel hub
and the position of the air valve.
* Be careful not to damage air valve.
. Turn front wheel assembly, then check that
runout is within 3 mm.
. After installing front wheel assembly, run 5
- 6 km to settle each contacting parts.
Then check that hub nuts are tightened to
the specified tightening torque.
HD325-6 30-145
0
DISASSEMBLY AND ASSEMBLY FRONT WHEEL
REMOVAL OF FRONT WHEEL ASSEMBLY

HD325-6W
A Stop the machine on level ground, and

blocks under both sides of the rear wheels.
put
A Jack up the frame, set block (I) under the

bumper, then insert a hydraulic jack (30t) under
the suspension cylinder and jack up the front
wheel assembly.
1. Remove 12 wheel clamp nuts (I). m
2. Remove front wheel assembly (2). m

566FO6729
& Ire Front wheel assembly: 650 kg
* Use a forklift truck (5 ton).

* When removing, be careful not to damage
the air valve of the wheel assembly.
A After removing the wheel assembly, stand it in

a safe place and use blocks to prevent it from
falling over.
WHEEL ASSEMBLY
HD325-6W 566CK06016
. Carry out installation in the reverse order to

removal.
m
* Follow the order for tightening the wheel
clamp nuts and install uniformly. 02
* Tighten fully after lowering the machine to
the ground.
w Wheel clamp nut:

926.8 ? 103.0 Nm (94.5 + 10.5kgm)
1,201.4f 122.6 Nm (122.5 f 12.5 kgm)
F56103528
* When the thread is coated with LM-G (Mo-
m
* Align the notched groove of the wheel hub
and the position of the air valve.
* Be careful not to damage air valve.
. Turn front wheel assembly, then check that
runout is within 3 mm.
. After installing front wheel assembly, run 5 -
6 km to settle each contacting parts.
Then check that hub nuts are tightened to the
specified tightening torque.
30-145-l HD325-6
0
DISASSEMBLY AND ASSEMBLY REAR WHEEL
REMOVAL OF REAR WHEEL

ASSEMBLY
g Stop the machine on level ground, and put blocks
on both sides of the front wheels.
g Put a hydraulic jack 0 (30 ton) under the rear axle,

and jack up the rear wheel assembly.
1. Remove air valve lock plate (I).
2. Remove 16 wheel clamp nuts (2).
3. Remove wedge ring (3).
4. Remove outside wheel assembly (4). m
& kg Wheel assembly: 650 kg
* Using a forklift truck (5 ton), remove the wheel

assembly together with the wedge ring (3).
* Be careful not to break the air valve of the in-
side wheel assembly, then remove it.
A After removing the wheel assembly, stand

it in a safe place and use blocks to pre-
vent it from falling over.
5. Remove spacer (5).

+r Use a forklift truck (5 ton).
& kg Spacer: 50 kg
6. Remove 3 wheel clamp nut (6). m
7. Remove inside wheel assembly (7). m
6 kg Wheel assembly: 650 kg
+ Use a forklift truck (5 ton)

* Be careful not to break the air valve of the in-
side wheel assembly, then remove it.
g After removing the wheel assembly, stand it in a

safe place and use blocks to prevent it from fall-
ing over.
\ ’ //
' F56103532
30-146 HD325-6
0
DISASSEMBLY AND ASSEMBLY REAR WHEEL
INSTALLATION OF REAR
WHEEL ASSEMBLY
moval.
* Tighten wheel clamp nuts uniformly in the cor-

rect order of tightening.
+ Tighten fully after lowering the machine to the
ground.
m Clamp nut:
926.8 * 103.0 Nm (94.5 k 10.5 kgm}
1 566FO6617

1201.4 + 122.6 Nm 1122.5 k 12.5 kgm}
* When the thread is coated with LM-G (mo-

m
* Install the wedge ring so that the protrusion
of the wedge ring from the cover surface is
uniform around the whole circumference of
the ring.
* Align the notched groove in the wheel hub

with the wheel rim stopper.
+ When installing, be careful notto damage the
air valve.
Rotate the wheel and check that the runout is

within 5 mm.
After installing the rear wheel assembly, travel
approx. 5 - 6 km to settle all contacting portions,
then always check that the torque is the specified
tightening torque.
HD325-6 30- 147

0
DISASSEMBLY AND ASSEMBLY FRONT BRAKE CALIPER
REMOVAL OF FRONT BRAKE

CALIPER ASSEMBLY
1. Front wheel assembly
* For details, see REMOVAL OF FRONT WHEEL
ASSEMBLY.
2. Disconnect tube (I).

+ Disconnect two tubes on both sides.
3. Remove caliper assemblies (2). m

* Leave 2 or 3 of the 10 mounting bolts in posi-
tion, then use a forklift truck or other equip-
ment as support, remove the remaining II ’ F56103481 K
mounting bolts, and remove caliper assem-
bly (2).
& kg Caliper assembly: 75 kg
BRAKE CALIPER ASSEMBLY
moval.
I
566FO6620‘

w Mounting bolt:
926.8 + 103.0 Nm I94.5 f 10.5 kgm}
* Bleed air from front brake circuit after seeing

“AIR BLEEDING FOR BRAKE CIRCUIT” OF
TESTING AND ADJUSTING.
HD3256 30-149
0
DISASSEMBLY AND ASSEMBLY FRONT BRAKE CALIPER
• Lock bolts (1) and (2) are different from the

normal bolts: the tip (portion a) cuts into the
surface of the torque pin. (Creates plastic de-
formation.)
fl When 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 speci-
fied 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
fl Be sure to install short torque pin (5) of pins
(4) and (5) at the plate end.
fl Install so that clearance d between disc (16)
and torque pin (3) is 1.5 – 3.0 mm.
fl Assemble the other pistons in the same way.
5. Install caliper assembly.

For details, see INSTALLATION OF FRONT CALI-
PER ASSEMBLY.
30-150-2 HD325-6
C
DISASSEMBLY AND ASSEMBLY FRONT WHEEL HUB
DISASSEMBLY OF FRONT
WHEEL HUB ASSEMBLY
1. Front caliper assembly
For details, see REMOVAL OF FRONT CALIPER AS-
SEMBLY.
2. Cover
Remove cover (I 1.
3. Wheel hub assembly w 566FO6622
1) Support wheel hub assembly (2) with forklift

truck.
2) Remove retainer (3).
* Check the number and thickness of the
3) Lever wheel hub assembly (2) lightly from

rear, and push out together with bearing (4).
4) Remove bearing (4), then remove wheel hub
assembly (2).
569F 115A
&I ku Wheel hub assembly: 225 kg
5) Disassemble wheel hub assembly as follows.

i) Remove mounting bolts, then remove
brake disc (5).
ii) Remove oil seal (6).
iii) Remove outer race (7).
iv) Remove outer race (8).
569F211
‘8
F56103537
HD325-6 30-151
0
4. Bearing, retainer 1
1) Remove bearing (IO).

2) Remove retainer (II).
I
/
569F212
30-152 HD325-6
0
ASSEMBLY OF FRONT WHEEL

HUB ASSEMBLY
1. Retainer, bearing
1) Install retainer (I I).
2) Install bearing (IO).
I 569F212
2. Wheel hub assembly

1) Assemble wheel hub assembly as follows.
i) Using push tool, press fit outer race (8).
ii) Using push tool, press fit outer race (7).
iii) Using push tool, press fit oil seal (6).
* Rem,ove all grease from the seal sur-
face of the wheel hub and the outside
circumstance of the seal.
Outside surface of seal:
Tread tightener (Loctite #64B) 8
i F56103537
Between seal and lip:
Fill with grease (See table A)
iv) Set brake disc (5) in position, and tighten Remove all orease,and dru
with mounting bolts.

Mounting bolt:
549.2 + 58.8 NmE6 * 6 kgml
1 Fill with grease DWH00122
HD325-6 30-153
0
2) Support wheel hub assembly (2) with forklift

truck, then install.
Fill the shaded portion fully with grease.

(Amount of grease:
Approx. 5 liter each wheel)
* Be careful not to damage the oil seal on the

inside of the hub.
3) Install bearing (4).
569F213
4) Adjust preload of bearing as follows.

i) Install retainer (3) with 3 mounting bolts
without installing any shim, rotate hub 20
- 30 times and tighten uniformly until
torque is specified tightening torque.
w Mounting bolt (when adjusting):

63.7 & 5.9 Nm I6.5 f 0.6 kgml
ii) Measure dimension c from retainer to tip

surface of axle with depth micrometer @I.
569F211
* Measure 2 places and take the aver-
age.
iii) Remove retainer (3), and measure retainer
thickness T, then select shim thickness of
difference d in measured value (d = c -T)
+ 0.3 mm.
* Measure 2 places and take the aver-
age.
* Select the combination of shims that
gives the minimum number of shims.
* When removing the retainer, be care-
ful that the bearing does not come out.
F56103538
30-l 54 HD325-6
0
5) Fit shim and retainer (31, rotate hub 20 - 30

times and tighten uniformly until torque is
specified tightening torque.
w Mounting bolt:
384.9 + 41.7 Nm I39.25 i 4.25 kgm}
t After tightening the bolts, rotate the hub and

check that there is no abnormality in rotation.
566FO6622
3. Cover
Fit O-ring and install cover (1).
& Fill the inside of the cover (shaded por- .l

tion) with grease.
* Use the same type of grease that was used to

fill the inside of the hub in Step 2 for the wheel
hub assembly.
4. Front caliper assembly

For details, see INSTALLATION OF FRONT CALI-
PER ASSEMBLY. 569F-214
HD325-6 30-155
0
DISASSEMBLY AND ASSEMBLY FRONT FINAL DRIVE CLUTCH, CARRIER
FINAL DRIVE CLUTCH, CARRIER
ASSEMBLY
HD3256W
1. Remove drain plug and drain final drive oil.

:
w Final drive oil: 28 e (each)
566FO6730
2. Cover
1) Remove 12 cover mounting bolts then set
guide bolt 0, pull out cover (I) with forcing
screw 0, fit lifting shackle 0, and lift off cover
(I).
2) Remove washer (2) and button (3) from cover.
566FO6731
3. Thrust washer
Remove thrust washer (4).
4. Plates, springs, discs

Remove plates (51, springs (61, and discs (7).
. Plates :5
Discs :4
Springs : 5
30-155-l HD325-6
0
5. No. 1 sun gear shaft

Remove No. 1 sun gear shaft (8).
6. No. 1 carrier assembly

1) Remove No. 1 carrier assembly (9).
2) Disassembly of No. 1 carrier assembly

i) Remove.mounting bolts (IO), then remove r
holder.
ii) Set carrier assembly (9) to press, and us-
ing push tool 0, remove pin (I I), then re-
move gear assembly (12).
205F05427A-K 205F05428A-K
iii) Remove bearing (14) and spacer(l5)from

gear (13).
1 ” l6 II5 't,,.,.,, A-K
HD325-6 30-155-2
0
7. No. 2 sun gear

Remove No. 2 sun gear (17).
8. Thrust washer
9. Ring gear

1) Lift off No. 2 carrier assembly (20).
2) Disassemblv of No. 2 carrier assembly

i) Remove’mounting bolts (21), then remove
holder.
ii) Set carrier assembly (20) to press, and
using push tool 0, remove pin (22), then
remove gear assembly (23).
iii) Remove bearing (25) and spacer (26) from

gear (24).
30-155-3 HD325-6
0
11. Piston, washer

Remove piston (28) and washer (29).
28 is 566FO6740
12. Ring gear

Lift off ring gear (30).
30 566FO6741
HD325-6 30- 155-4

;($I
ASSEMBLY OF FRONT FINAL

DRIVE CLUTCH, CARRIER
ASSEMBLY
HD325-6W
the sliding surface of all parts with engine oil be-
fore installing.
1. Ring gear
Fit O-ring to ring gear (301, then lift gear and in-
stall.

I 30
566FO6741
w Mounting bolt:
110.8 a 12.8 Nm {11.3f 1.3 kgm}
2. Washer, piston
Fit thrust washer (29), assemble 2 seal rings to
piston (281, and install.
* Check that there is no clearance between the
hub and the thrust washer.
* Install the seal ring with the side receiving the
pressure facing the groove.
20 is 566FO6740
+bz3 DVH00137

I) Assembly of No. 2 carrier assembly
* The taper roller bearing consists of a set
of inner race, outer race, and spacer, so
assembly the parts with the same
stamped mark.
i) Using push tool, press fit outer race (27)
to gear (24).
ii) Assembly spacer (26) and bearing (25).
205F05434A-K
30-155-5 HD325-6
0
iii) Set carrier assembly (20) to press, and

assembly gear assembly (23), then using
push tool 0, press fit pin (22).
* When press fitting the pin, rotate the
gear and be extremely careful not to
insert the pin at an angle.
iv) Fit holder and tighten with mounting bolts
C-21).
6 Mounting bolt:
m Mounting bolt: 205F05441A-I( 205F05432A-K
110.8 + 12.7 Nm Ill.3 f 1.3 kgm}
2) Raise No. 2 carrier assembly (20) and install

* Put any one of the planet gears at the bot-
tom when assembling.
4. Ring gear
Install ring gear (19).’
1566FO6739 520 11 566FO6738
TOP
566CK06019
5. Thrust washer
install thrust washer (18).
6. No. 2 sun gear

Install No. 2 sun gear (17).
HD325-6 30-155-6
0

1) Assembly of No. 1 carrier assembly
The taper roller bearing consists of a set
of inner race, outer race, and spacer, so
assembly parts with the same stamped
mark.
i) Using push tool, press fit outer race (16)
to gear (13).
ii) Assembly spacer (15) and bearing (14).
iii) Set carrier assembly (9) to press, and as-
sembly gear assembly (121, then using
push tool 0, press fit pin (I I).
205F05429A-K
Ir When press fitting the pin, rotate the
gear and be extremely careful not to
insert the pin at an angle.
iv) Fit holder and tighten with mounting bolts
(IO).
& Mounting bolt:

m Mounting bolt:
66.7 * 7.8 Nm t6.8 f 0.8 kgm}
205F05442A-E ;05F05427A-K
2) Install No. 2 carrier assembly (9) .

Install No. 1 sun gear shaft (8).
30-l 55-7 HD325-6

0
9. Discs, springs, plates

Assembly discs (7), springs (6), and plates (5).
l Plates :5
Discs :4
Springs: 4
.6
L 566CK06020
10. Thrust washer

Install thrust washer (4).
11. Cover
I) Install button (3) and thrust washer (2) to
cover.
* Check that there is no clearance between
the thrust washer and the cover.
3
566FO6731
HD325-6 30-155-8
0
2) Measuring clearance between No. 1 sun gear

and button.
i) Temporarilly fill button hole with solder
wire or other soft metal as shown in dia-
gram.
ii) In this condition, install cover to hub, and
tighten any 3 or 4 bolts.
iii) Remove cover, then measure thickness of
deformed soft metal wire to check that Trire soft metal wire 8s
clearance is 1.99 - 4.11 mm. shown in diagram betor
tightening bolt.
DVHOOI 38
3) Set guide bolt 0, and fit O-ring to cover (I),

then using shackle 0, raise hub and install.
& Thread of cover mounting bolt:

m Cover mounting bolt:
110.8 f 12.7 Nm (11.3 k 1.3 kgm}
566FO6742
. Refilling with oil (front final drive)

Tighten drain plug P2, and add oil thorugh PI to
specified leve.
566CK06022
30-1x5-9 HD325-6
0
DISASSEMBLY AND ASSEMBLY FRONT FINAL DRIVE, BRAKE
DISASSEMBLY OF FRONT FINAL

DRIVE, BRAKE ASSEMBLY
HD325-6W
1. Remove front wheel assemblv.

r
For details, see REMOVAL CF FRONT WHEEL
ASSEMBLY.
2. Remove final drive clutch and carrier assembly.

For details, see REMOVAL OF FRONT FINAL DRIVE
CLUTCH AND CARRIER ASSEMBLY..
3. Sensor cover
Remove sensor cover (I).
4. Sensor
Disconnect clamp of sensor wiring harness, and
remove sensor (2).
5. Hoses, tube
Disconnect hoses (3) and (4), and grease tube
(5).
6. Retainer, shim
1) Using tool Jl, secure wheel hub (6) and brake
hub (7), then sling final drive assembly.
* When installing tool Jl, remove bolt (a)
at the outer gear side, and install to the
three tap holes on the inner gear side pro-
vided for installing tool Jl.
* To prevent damage to the floating seal,
always install tool Jl before removing the
retainer.
2) Loosen 16 bolts (91, leave 2 in position, and
remove the remaining bolts. 566F06746A
HD325-6 30-155-10
0
3) Remove retainer (IO) and shims (I 1).

566FO6747
7. Inner hub
Remove inner hub (12).
8. Final drive, brake assembly

Because the final drive and brake assembly (13)
is raised at an angle, set transmission jack under
final drive and brake assembly (13) to prevent it
from flying out, then remove remaining 2 bolts
(9), and use forcing screws @ to remove.
9. Coupling
Remove coupling (14).
L-2 566FO6750
30-155-11 HD325-6
0
10. Hub
Lift off hub (15).
11. Piston
Remove piston (16) from hub (15).
566FO6751 566FO675;
12. Collar
Using bearing puller 0, remove collar (17).
13. Bearing, spacer

Remove bearing (18) and spacer (19).
kc4 566CKO602:
. Disassembly of brake, wheel hub assembly

1) Remove 2 lock bolts (20).
2) Remove damper (21).
I 566FO675,
tlD325-6 30-155-12
0
3) Remove discs (221, springs (23, and Plates

(24).
. Plates :6
Discs :4
Springs : 6
566FO6755
4) Remove damper (25) and inner gear (26).
26
5) Remove 3 tools Jl.
J I
CWH01032
6) Fit eyebolts 0, and remove brake hub assem-

bly (27) from wheel hub (28).
566FO6757
7) Remove hub (29) from outer gear (30).
566FO6758
30-155-13 HD325-6
0
DISASSEMBLY AND ASSEMBLY FRONT FINAL-DRIVE, BRAKE
8) Remove floating seal (32), oil seal (311, and

O-ring from hub (29).
566CK06024
9) Remove floating seal (32) and cage (33) from

wheel hub (28).
IO) Remove outer races (34) and (35), and collar

(36).
HD325-6 30-155-14
0
ASSEMBLY OF FRONT FINAL

DRIVE, BRAKE ASSEMBLY
HD325-6W
Clean all parts, and check for dirt or damage. Coat

the sliding surface of all parts with engine oil be-
fore installing.
Use alcohol to remove all the white powder from
the surface of the O-ring before assembling the
floating seal.
Assembly of brake, wheel hub assembly

1) Install collar (361, and outer races (35) and (34)
to wheel hub (28).
Ir When installing collar (36) to wheel hub
(28), align the position of the holes and
install.
2) Fit O-ring to cage (33), and install to wheel

hub (31).
3) Using tool J2, install floating seal (32).

Ir After installing the floating seal, measure
dimension a of the inner gear and float-
ing seal at four places around the circum-
ference and check that the dimension is
within 1 mm. 566CK06026
4) Install oil seal (31) to hub (29).

* When assembling the seal, coat portion
(b) between the seal lips with grease.
29 31 J2
CWH01033
566CK06028
30-155-15 HD325-6
0
DISASSEMBLY AND ASSEMBLY FRONT FINAL DRIVE. BRAKE
5) Using tool J2 install floating seal (32).

J, After installing the floating seal, measure
dimension a of the inner gear and float-
ing seal at four places around the circum-
ference and check that the dimension is
within 1 mm.
566CK06026
6) Install hub (29) to outer gear (30).
I 566FO6758
7) Fit eyebolts 0, raise brake hub assembly (27),

then set to wheel hub assembly (28).
* Coat the sliding surfaces of the floating
seal thinly with engine oil.
t Assembly slowly and be careful not to
damage the floating seal.
I 566FO6757
8) Using 3 tools Jl, secure brake hub assembly

(27) and wheel hub assembly (28).
CWH01034
HD325-6 30-155-16
0
9) Install inner gear (26).
6 Mounting bolt:
w Mounting bolt:
549.2 + 58.8 Nm (56 * 6 kgm}
IO) Install damper (25).
J I
CWH01032
11) Assembly discs (24), springs (23), and plates

(22).
. Plates :6
Discs :4
Springs : 6
Ir If the notches are not aligned properly
when assembling, there will be insuffi-
cient lubrication and cooling, and this will
cause seizure.
566FO6755
12) Assemble damper (211, and install 2 lock bolts I

(20).
566FO6760
1. Bearing, spacer
Install spacer (19) to axle, and press fit bearing
(16).
566CK06023
30-155-17 HD325-6
0
2. Collar
Press fit collar (17) to axle, and assembly seal ring.
* Align the position of the holes of the collar
and axle before press fitting.
17 566FO6761
3. Piston
1) Assemble seal ring and O-ring to piston (16)
and hub (15).
Ir Install the seal ring with the side receiv-
ing the pressure facing the groove.
2) Assemble piston (16) to hub (15).
4. Hub
Raise hub (15) and install.
m Mounting bolt: 566FO6752

549.2 k 58.8 Nm I56 k 6 kgm}
Receiving
pressure aide
DVH00140
5. Coupling
Assemble coupling (14).
\+ 566FO6750
HD325-6 30-155-18
0
6. Final drive, brake assemble

Raise final drive and brake assemble (131, and
assemble to axle. 13
* When installing the assembly to the axle, the
lifting wire is at a large angle and the assem-
bly cannot be assembled horizontally. Put a
transmission jack under the final drive and
brake assembly to keep it horizontal, and ad-
just the lifting wire to assemble, then install
the bolts.
& Mounting bolt: Thread tightener ILT-2)

566FO6762
w Mounting bolt:
549.2 + 58.8 Nm (56 f 6 kgml
7. Inner hub
Install Inner hub (12).
8. Adjusting preload of bearing

1) Adjust preload of bearing as follows.
i) Without assembling shim (ll), install re-
tainer (IO) with 3 bolts.
* After installing the retainer, remove
the lifting wire, transmission jack, and
tool Jl.
ii) Rotate wheel hub 5 - 6 turns, and tighten
3 bolts uniformly at 78.5 f 9.8 Nm 18 f 1
kgm} until specified torque is reached.
+ If the wheel hub is not rotated when
tightening the bolts, the bearing will
not settle, and the proper preload will
not be given.
iii) Using depth micrometer 0, measure di-
mension c between end face of shaft and
end face of retainer.
* Measure at 2 places and take the av-
erage.
iv) Remove retainer, measure thickness a of
retainer, calculate difference b (b = c-a),
then add 0.3 mm to value b to obtain thick-
ness for shim.
30-155-19 HD325-6
0
2) Using tool Jl, secure wheel hub and brake

hub, then remove retainer (IO), assemble cal-
culated thickness of shim (I I), and install re-
tainer (IO) again.
& Thread of bolt:

m Bolt: 277.5 * 32.4 Nm (28.3 * 3.3 kgm}
* After installing the bolts, remove tool Jl

then rotate the wheel hub to check that
there is no abnormality in the rotation.
+ After removing tool Jl, do not forget to
tighten the mounting bolts to the speci-
fied value.
9. Hoses, tube
Install grease tube (5) and hoses (4) and (3).
10. Sensor
Install Sensor (2).
HD325-6
Sr Tighten the sensor until it feels that it is touch-

ing the pulse wheel.
& Sensor: Grease (G2-Ll)
I DVH0014’ I
11. Sensor cover

Clamp sensor wiring harness to cover (I), then
install cover (1).
m Mounting bolt:
549.2 k 58.8 Nm I56 f 6 kgm1
12. Install final drive clutch and carrier assembly. For

details, see INSTALLATION OF FRONT FINAL
DRIVE CLUTCH, CARRIER ASSEMBLY.
13. Install front wheel assembly. For details, see IN-

STALLATION OF FRONT WHEEL ASSEMBLY.
30-155-21 HD325-6
0
DISASSEMBLY AND ASSEMBLY FRONT DRIVE SHAFT
DRIVE SHAFT
HD3256W
* Before draining the front drive oil, turn the steer-
ing wheel and turn the tires to give a wider work-
ing space at front.
* If the oil has already been drained from the front
drive, operate the emergency steering and turn
the tires to give a wider working space at the front.
1. Draining oil
Remove drain plug and drain final drive oil.
_
: Final drive oil: Approx. 28 e
‘-\! I.
\ \ \ 566FO6766
2. Cover
Remove 12 cover mounting bolts, then set guide
bolt 0, and using forcing screw 0, pull out cover
(I), fit lifting shackle 0, and lift off cover (1).
3. Thrust washer

Remove No. 1 sun gear shaft (3).

Remove No. 1 carrier assembly (4).
HD325-6
6. No. 2 sun gear

Remove No. 2 sun gear (5).
7. Thrust washer

Lift off No. 2 carrier assembly (7).
9. Coupling
Remove coupling (8).
10. Snap ring

Remove snap ring (9).
II I I
I
I
I
566CK0603
11. Protector
Remove protector (IO).
30-155-23 I-D3256
0
12. Travel motor assembly

Using lever block, raise travel motor assembly
(1 I), then remove 7 mounting bolts (13) (marked
SC)of plate (121, disconnect and move motor as-
sembly to side.
* Do not remove the bolts marked 0.
13. Gear
Remove mounting bolt (141, then remove retainer
(15) and gear (16).
14. Spacer
Remove snap ring (171, then remove spacer (18).
L 566CK06032
566CKO6033
15. Torque shaft assembly

Remove torque shaft(i9) from outside of machine
to inside.
Jr When removing the shaft, set a tool in con-
tact with the end face of the shaft, then hit Outside
with a plastic hammer to remove.

c
If a steel hammer is used, there is danger that
the impact will damage bearing (20).
DVHOO149
HD325-6 30-155-24
0
16. Bearing
1) Remove bearing (21) from shaft (22).
* When removing the bearing, heat the
outer race of the bearing, then hit with a
plastic hammer to remove.
When heating, be careful not to let the
heat affect the shaft and cause deforma-
tion.
Plastic
2) Remove bearing inner race (23) from shaft
hammer
++
(22). Heat Heat
DVHDD144
30-155-25 HD325-6
0
ASSEMBLY OF FRONT DRIVE

SHAFT
HD325-6W
+ Clean all parts, and check for dirt or damage.
1. Bearing inner race

Press fit bearing inner race (23) to shaft (22).
566CK06036
2. Bearing
k Match marks are made on the inner race, outer Position of natch mark(Example of Dart no.71
race spacer, and inner race spacer of the bear-

ing. Always be sure to use the bearing as a
correct set. Do not use combinations of parts oute
race
from different sets. outer race
As shown in the diagram on the right, the
combinations of inner race and outer race are
also distinguished by match marks (7A and
7A, 7 and 71, so use these combinations. Each has mark
at one place an th 1e
circumference.
1
Outer race *ptacer
DVHOOl 45
I) Using push tool 0, tap inner race (24) with a

plastic hammer to press fit it to shaft (22).
Plaat ic
hammer
DVH00141
Push tool
0 4
DVH00147
HD325-6 30-155-26
0
2) Fit outer race (251, inner race spacer (26), outer

race spacer (27), and outer race (281, then use
push tool @ and tap inner race (29) with a
plastic hammer to press fit it.
Plastic
hammer
27 26
DVH00148
3. Toraue shaft assemblv

1) insert torque shaft assembly (19) inside axle.
2) Using push tool 0, tap torque shaft assem-
bly (19) with plastic hammer to press fit to
housing.
* When installing the torque shaft assem-
bly, be extremely careful not to damage
bearing (19).
566CK06041
Outside
DVH00149
3) Assemble spacer (18), then use push tool 0

to push in outer race and install torque shaft
assembly securely to housing.
566CK06042
30-155-27 HD325-6
0
Push tool
0 5
DVHD0160
4. Spacer
Fit spacer (18) and install snap ring (17).
5. Gear 566CKO6044
install gear (16) to torque shaft, then fit retainer

(15) and tighten bolt (14).
* Tighten the bolts gradually while rotating the
gear 20 - 30 times.
& Tread of mounting bolt:

m Mounting bolt:
110.3 & 12.3 Nm {Il.25 f 1.25 kgm1
* After tightening the bolt to the specified

torque, rotate the gear 20 -30 turns, and check
that there is no looseness in the specified
torque.
566CK06045
6. Checking starting torque, end play
l Checking starting torque
Align one end of the string in the diagram
with the width of the gear, hookthe other end
to spring balance 8, and wind the string at
least one turn around the outside circumfer-
ence of the gear. Then pull the string slowly
in the tangential direction and measure the
starting torque.
+ Measure at several points (5 - 6 points)
around the circumference.
P Tie strino(70-80cm)as shorn in diagram
* Tangential force when starting:
Max. 16.5 N (1.68 kg}
Knots
[torgue: Max. 1 Nm (0.10 kgm]] DVHOOl 61
HD325-6 30-155-28
0
. Checking end play

Fix dial gauge @to end face of axle, align in-
Iron bar
dicator with bolt head and set to 0 point.
Push and iron bar (length at least 70 cm) be-
-dl
tween axle and gear, apply force in axial di-
rection, and measure play in axial direction.
+ Check that the reading for the play in the
axial direction is within 0.008 - 0.124 mm
on the dial gauge.
DVHOO162
7. Travel motor assembly I

Fit gasket and set travel motor assembly (11) to
axle, then tighten 0 mounting bolts (13) of plate
(12).
----T s 566FO6774
8. Protector
Install protector (IO).
9. Snap ring
Install snap ring (9).
I 566CK06031
30-155-29 HD3256
0
IO. Coupling
Ins&l coupling (8).

Raise No. 2 carrier assembly (7) and install.
* Put any one of the planet gears at the bottom
when assembling.
DVHOCtt 63
12. Thrust washer

13. No. 2 sun gear

Install No. 2 sun gear (5).

install No. 1 carrier assembly (4).

Install No. 1 sun gear shaft (3).
HD325-6
DISASSEMBLY AND ASSEMBLY FRONT DRIVE SHAFI-
16. Thrust washer

17. Cover
Set guide bolt @ in position, fit O-ring to cover
(I), then use shackle @ to raise, and install to hub.
A& Tread of mounting bolt:

m Cover mounting bolt:
110.3* 12.7 Nm 111.3? 1.3 kgm}
566FO6775
. Refilling with oil (front final drive)

Tighten drain plug P2 and add oil through PI to
specified level.
566CK06022
30-155-31 HD3256
0
DISASSEMBLY AND ASSEMBLY REAR FINAL DRIVE CARRIER
REMOVAL OF REAR FINAL

DRIVE CARRIER ASSEMBLY
1. Remove drain plug (I) and drain oil from final
drive (both left and right).
b
& Final drive: Approx. 13 e (each)
t If the drain plug is not directly at the bottom,

use a hydraulic jack (min. 30-ton) to jack up
the machine, then rotate the hub.
i 566FO6623
2. Using guide bolt, remove cover (2).
’ 566~06624
3. Using eye bolt 0, pull out shaft (3).
4. Remove snap ring (41, then remove sun gear (5).
5. Using eye bolt, remove carrier assembly (6).
&l kg Carrier assembly: 100 kg
566FO6625
Disassemble carrier assembly as follows.

I) Remove plate (71, then remove shaft (8).
2) Remove gear (9) and thrust washer (IO).
3) Remove bearing (1 I) from gear.
566F06626
30-156 HD325-6
0
INSTALLATION OF REAR FINAL

* Clean all parts, and check for dirt or damage.
Coat sliding surfaces of all parts with engine oil
before installing.
1. Assemble carrier assembly as follows.

I) Assemble bearing (11) on gear (9).
2) Fit thrust washers (10) on both sides of gear,
and set in carrier.
3) Install shaft (8), then install lock plate (7).
2. Using eye bolt 0, install carrier assembly (6). 566FO6627
3. Align planetary gear, install sun gear (5), then in-

stall snap ring (4).
* If the gear cannot be aligned, use a hydraulic
jack (min. 30-ton) to jack up the machine, then
rotate the hub.
4. Using guide bolt, fit O-ring and install cover (2).
5. Tighten drain plug (1) and add engine oil through

oil filler (12) to the specified level.
%# Final drive: Approx. 13 !I (each)
/ ” 566FO6629 I/ 566FO663C 1
9’
566FO6631 566FO6632
HD325-6
DISASSEMBLY OF REAR FINAL

DRIVE CARRIER ASSEMBLY n
1. Using push tool 0, push out shaft (2) from car-

rier (1) with press.
* When pulling out the shaft, ball (3) will come
out at the same time, so remove the shaftcare-
fully so as not to lose the ball.
566FO6633
2. Pull out pinion gear assembly (4) from carrier (1).

4
* When pulling out the pinion gear assembly, \
pull out carefully so as not to drop the inner
bearing.
3. Pinion gear assembly

I) Remove bearing inner races (5) and (6).
566FO6634
2) Remove outer bearing (7) and pull out spacer

(8).
3) Remove outer bearing (9) and remove snap
ring (IO).
I 566FO6635
30-158 HD325-6
0
ASSEMBLY OF REAR FINAL

1. Planetary gear assembly
I) Install snap ring (IO) to planetary gear (4).
2) Using push tool 0, press fit outer bearing
(9) with press.
3) Install spacer (S), and using push tool 0,
press fit outer bearing (7).
* 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 9 10
spacer. 566FO6636
Oistinauishina mark Distinouishina mark

for inner. outer race for inner, outer race
(Example:MZ-126) (ExamPle:MZ-12A)
Distinouishino
mark for spacer
[Example:MZ-12)
DWH00123
4) Assemble bearings (6) and (5) to carrier (I). 566F06637
2. Push planetary gear assembly (4) into carrier (1). 4
3. Press fit shaft (2) to carrier (I ).

-k Expand fit the shaft or press fit the shaft with
a press.
* 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.
566FO6634
2 566FO6638
HD325-6 30-l 59
0
DISASSEMBLY AND ASSEMBLY REAR FINAL DRIVE
DISASSEMBLY OF REAR FINAL

DRIVE ASSEMBLY
1. Rear wheel assembly
For details, see REMOVAL OF REAR WHEEL AS-
SEMBLY.
2. Carrier assembly
For details, see REMOVAL OF FINAL DRIVE CAR- El
RIER ASSEMBLY.
3. Retainer, shim
I) Using tool El, secure inner gear (I) and outer
gear (2).
-k To install the tool, remove bolt (3) from
the outer gear, and use the three tool
mounting tap holes in the inner gear.
* To prevent damage to the floating seal,
always remove before removing retainer
(4).
2) Remove mounting bolts, then remove retainer
(4) and shim.
4. Ring gear akembly

1) Lift off ring gear assembly (5).
&I kg Ring gear assembly: 40 kg
ill F56103459
2) Disassemble ring gear assembly as follows.

i) Remove mounting bolts (61, then remove
holder (7). 6 79 8
\ /I \
ii) Remove inner hub (9) from ring gear (8).
F5610346OK
30-160 HD325-6
0
5. Rear wheel hub assembly

1) Slingwheel hubassembly(lO)orsupportwith
forklift, then remove nut (11).
F56103461 1 CWH01037
2) Pull out wheel hub assembly (IO) partly, re-

move bearing (12), then remove wheel assem-
bly.
* The bearing comes out easily, so be ex-
tremely careful not to let it drop.
l+lkg Rear wheel hub assembly: 250 kg
3) Remove outer races (13) and (14) from wheel

hub assembly (IO).
F56103463 566FO6640
6. Bearing
Remove bearing (15).
HD325-6 30-161
0
ASSEMBLY OF REAR FINAL

DRIVE ASSEMBLY
1. Bearing
Install bearing (15).
F56103465
2. Wheel hub assembly

1) Using push tool I press fit outer races (13) and
(14) in wheel hub (10).
2) Fit O-ring, then raise rear wheel hub assem-
bly (IO), and set to inner gear.
566FO6640 F56103461
3) Install bearing (121, and tighten nut (II).
Nut thread: Thread tightener (LT-2)

Nut: 176.5 & 19.6 Nm (18 f 2 kgm}
Do not remove tool J3 until the retainer
has been completely secured.
3. Ring gear assembly

I) Assemble ring gear assembly as follows. CWH01037 566FO6641
i) Set inner hub (9) to ring gear (8).
ii) Fit holder (71, and tighten mounting bolts
(6).
Bolt thread: Thread tightener (LT-2)

Bolt: 30.9 i 3.4 Nm I3.15 f 0.35 kgm}
2) Raise ring gear assembly (5) and install.
F5610346OK
30- 162 HD325-6

0
DISASSEMBLY AND ASSEMBLY REAR BRAKE
REMOVAL OF REAR BRAKE

ASSEMBLY
1. Remove final drive assembly
For details, see REMOVAL OF FINAL DRIVE AS-
SEMBLY.
2. Drain oil.
:
w Brake cooling tank: 90 e
3. Remove retainer (1).

* Remove floating seal (2) from the retainer.
F56103467 F56103617
4. Disconnect hoses (3).
5. Remove tubes (4).
6. Lift off brake assembly (5). a
&I kg Brake assembly: 300 kg
7. Remove piston (6). m

* Loosen the air bleed plug and remove piston (6).
8. Remove cylinder assembly (7). m
f‘56103468
ASSEMBLY
moval.

m Mounting bolt:
176.5 + 19.6 Nm {I8 & 2 kgm}
* Install the piston seal with the grooved side

‘5 F56103469
facing the side taking the pressure.
fGJ
-f- install the cylinder seal with the side with the
groove facing the side taking the pressure.

m Mounting bolt:
549.2 f 58.8 Nm (56 & 6 kgm}

* Refill oil to the specified level and check the
oil level again.
F56103470
I& Brake cooling tank: 90 e
30-164 HD325-6
0
-DISASSEMBLY AND ASSEMBLY REAR BRAKE
DISASSEMBLY OF REAR BRAKE
1. Outer gear assembly

1) Remove tool J3.
2) Using eyebolts, lift off outer gear (I) together
with disc and plate.
* Be careful not to damage the floating seal
when removing.
1 CWH01037
2. Damper, disc, plate

Remove damper (2), disc (3), and plate (4) from
outer gear (1).
3. Hub
1) Remove mounting bolts, then remove hub (5)
from outer gear (1).
2) Remove floating seal (6) and dust seal (7) from
hub (5).
F56103473A-K
4. Floating seals
Remove floating seals (9) and (’IO) from inner gear
(8).
7 6 566FO6642
HD325-6 30- 165

0
ASSEMBLY OF REAR BRAKE

ASSEMBLY
* Clean all parts, and check for dirt or damage. Coat
before installing.
* When assembling the floating seals, use alcohol
to remove all the white powder from the O-ring
surface before assembling.
8 9
F56103473A.K
1. Floating seals
Using tool J4, install floating seals (9) and (IO) to
inner gear (8).
+ After installing the floating seals, measure di-
mension a between the inner gear and float-
ing seal at four places around the circumfer-
ence and check that the measurement is
within 1 mm.
2. Hub
I) Install oil seal (7) to hub (5).
6 Lip of oil seal: Grease (G2-LI)
w Oil seal periphery surface:
568F056 5609FO5245
Thread tightener (Loctite #848)
2) Using tool 54, install floating seal (6) to hub

(5). J4
\
* For precautions to take after installing the
floating seal, see Item 1.
3) Align match marks, and install hub (5) to outer

gear (I ).
m Mounting bolt: I CWH01038
110.3? 12.3 Nm{11.25* 1.25 kgm}
I F56103475
30-166 HD325-6
0
3. Outer gear
1) Using eyebolts, assemble outer gear assem-
bly (I) to inner gear.
* Coat the sliding surfaces of the floating
seals thinly with engine oil.
* Assemble slowly and be careful not to
damage the floating seals.
2) Align center of inner gear and outer gear (I),

then using tool J3, secure inner gear and
outer gear.
F56103476
F56103619
4. Damper, disc, plate

Align notches at 6 places around the circumfer-
ence of damper (2) and plate (4), then assemble
togetherwith disc (3) to inner gear and outer gear
assembly.
* If the notches are not aligned before assem-
bling, there will be a lack of lubrication and
cooling, and this will cause seizure.
F56103477K
HD325-6 30-167
0
DISASSEMBLY AND ASSEMBLY PARKING BRAKE PAD
REMOVAL OF PARKING BRAKE

PAD
A Stop the machine on level ground, and put blocks
under the wheels.
A Raise the dump body and lock with the safety pin.
* Release the parking brake.
1. Turn adjustment bolt (I) counterclockwise, and

make clearance between pad and disc larger.
2. Remove bolt (21, then remove bracket (3) and

spring (4). m I 566FO6643
* Check the mounting direction of the spring.
3. Loosen 8 bolts (51, and sling so that caliper does

not drop. m
4. Remove pads (6). m

* Move plate (7) when removing the pads (6)
so that the pads do not fall.
+ After removing the rear pad, move the cali-
per to the front, and remove the front pad.
566FO6644
30- 168 HD325-6

0
DISASSEMBLY AND ASSEMBLY PARKING BRAKE PAD
INSTALLATION OF PARKING
BRAKE PAD Ah
moval.
m
* Install the springs as follows.
1) Turn adjustment bolt (I) counterclockwise,
and make clearance a between pads at least
60 mm.
2) Fit spring (4) in bracket (3) and install to posi-
tion shown in Fig. 1.
* For details of the mounting position for 566FO6644
each spring, see Fig. 2. Fig.1

* Screw in mounting bolts (2) of the bracket
2 - 3 turns so that the bracket moves Palntino(YeIIow) Paintino (Black)
freely.
3) Turn adjustment bolt (I) clockwise to bring
both pads into close contact with disc, then
tighten to a point where it becomes difficult
to turn bolt.
4) Tighten mounting bolts (2) and be careful that
bracket does not come out of position.
+ After installing to the machine, check that
the clearance between the pad and disc
is at least 0.05 mm (each side). -7
DWHOOl24
If there is not sufficient clearance, move
the bracket in the direction to increase the Fig.2
clearance, install it again, and check that
the clearance is correct.
m
* Align the grooves of the pad and the caliper
with both sides of the plate securely.
& Plate mounting bolt:

m Plate mounting bolt:
926.8 f 103.0 Nm (94.5 f 10.5 kgm}
* Adjust the clearance between brake pad and

disc.
For details, see TESTING AND ADJUSTING.
HD325-6 30-l 69
0
DISASSEMBLY AND ASSEMBLY PARKING BRAKE CALIPER

CALIPER ASSEMBLY I
1. Remove parking brake chamber assembly
For details, see REMOVAL OF PARKING BRAKE
CHAMBER ASSEMBLY.
2. Remove plate
For details, see REMOVAL OF PARKING BRAKE
PAD ASSEMBLY.
3. Remove pads (I ).
4. Lift off caliper (2). 566FO6646
&I kg Caliper: 35 kg
BRAKE CALIPER ASSEMBLY
moval.
& Plate mounting bolt:

m Plate mounting bolt:
926.8 + 103.0 Nm 194.5 ?I 10.5 kgm}
30-170 HD325-6
0
DISASSEMBLY AND ASSEMBLY PARKING BRAKE CALIPER
DISASSEMBLY OF PARKING ASSEMBLY OF PARKING

BRAKE CALIPER BRAKE CALIPER
I: Remove snap ring (I), and pull out adjuster 1. Assemble piston seal (12) to caliper (IO), and
(2). insert piston (I 1).
2. Remove washer (3) and (4). and seal (5). & Piston, piston seal: Grease (G2-LI)
3. Remove bolts, then remove cap (6) and gas- 2. Screw piston shaft (8) into piston (1 I), and
ket (7). install thrust bearing (9).
4. Remove piston shaft (8) and thrust bearing * Be careful to install the thrust bearing fac-
(9) from piston. ing in the correct direction.
5. Remove piston (I 1) and piston seal (12) from
& Thrust bearing: Grease (G2-LI)
caliper (IO).
3. Fit gasket (7) and install cap (6).
4. Install seal (5), and washers (4) and (3).
Ir Fit the seal securely in the groove.
& Seal: Grease (G2-LI)
5. Assemble adjuster (21, and secure with snap
ring (1).
F56103479
HD325-6 30-171
0
DISASSEMBLY AND ASSEMBLY FRONT SUSPENSION CYLINDER
REMOVAL OF FRONT
SUSPENSION CYLINDER
ASSEMBLY
HD325-6, HD4056
1. Remove front wheel assembly

For details, see REMOVAL OF FRONT WHEEL HUB
ASSEMBLY.

Release nitrogen gas from front suspension cyl-
inder.
566FO6647 566FO6648
For details, see TESTING AND ADJUSTING OF
SUSPENSION CYLINDER, Releasing nitrogen gas.
m
3. Remove cover (I ).
4. Disconnect brake hoses (2).

* Fit tags to the hoses to mark the mounting
position.
5. Disconnect air hoses (3).
6. Remove grease tubes (4).
7. Remove 2 elbows (5). 566FO6649 566FO6650
8. Remove pins (6) and (7).
9. Remove tie rod (8).
10. Disconnect steering cylinder rod (9).
11. Remove 4 bolts (IO).

* When removing the bolts marked 0, turn the
knuckle arm approx. 40” towards the chassis,
then remove the bolts marked 0. When do-
ing this, return the knuckle arm to its original
position, and use a jack (30 ton) to raise the
bottom of the king pin when removing.
12. Remove pin (11) at suspension cylinder rod end.

t Using a fork-lift (5 ton), sling the suspension
cylinder assembly.
13. Remove suspension cylinder assembly (12).

* Disconnect the suspension cylinder assembly
from the knuckle arm.
& kg Suspension cylinder assembly: 300 kg
&561035421-K
30-172 HD325-6
0
SUSPENSION CYLINDER
ASSEMBLY
HD325-6, HD405-6

moval.
w Valve: 44.1 + 4.9 Nm I4.5 + 0.5 kgm}
l Refilling with oil, charging nitrogen gas

Adjust front suspension cylinder.
FRONT SUSPENSION CYLINDER.
HD325-6 30-173
0
REMOVAL OF FRONT
SUSPENSION CYLINDER
ASSEMBLY
HD325-6W
1. Disassembly front final brake assembly.

For details, see REMOVAL OF FRONT FINAL
BRAKE ASSEMBLY.

. Release nitrogen gas from front suspension
cylinder. For details, see TESTING AND AD-
JUSTING OF SUSPENSION CYLINDER, Re- 566FO6776 566FO6777
leasing nitrogen gas. m
Remove cover (1) and 2 brackets (2).
Disconnect air hoses (3).
Disconnect clutch hoses (4).
Disconnect hose between motor and pump, mo-

tor cooling hose, axle cooling hoses (51, and wir-
ing (6).
+ Before disconnecting, fit tags to the hoses and
wiring to mark the mounting position.
7-. Remove grease tube (7).
8. Remove 2 elbows (8).
9. Remove pins (9) and (IO). m
10. Remove tie rod (I I).
11. Disconnect steering cylinder rod (2).
566FO665OA
12. Remove 4 bolts (13).

* When removing the bolts marked l , turn the
knuckle arm approx. 40” towards the chassis,
then remove the bolts marked 0 _ When do-
ing this, return the knuckle arm to its original
position, then use a jack (30 ton) to raise the
bottom of the king pin when removing.
566F06651A
30-173-l HD325-6
0

* Using a forklift (5 t), sling the suspension cyl-
inder assembly.
14. Remove suspension cylinder assembly (15).

* Disconnect the suspension cylinder assembly
from the knuckle arm.
&I ks Suspension cylinder assembly: 350 kg
SUSPENSION CYLINDER
ASSEMBLY
HD325-6W

moval.
m Valve: 44.1 f 4.9 Nm (4.5 + 0.5 kgm}
Jr & Bushing stopper bolt (16):

+ w Bushing stopper bolt (16):
549.2 k 58.8 Nm (56.0 f 6.0 kgm1
l Refilling with oil, charging nitrogen gas

l Adjust the front suspension cylinder.
For details, see TESTING AND ADJUSTING
OF SUSPENSION CYLINDER.
566FO6779
HD325-6 30-173-2
0
SUSPENSION CYLINDER
ASSEMBLY
• Using a block, stand the cylinder assembly up-
right.
1. Remove cover.
2. Remove intake valve (1) and oil level valve (2).
3. Cylinder rod assembly

1) Remove flange mounting bolts (3) and air
bleed valve (4).
2) Raise cylinder rod assembly (5) with plate (6),
retainer (7) and flange (8) still installed.
4. Disassembly of flange
1) Remove plate (6), retainer (7), and flange (8)
from rod assembly (5).
2) Remove dust seal (9) and bushing (10) from
retainer (7).
3) Remove packing (11) and bushing (12) from
flange (8).
5. Remove wear ring (13) from cylinder rod (5).
30-174 HD325-6
(14)
ASSEMBLY OF FRONT
SUSPENSION CYLINDER
ASSEMBLY
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 in-
stall dust seal (9).
fl Be careful not to deform the bushing
when press fitting.
3. Assembly of rod assembly

• If stopper (14) installed to the rod is broken or
shifted out, replace it with new one.
1) Place stopper (14), aligning it with rod (5).
fl Place stopper (14) with the round rim end
up.
2) Using tool [1], press fit stopper (14).

• Press fit stopper (14) to the rod mounting
part securely.
3) Press fitting tool [1] (Reference)

[1a]: Nylon (For protection of rod)
HD325-6 30-175
(14)
4. Assembly of cylinder rod assembly

1) Install wear ring (13) to cylinder rod (5).
2) Install flange (8), retainer (7), and plate (6) to
cylinder rod.
3) Using block, stand cylinder upright.
fl Fill inside of cylinder with engine oil.
- Cylinder: 14 ¬ (EO10-CD)
4) Raise cylinder rod assembly (5), and assemble
in cylinder.
fl 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.
fl After completely installing the suspension
to the machine, use tool G2 to adjust the
oil and gas levels.
For details, see TESTING AND ADJUST-
ING OF SUSPENSION CYLINDER.
5) Install flange (8), retainer (7), and plate (6) to
cylinder with bolts (3).
6) Install air bleed valve (4).
9 Valve: 44.1 ± 4.9 Nm {4.5 ± 0.5 kgm}
5. Install oil level valve (2) and intake valve (1).

9 Valve: 44.1 ± 4.9 Nm {4.5 ± 0.5 kgm}
6. Install cover.
30-175-1 HD325-6
(14)
DISASSEMBLY AND ASSEMBLY VARIABLE DAMPING SELECTOR VALVE
ASSEMBLY OF VARIABLE
DAMPING SELECTOR VALVE
ASSEMBLY
1. Assembly of tube assembly (28)
Install O-ring (301, ring (31), and O-ring (30) to tube
(29).
2. Install tube assembly (28).
3. Assemble orifice plate assembly (20). 24

1) Install pin (27) to plate (25).
2) Assemble plates (26), (251, (24), (231, and (221,
and install with bolt (21). DWH00125
* Assemble plates (251, (241, and (23) with
the chamfered side facing plate (26).
4. Install orifice plate assembly (20) to valve body outer race

If ixed race1
(7).
5. Assemble valve body assembly (6). lder

Li
1) Assembly of shaft assembly (17).
Using push tool (outside diameter: 42 mm),
install bearing (19) to shaft (18).
Ir Press fit the outer race (fixed race) of bear-
ing (191, then install the lip of the holder
facing the outer race (fixed race).
2) Install shaft assembly (17). Inner race
(rotat ino race)
3) Assembly of shaft assembly (12). DWHOOt26
Install ring (16), O-ring (151, and U-packing (14)
to flange (13).
4) Install flange assembly (12).
5) Assembly of retainer assembly (8).
Using push tool (outside diameter: 20 mm),
press fit bushing (I 1) in retainer (91, then in-
stall dust seal (IO).
6) Install retainer assembly (8) to valve body (7).
Fit O-ring and install valve body assembly (6).
Fit O-ring and install tube (5).
Install bracket (4).
Fit key (3) to shaft assembly (17), and install lever

(2).
10. Install bracket (I).

. Refilling with oil, charging with gas
* Add oil and charge the suspension cylinder
with nitrogen gas.
Adjusting suspension cylinder.
%3 14 e (each side)
11. Tighten 6 mounting bolts (32) of valve assembly

(6).
m Mounting bolt:
274.6 f 29.4 Nm (28 k 3 kgm}
HD325-6 30-177
0
DISASSEMBLY AND ASSEMBLY REAR SUSPENSION CYLINDER
REMOVAL OF REAR
SUSPENSION CYLINDER
ASSEMBLY
Release nitrogen gas from rear suspension cyl-
inder. For details, see TESTING AND ADJUST-
ING SUSPENSION CYLINDER, Releasing nitro-
gen gas. m
2. Remove cover.
3. Remove pressure sensor (I).
4. Remove pin (2) at suspension cylinder bottom

end.
* Using a fork-lift (5 ton), sling the suspension
cylinder assembly.

4
6. Remove rear suspension cylinder assembly (4).
&I kg Rear suspension cylinder assembly:

135 kg
CEH00116
SUSPENSION CYLINDER
ASSEMBLY

moval.
B Valve: 44.1 + 5 Nm I4.5 * 0.5 kgm1
l Refilling with oil, charging with nitrogen gas.

REAR SUSPENSION CYLINDER.
30- 178 HD325-6

0
DISASSEMBLY OF REAR SUSPENSION CYLINDER ASSEMBLY

1. Cover
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.
CWHOl040

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 (IO), without
removing retainer (8) and flange (9).
I CEH00132
4. Flange
1) Remove retainer (8) and flange (9) from rod
assembly (7).
2) Remove U-packing (1 I), backup ring, and O-
ring (12) from flange (9).
3) Remove the bushing from flange (9).
4) Remove seal (13) and bushing from retainer
(8).
DEH00064 CEH0007'
5. Wear ring
Remove wear ring (14) from rod (15).
CEH00133
HD325-6 30-179
0
ASSEMBLY OF REAR SUSPENSION CYLINDER ASSEMBLY

1. Wear ring
install wear ring (14) to rode (15).
2. Flange
1) Install the bushing to flange (9) with tool Ql.
2) Install U-packing (I I) to flange (9).
3) Install backup ring and O-ring (12) to flange
(9).
II
///////////////////////// I
DWH00155
3. Retainer
1) Install the bushing to retainer (8) with tool 01.
2) Install seal (13) to retainer (8).
I DWH00156

1) Erect cylinder (IO) 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) to-
gether with mounting bolts (15).
w Mounting bolt:
66.2 + 7.4Nm I6.8 k 0.7 kgm}
5. Intake valve and oil level valve

Turn the cylinder assembly in reverse.
1) Hang cylinder (IO) until dimension A becomes
I 7b 0 CWH01043
llOf3mm.
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).
m Intake valve and oil level valve:
44.1 k 5Nm I4.5 k 0.5kgmI
6. Cover
1) Install cover (2) and tighten band (I).
2) Install the protector of the intake valve and
oil level valve.
30-180 HD325-6
0
DISASSEMBLY AND ASSEMBLY AIR GOVERNOR
REMOVAL OF AIR GOVERNOR

ASSEMBLY
g Open the drain valve of the air tank and release
the air pressure.
1. Disconnect tubes (1).
2. Remove air governor assembly (2).
1
INSTALLATION OF AIR 566FO6654
GOVERNOR ASSEMBLY
moval.
HD3256 30-181
0
DISASSEMBLY AND ASSEMBLY AIR GOVERNOR
DISASSEMBLY OF AIR
GOVERNOR ASSEMBLY
2. Remove snap ring (2), then remove adjustment
screw and spring assembly (3).
3. Pull out piston assembly (41, and remove stem
(5) and spring (6).
ASSEMBLY OF AIR GOVERNOR

ASSEMBLY
Clean all parts, and checkfor dirt or damage, then
coat all parts with grease before installing.
Fit O-ring and install spring (6) and stem (5) to

piston (7).
Fit O-ring and install piston assembly (4) to body
(8).
Fit adjustment screw and spring assembly (3) to
body (8), then install snap ring (2).
* Measure adjustment screw dimension A.
A dimension : 50mm
569F092
566FO6656
4. Install cover (I).

* After installing to the machine, measure the
air pressure.
Measuring air pressure.
30-182 HD325-6
0
DISASSEMBLY AND ASSEMBLY BRAKE VALVE
REMOVAL OF BRAKE VALVE

ASSEMBLY
1. Depress brake pedal several times to bleed air
from air tank.
2. Remove cover.
3. Disconnect tube (I) between air tank and brake
valve at valve end.
4. Disconnect tube (2) between relay valve and brake
valve at valve end.
6. Remove pin (4), then remove brake pedal (5).
7. Remove 3 mounting bolts (6), then leave mount- \ F56103556
ing plate (7), and remove brake valve assembly

(8).
1NSTALLATlON OF BRAKE
VALVE ASSEMBLY
1. Install brake valve assembly (8) to plate (7).
2. Install brake pedal (5).
3. Install cover (3).
4. Connecttube betweenairtankand brakevalve.
5. Connect tube (2) between relay valve and brake
valve.
m Sleeve nut: 10.8i 1.0 Nm Il.1 & 0.1 kgm} 3 4 5kFO6657
* Check that there is no air leakage.
6. Install cover.
F56103558
HD325-6 30-183
0
DISASSEMBLY OF BRAKE
VALVE ASSEMBLY
1. Retainer
Push piston assembly (I) and remove retainer (2).
F56103559
2. Piston assembly
Remove piston assembly (I).
3. Spring
Remove spring (3).
F56103560
4. Lower cover assembly

Remove mounting bolts, then remove lower cover
assembly (4).
5. Spring
Remove spring (5).
F56103561
inner relay piston

Pull out inner relay piston (6) from body.
Ir Be careful not to damage the sliding surface
of the piston.
Outer relay piston

Pull out outer relay piston (7) from body.
* Be careful not to damage the sliding surface
of the piston.
F56103562
30- 184 HD325-6

0
8. Snap ring
Remove snap ring (8).
FE16103563
9. Upper valve
Pull out upper valve assembly from body (91, and
remove snap ring (IO), then disassemble into
washer (1 I), retainer (12), spring (131, and upper
valve (14).
F56103564
IO. Check valve assembly

Remove snap ring (151, then remove checkvalve
assembly (16) from cover (17).
11. Lower valve

Remove snap ring (18), and disassemble into
guide (191, spring (201, and lower valve (21).
QzzY F5610356E ,
HD325-6 30- 185

0
ASSEMBLY OF BRAKE VALVE

ASSEMBLY
1. Lower valve
Assemble spring (20) and guide (19) in lower valve
(21), assemble snap ring (181, then assemble in
cover (17).
2. Check valve assembly

Assemble checkvalve assembly (16) in cover, then
assemble snap ring (15).
%z@ F56103565
3. Upper valve
Assemble spring (13), retainer (12), and washer
(11) in upper valve (141, then assemble snap ring
(IO), and assemble in body (9).
* Assemble the O-ring (2 types 1to the retainer.
F56103564
4. Snap ring
Assemble snap ring (8).
F56103563
L
5. Outer relay piston

Fit O-ring to sliding portion, and assemble
relay piston (7) in body.
outer
1
6. Inner relay piston
Fit O-ring to sliding portion, and assemble inner
relay piston (6) in body.
F56103562
30- 186 HD325-6

0
7. Spring
Assemble spring (5) in inner relay piston.
8. Lower cover assembly

Fit O-ring to mount and install lower cover as-
sembly (4) to body.
F56103561
9. Spring
Assemble spring (3) in body.
10. Piston assembly

Assemble piston assembly (1).
F56103560
11. Retainer
Push piston assembly (I) and compress spring,
then install retainer (2).
F56103559
HD325-6 30-187
0
DISASSEMBLY AND ASSEMBLY PARKING BRAKE CHAMBER

CHAMBER ASSEMBLY
g Stop the machine on level ground, and put blocks
under the wheels.
A Raise the dump body and lock with the safety pin.
1. Remove pin (1). m

* With the parking brake released, turn adjust-
ment bolt (2) counterclockwise and checkthat
there is play in linkage (3).
2. Disconnect air hose (4). 658

* With the parking brake applied, disconnect the
air hose from the chamber.
t Check that the air pressure of the chamber is
released.
3. Remove chamber assembly (5). m
BRAKE CHAMBER ASSEMBLY

moval.
* Adjust the linkage.

Testing and adjusting performance of park-
ing brake.
w Mounting nut:
196.1 + 19.6 Nm {20? 2 kgm)
30-188 HD325-6
0
DISASSEMBLY OF PARKING
1. Remove screw, then remove holder (I) and filter
(2).
2. Remove retainer (3) and nut (191, then remove

boot (4).
3. Remove nuts (5) and (6), then remove shaft (7).
4. Remove nut (8) and (9) from shaft (7).
5. Using press, support piston (IO) and support(

and remove bolts (12). Then loosen press slowly,
and remove support (II) and spring (13).
g The piston and support are under high pres-

sure, so be careful when operating the
press.
6. Remove piston (IO), then remove rings (14) and

(15) from piston.
7. Remove rings (17) and (18) from case (16).
427F2048A-K
II
Push-tool DWH00127
HD325-6 30-l 89
0
ASSEMBLY OF PARKING BRAKE

CHAMBER ASSEMBLY
* Clean all parts, and check the inside of the cylin-
der for dirt or damage.
* Coat the sliding surfaces of all parts with grease.
1. Install rings (18) and (17) to case (16).

& Ring (17): Engine oil (EO-30CD)
2. Install rings (15) and (14) to piston (IO), and set in

case (16).
& Ring (15): Engine oil (EO-30CD) 569FO5252
3. Set spring (13) and support (II) in position, and

using press, slowly compress spring so that sup-
port bolt hole matches cylinder bolt hole.
a The piston and support are under high

pressure, so be careful when operating the
press.
& Outer circumference of support:
Adhesive
4. Align bolt hole, and install bolts (12).

m Bolt: 13.7 & 3.9 Nm (1.4 f 0.4 kgm}
5. Install nuts (8) and (9) to shaft (71, then adjust so

that nut (9) and end face of shaft (7) is standard
dimension a.
* Standard dimension a: 21.0 mm
569FO5253
6. Install shaft (7) to cylinder, then install nut (61, ad-
just so that clearance from end face of piston (IO)
is dimension b, then tighten nut (5).
J, Clearance dimension b: 2.0 mm
m Nut (5): 44.1 k 4.9 Nm 14.5 f 0.5 kgm}
30- 190 HD325-6

0
7. Install nut (19).

Sr Check that nut (19) and end face of shaft (7) is
Standard dimension c: 24 mm
8. Check that case (16) and end face of shaft (7) is

standard dimension d.
* Standard dimension d: 128.0 mm
d
9. Set boot (4) in position, and install nut and re-
tainer (3).
10. Set filter (2) in position, and install holder (I).
569FO5254
HD325-6
DISASSEMBLY AND ASSEMBLY FRONT BRAKE CHAMBER
REMOVAL OF FRONT BRAKE

HD325-6, HD405-6
CHAMBER ASSEMBLY
HD3256, HD405-6
A Open the
the tank
drain valve to release the air inside
1. Disconnect air tubes (1).

* The oil in the brake oil tank will flow out, so
fit corks.

HD325-6. HD405-6
4. Remove rear brake chamber assembly (4).
HD325-6W
HD325-6W
A Open the drain valve to release the air inside
the tank
1. Remove cover, and disconnect 2 connectors (I).

* Left brake chamber assembly only.
2. Disconnect 4 hoses (2).
3. Disconnect 2 air hoses (3).
4. Disconnect air tubes mounting block (4) for sus-

pension controller.
5. Disconnect 2 hoses (5) for front drive valve.
6. Lift off front brake chamber assembly (6) together

with bracket.
moval.
30- 192 HD325-6

0
DISASSEMBLY AND ASSEMBLY REAR BRAKE CHAMBER
REMOVAL OF REAR BRAKE

CHAMBER ASSEMBLY
A Open the drain
the tank
valve to release the air inside
1. discommect air tubes (I).
2. disconnect hoses (2).

-k The oil in the brake oil tank will flow out, so
fit corks.
4. Remove rear brake chamber (5) and mounting

bolt assembly (4).
INSTALLATION OF REAR BRAKE

CHAMBER ASSEMBLY
l Carry out installation in the revers order to
renoval.
Rear ’
DEH00067
HD325-6 30- 193

0
DISASSEMBLY AND ASSEMBLY OF FRONT BRAKE CHAMBER
DISASSEMBLY OF FRONT BRAKE CHAMBER ASSEMBLY
F569S3013
Precautions when disassembling

Before disassembling, make match marks at all
joints to act as a guide when reassembling.
Oil cylinder
Remove 4 bolts (I), then remove all cylinder (2).
bs
l------"
FEZ:
F56103569
Oil piston
1) Supply compressed air at 0.1 - 0.2 MPa (1 - 2
kg/cm21 to air cylinder, and push out rod (4)
of piston and rod complete (3) fully.
2) Remove ring (5) from ring groove, then move
towards push rod, and pull out pin (6).
F56103570
30-194
0
DISASSEMBLY AND ASSEMBLY OF FRONT BRAKE CHAMBER
3) When pin (6) is pulled out, it is possible to

remove oil piston (7), bushing guide (8), and
ring (5).
4) After removing oil piston, exhaust com-
pressed air from air cylinder (9).
7 8 6 5
3. Remove seal (IO) and backup ring (11) from oil
piston assembly.
F56103571
4. Air cylinder assembly
AThe spring has a reaction force of 637.4 N (65

kg} when compressed approx. 100 mm, so be
extremely careful when loosening the bolts.
* Check that there is no compressed air inside

the air cylinder.
1) Loosen 6 bolts (12), then remove air cylinder
(9), piston and rod complete (3), and spring
(13) from cover assembly (14).
* When removing bolts (12), it is safer if 2 -
3 fully threaded bolts @ with a length be-
low the head of approx. 150 mm are used
as a loosening jig. F56103572
2) Remove packing (15) from piston and rod
complete (3).
5. Cover assembly
1) Remove stop ring (16) with flat-headed screw-
driver, then remove cup support (17), second-
ary cup (18), spacer (19), secondary cup, and
cup supporter in order.
2) Use a spatula to push bushing (20) in, then
pull out and remove.
3) Remove ring (22), then remove filter (21).
4) Remove plug (23).
19 14 17 16 18
/ 71’
23 20 22 21
F56953014
HD325-6 30-l 95
0
ASSEMBLY OF FRONT BRAKE CHAMBER ASSEMBLY
15 9 17 18 13 14 23 1‘ 5 6 11 2
F569S3013
Precautions when assembling

1) Coat the outside diameter of air piston rod
(4), the cup groove, cup (14) and air cylinder
(9), and the inside diameter (sliding part) with
a suitable amount of lithium grease.
2) Coat the outside diameter of oil piston (7), the
cup groove, cup (IO), the inside diameter of
oil cylinder (2), and the inside diameter (cup 16
groove) of cover (14), and 2 cups (18) with a
suitable amount of brake oil.
F56103573
Cover assembly
1) Install plug (23).
& Plug: Adhesive (LT-2A)
B Plug: 19.6 + 2.0 Nm I2.0 * 0.2 kgml
2) Install filter (21) and ring (22).
3) Assemble bushing (20), secondary cup (18),
spacer (191, secondary cup, cup supporter
(17), stop ring (16) in order.
2j ill 2i 21
F569S3014
30-196 HD3256
0
2. Air cylinder assembly

1) Assemble packing (15) to piston and rod com-
plete (3).
2) Assemble spring (131, piston and rod com-
plete assembly 131, O-ring, and air cylinder (9)
to cover assembly (141, then tighten bolts (12).
* Using 2 - 3 fully threaded bolts @ with a
length belowthe head of approx. 150 mm,
compress spring (13) uniformly and screw
in.
F56103572
m Mounting bolt:
65.7 & 7.4 Nm I6.7 + 0.75 kgm}
3. Oil piston assembly

I) Supply compressed air at 0.1 - 0.2 MPa (I- 2
kg/cm*} to air cylinder, and extend rod (4) of
piston and rod complate (3) fully.
2) Assemble backup ring (11) and seal (IO) to
oil-piston (7).
F56103i71
3) After moving ring (5) towards air chamber

end, secure bushing guide (8) and oil piston
(7) to oil piston with mounting pin (61, then
install ring (5) to ring groove.
4) Exhaust compressed air from air cylinder.
F56103570
4. Oil cylinder
Install oil cylinder (2) with bolts (1).
m Mounting bolt:
37.8 + 3.4 Nm 13.85 f 0.35 kgm}
5. Checking
I) Bleed air from oil cylinder.
2) Check that at least 17.6 MPa (180 kg/cm*} of
oil pressure is generated in the oil cylinder
when 0.8 MPa {8 kg/cm*} of air pressure is
applied to air cylinder.
3) Check that there is no leakage of air or oil. F56103569
HD325-6
DISASSEMBLY OF REAR BRAKE CHAMBER ASSEMBLY
CDH00739
p Before starting the disassembly operation, make

counter marks on all the welds to act as a guide
when installing.
1. Accessory
Remove breather (1).
CEH00740
2. Cylinder
Loosen locknut (2) and remove cylinder (3).
* There is an O-ring at the cylinder thread, so
remove it.
CEH00741
30-198 HD325-6
0
3. Piston assembly
I) Move retainer (4) to right and pull out pin (5),
then remove piston assembly (6).
* Pull out the pin using a guide pin (2.5 x
50mm).
CEH00742
‘I I 1 I/ CDH00743
4. Disassembly of piston assembly

1) Remove snap ring (71, then remove seat (8),
spring (91, and valve (IO).
* Spring (9) is small, so be careful not to
lose it.
2) Remove packing (12) from piston (11).
CLH00598
5. Body
Hold down body (13) with your hand and remove
mounting bolts, then remove body.
g The body is under a spring force of 25kg, so

be extremely careful when removing it.
+ Remove O-ring from the mating surface of

the body and air cylinder.
CEH00745
HD325-6 30-199
0
6. Disassembly of body
1) Remove snap ring (14), then remove ring (151,
packing (161, seat (17), and packing (18).
13 CEH0074E CDH00764
2) Remove snap ring (191, then remove ring (20)

and seal (21).
CEH00747
7. Air piston
1) Remove spring (23) and piston assembly (24)
from air cylinder (22).
CEH0074P
2) Remove nut, then remove piston (25) and rod

(26).
3) Remove packing (27) and ring (28) from pis-
ton.
CEH00749
30-200 HD325-6
0
4) Remove O-ring (29) and washer (30) from rod.
CEH00750
HD325-6 30-201
0
ASSEMBLY OF REAR BRAKE

CHAMBER ASSEMBLY
1. Assembly of piston assembly
1) Install washer (30) and O-ring (29) to rod (26).
* When assembling the O-ring, wrap the
thread portion with tape to protect the O-
ring.
6 O-ring : Engine oil
CEH00751
2) Assemble packing (27) and ring (28) to piston

(25).
& Packing : Grease (G2-LI)
CEH00752
3) Insert rod (26) in mounting portion of piston I

(251, and secure with nut.
* After securing the nut, check that there is
no clearance between the rod stepped
portion and the piston.
& Piston mounting hole : Grease (G2-LI)
m Nut : 137.2 f 19.6 Nm I14.0 ? 2.0 kgm}
CEH0075
2. Assembly of body
I) Assemble seal (21) and ring (20) to body (13),
and secure with snap ring (19).
* Assemble so that the seal lip is facing the
outside.
* Check that the snap ring is fitted securely
in the groove.
& Seal : Engine oil
CDH007-54
30-202
0
2) Turn over body, assemble packing (18), seat

(17), and packing (16) and insert ring (15), then
secure with snap ring (14).
+ Assemble so that the seal lip is facing the
outside.
* Check that the snap ring is fitted securely
in the groove.
w Packing : Engine oil
CDH0075!
3. Piston assembly
Insert air cylinder (22) in piston assembly (25).
Coat the inside circumference of the air cylin-
der well with grease.
When inserting the piston, insert it at an angle
of approx. 30”. When it is inserted about l/3,
set the air cylinder on its side and push in fully.
Check that the piston assembly moves
smoothly.
CEH00756
4. Body assembly
Insert spring (23) in mounting portion of air cyl-
inder, assemble O-ring (31) to body assem-
bly (13), then install to air cylinder.
* Push the body by hand and tighten the mount-
ing bolts on opposite sides in turn to install.
m Mounting bolt :
43.12 f 5.88 Nm 14.4 + 0.6 kgm}
I CEH00757
5. Assembly of piston
1) insertvalve (IO), spring (91, and seat (8) in pis-
ton (1 I), and secure with snap ring (7).
* Be careful to insert the spring facing in
the correct direction.
Ir Check that the snap ring is fitted securely
in the groove.
I CEH0075f
HD325-6
2) Install packing (12) to piston.

* Assemble so that the packing lip is facing
the outside.
& Packing : Grease (G2-LI)
CEH00759
6. Piston assembly
Blow air into air cylinder to push out rod, then set
to mount of piston assembly (6) and connect with
pin (5).
CEH00760
7. Cylinder
Assemble nut (2) and O-ring ‘(32) to cylinder (3), then
screw in mounting portion and secure with nut.
* Tighten the cylinder fully, then turn the cylin-
der back so that the breather and bleeder are
in a straight line.
& Inside circumference of cylinder :
Engine oil
CEH00761
8. Accessory
Install breather (I).
CEH00762
30-204 HD325-6
0
DISASSEMBLY AND ASSEMBLY SLACK ADJUSTER
REMOVAL OF SLACK
ADJUSTER ASSEMBLY
A Stop the machine

under the wheels.
on level ground and put blocks
A Raise the dump body and lockwith the safety pin.
AOpen the drain valve of the rear air tank to re-

lease the air inside the tank.
l Remove cover.
I- 2. -I’ 566FO6661
2. Remove tube (2).
3. Remove slack adjuster (3).
INSTALLATION OF SLACK
ADJUSTER ASSEMBLY
moval.
* Bleed the air from the brake circuit.
Bleeding air from brake circuit.
HD325-6 30-205
0
DISASSEMBLY AND ASSEMBLY SLACK ADJUSTER
DISASSEMBLY OF SLACK
ADJUSTER ASSEMBLY
1. Remove cylinders (I), then remove pistons (3) and
springs (2).
2. Remove seals (4) from pistons (3).
3. Remove cap (51, then remove spring (6) and valve

(7).
ASSEMBLY OF SLACK
ADJUSTER ASSEMBLY
* Clean all parts and check for dirt or damage. Coat
sliding surfaces of all parts with engine oil, and
coat surface of spring with grease (G2-LI) before
installing.
1. Fit O-ring, then install valve (7).
2. Install spring (6). 566FO6662
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.
30-206 HD325-6
0
TRANSMISSION LUBRICATION,
DISASSEMBLY AND ASSEMBLY RETARDER BRAKE PUMP
REMOVAL OF TRANSMISSION
LUBRICATION, RETARDER
BRAKE PUMP ASSEMBLY
HD325-6, HD405-6
A Raise the dump body and lockwith the safety pin.
1. Drain transmission oil.

:
w Transmission oil: 90 e
2. Remove protection cover (I).
3. Remove piping tube (2).
4. Remove piping tube (3).
5. Remove transmission lubrication and retarder

brake pump assembly (4).
INSTALLATION OF
RETARtDER BRAKE PUMP
ASSEMBLY
HD325-6, HD405-6

moval.
HD325-6 30-207
0
DISASSEMBLY AND ASSEMBLY RETARDER BRAKE PUMP
LUBRICATION, RETARDER
BRAKE PUMP ASSEMBLY
HD325-6W
g Raise the dump body and lock with the safety pin.

: oil: Approx. 90 e
u Transmission
2. Using transmission jack 0, remove undercover

UJ
(I). 566FO6720
3. Remove fire prevention cover (2).
4. Remove piping tube (3) and (4).

INSTALLATION OF
RETARDER BRAKE PUMP
ASSEMBLY
HD325-6W

moval.
. Refilling with oil (transmission case)

Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then check the oil level again.
30-208 HD325-6
0
DISASSEMBLY AND ASSEMBLY BRAKE COOLING PUMP
REMOVAL BRAKE COOLING

PUMP ASSEMBLY
HD325-6, HD405-6

: Transmission oil: 90 !?
w
2. Remove protection cover (I ).

I
566F&m
4. Remove top piping tube (3).
5. Disconnect bottom piping tube (4).

&I kg Brake cooling pump assembly: 25 kg
INSTALLATION OF BRAKE
COOLING PUMP ASSEMBLY
HD325-6, HD405-6
moval.

* Add oil to the specified level and check the oil
level again.
Q Transmission oil: 90 4
HD325-6 30-208-l
0
DISASSEMBLY AND ASSEMBLY BRAKE COOLING PUMP
REMOVAL BRAKE COOLING

PUMP ASSEMBLY
HD325-6W

:
w Transmission oil: Approx. 90 e
2. Remove fire prevention covers (I).
3. Disconnect 2 clamps of hose (2).

* Disconnect the sensor wiring clamped to the
hose.
5. Remove top piping tube (4).
6. Disconnect bottom piping tube (5).

& kg Brake cooling pump assembly: 25 kg
INSTALLATION OF BRAKE
COOLING PUMP ASSEMBLY
HD325-6W

moval.
. Refilling with oil (transmission case)

30-208-2 HD325-6
0
DISASSEMBLY AND ASSEMBLY HOIST, STEERING PUMP
REMOVAL OF HOIST, STEERING HD325-6

PUMP ASSEMBLY
A Raise. the dump body and lock with the safety pin.
1. Remove protection cover (1).
2. Disconnect sensor connector (2).
3. Disconnect hoses (3) and (4) from tube, then re-

move..
4. Remove hoses (5). / 566kO6663
5. Remove tubes (6) and (7). HD325-6W
6. Remove hoist and steering pump assembly (8).
& kg Hoist, steering pump assembly: 25 kg
INSTALLATION OF HOIST,
STEER!NG PUMP ASSEMBLY
HD325-6
4 ,3
moval.
HD325-6W
HD325-6 30-209
0
DISASSEMBLY AND ASSEMBLY FRONT DRIVE PUMP

PUMP ASSEMBLY
HD325-6W
a Raise the dump body and lock with the safety pin.

:
_ Front drive tank: 36 e
2. Using transmission jack 0, remove under cover

(I).
3. Remove fire prevention covers (2). 566FO6720
4. Disconnect tie rod as follows.

I) Using lever block 0, pull left and right tire
levers (4) so that tie rod (31 does not open.
2) Remove left and right mounting pins (5) of tie
rod (3). m
3) Move tie rod towards left side, and remove
pump to make space.
5. Disconnect hoses (6) and (71, and remove tube

(8).
6. Disconnect hoses (91, (IO), (II), and (12), then dis-

connect connector (13).
7. Sling front drive pump assembly (14), then re-

move mounting bolts and lower assembly.
el kg Front drive pump: 100 kg
/ 566~06786
566FO6788 566FO6787
30-209-l HD325-6
0
DISASSEMBLY AND ASSEMBLY FRONT DRIVE PUMP
DRIVE PUMP ASSEMBLY
HD325-6W

moval.
* & Bushing stopper bolt (15):

* m Bushing stopper bolt (15):
548.2 f 58.8 Nm I56.0 + 6.0 kgml
I 566FO6789
. Refilling with oil (front drive tank)
Add oil through the oil fillerto the specified level.
. Bleeding air
Bleed the air from the pump.
For details, see Bleeding air from hydraulic cir-
cuit.
HD325-6 30-209-2
0
DISASSEMBLY AND ASSEMBLY EMERGENCY STEERING MOTOR PUMP
REMOVAL OF EMERGENCY STEERING

MOTOR PUMP ASSEMBLY
pin.
g Disconnect the cable from the negative (-1 ter-

1. Remove protection cover (1).
2. Disconnect motor wiring (2).
I/’ ’ 566FO6663 1
4. Remove tube (4).
5. Disconnect emergency steering motor pump as-

sembly (5) together with bracket, then remove.
INSTALLATION OF
EMERGENCY STEERING
MOTOR PUMP ASSEMBLY
moval.
l Refilling with oil (Hydraulic tank)
* Refill oil to the specified level and run the
engine to circulate the oil through the sys-
30-210 HD325-6
0
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
REMOVAL OF TRAVEL MOTOR

ASSEMBLY
HD325-6W
* Before draining the front drive oil, turn the steer-

ing wheel and turn the tire to give a wider work-
ing space at the front.
* If the oil has already been drained from the front
drive, operate the emergency steering to turn the
tires to give a wider working space at the front.
1. Drain from front drive tank.
w : Front drive tank: Approx. 36 t
2. Remove protector (I ).
G566FO6791
4. Remove cover, and disconnect 3 suspension con-

trol air hoses (41, and 8 wiring clamps of 2 wires
(5).
5. Disconnect 2 hoses (61, hold tube, and remove

bolts (7) and (8).
* Using a rope, raise the disconnected hoses,
wiring, and other hoses with the support rod
under the cab.
* The.wiring of connector (9) is removed to-
gether with the motor assembly, so do not
raise it. 566FO6792 566FO6793
6. Disconnect connector (9), and move towards

motor assembly.
7. Fit chain block @to support rod, sling motor as-

sembly (IO), remove mounting bolts, then remove
motor assembly (IO).
&Ikg Motor assembly: 50 kg
566FO6794 566FO6795
HD325-6 30-21 O-l

0
INSTALLATION OF TRAVEL
MOTOR ASSEMBLY
HD325-6W
Carry out installation in the reverse order to re-

moval.
Refilling with oil (front drive tank)

Bleeding air
Bleed the air from the pump.
For details, see BLEEDING AIR FROM HYDRAU-
LIC CIRCUIT.
30-210-2 HD325-6
0
DISASSEMBLY AND ASSEMBLY

OF TRAVEL MOTOR
HD325-6W
REMOVAL OF OIL SEAL
1. Remove snap ring (I).
2. Using a screwdriver, pull seal case (2) up.
3. Remove oil seal (4) from seal case.

* After removing the oil seal, check the follow-
ing items. If any damage or scratches are
DZH00012
found with any part, replace that part.
i) Seal case: Check O-ring groove (g)
ii) Housing: Check O-ring contact surface (c)
iii) Shaft: Check oil seal sliding surface (S)
INSTALLATION OF OIL SEAL
1. Using press-fitting tool, install oil seal (4) to seal

case (2).
& Lip of oil seal: Grease (G2-LI)
2. Install O-ring (3) to seal case (2).

t Replace the O-ring with a new part.
DZH00013
3. Install to seal case assembly to shaft (5).
Sr When installing, wrap the shaft with tape to
prevent damage to the oil seal lip.
4. Install snap ring (I).
DZH00014
HD325-6 30-210-3
0
REMOVAL OF CONTROL BODY

1. Remove mounting bolts, then remove control
body (1).
2. Remove control plate (2)
DZH00016
* After removing the control body, check the fol-

lowing items. If any damage or scratches are
found with any part, replace that part.
i) Control plate and cylinder block:
Check sliding surface (Sl)
ii) Control plate and control body:
Check sliding surface (S2)
‘hrnh DZH00017
INSTALLATION OF CONTROL BODY

1. Set rotary shaft facing down, then install control
plate (2).
AJ& Sliding surface of control plate and

control body: Grease (G2-LI)
2. Install gasket (3).

Jr Remove all oil and grease from the gasket
contact surface.
Ir Replace the gasket with a new part.
3. Install control body (I).
m Mounting bolt:
110.5+ 12.5 Nm 111.25f 1.25 kgm)
n7Hnnni9
30-2 1 O-4 HD325-6

0
REMOVAL OF REGULATOR COVER

SUB-ASSEMBLY
1. Remove mounting bolts, then remove regulator
cover (I 1.
-+ After removing the regulator cover, check the
O-ring groove and replace the regulator cover
if it is scratched.
DZH00020
INSTALLATION OF REGULATOR COVER

SUB-ASSEMBLY
1. Install O-ring (2) to regulator cover (I 1.
* Replace the O-ring with a new part.
2. Install regulator cover (I).
m Mounting bolt: 62 + 7 Nm I6.3 f 0.7 kgm}
REMOVAL OF CONTROL SUB-ASSEMBLY

1. Remove mounting bolts, then remove magnet
sub-assembly (2).
2. Remove mounting bolts, then remove case sub-

assembly (I).
DO not
disasse
INSTALLATION OF CONTROL SUB-ASSEMBLY

1. Install case sub-assembly (I).
m Mounting bolt:
13.5 f 1.5 Nm II.35 + 0.15 kgm}
m Plug (3): 33.5 + 4.5 Nm 13.45 + 0.45 kgm}
2. Install magnet sub-assembly (2).
w Mounting bolt:
3.9 + 0.5 Nm IO.4 k 0.05 kgm)
DVH00164
HD325-6 30-2 1 O-5

0
DISASSEMBLY AND ASSEMBLY STEERING VALVE
REMOVAL OF STEERING VALVE ASSEMBLY

A Loosen the oil filler cap slowly to release
pressure inside the hydraulic tank.
the
-k Pass a rope through the yoke and secure the

yoke to the top to prevent the yoke from falling
out from the column shaft spline.
1. Remove yoke lock bolt (1).

The lock bolt has a fine thread, so be careful
not to lose it or to use force and damage the
thread.
Check that the yoke moves up and down
easily on the spline of the steering valve in-
put shaft, and that it comes off easily.
If the steering valve input shaft is hit
strongly, it may be deformed and cause
problems.
2. Disconnect 5 hoses (2).
3. Remove steering valve assembly (3).

* Lower it with a rope and be careful not to
drop it.
F56103485
INSTALLATION OF STEERING
VALVE ASSEMBLY
moval.
l Refilling with oil (hydraulic tank)

Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
again.
HD325-6 30-211
0
DISASSEMBLY OF STEERING
VALVE ASSEMBLY
Ir Maintaining clean working conditions
1. When carrying out maintenance of the power
steering system, cleanliness is absolutely essen-
tial. The hydraulic circuit must be completely iso-
lated from any dirt or dust.
2. If it is necessary to disassemble any part of the
unit, always use a clean work stand.
3. Before disconnecting any piping, always wipe off
all the dirt on the outside.
4. Before setting the unit on the work stand, always
wipe off any dirt on the outside.
5. After disassembly, clean with a petroleum base
solvent that is free from any impurity, then blow
with dry air that is free from any impurity.
t If any other solvent is used, it may cause de-
terioration of the rubber seal. Do not wipe any
part with a cloth or apply steam to the unit.
Ir The solvent is a flammable substance, so be
careful to handle it correctly and do not bring
any flame close to it.
Preparatory work
1) Fit blind plugs to 5 ports of the valve body,
clean the outer parts, then remove the blind
plugs.
2) Install tube nut @ to one of the ports.
3) Install in vice @ with the end cover facing up.
* Do not hold the valve body directly in the
vice. This may cause damage to the unit.
1. Remove 7 mounting bolts (I), then insert screw-

driver between end cover assembly (2) and sleeve
(3), and remove end cover assembly (2).
* After removing, check for any breakage
around the edge of the end cover hole.
30-2 12 HD325-6
0
2. Remove commutator (5) and washer (6).

+ Do not remove pin (4).
5
F5610346E I F56103489
3. Using 2 mounting bolts (I 1, remove commutator

ring (7) and manifold (8).
4. Using 2 mounting bolts (I), remove rotor set (9)
and wear plate (IO) in the same way as commu-
tator ring and manifold.
569FO68
5. Insert screwdriver between sleeve (3) and valve

body (I I), and remove sleeve (3).
6. Remove drive link (12).
7. Remove ball (13).

8. Remove rod (141, roller (15), rod (16), and spring
(17).
F5_6!03493
HD325-6 30-213
0
9. Install in vice so that input shaft (18) faces up,

then make match marks with a punch in upper
cover (19) and valve body (II).
IO. Remove 4 mounting bolts (20), hold input shaft

(18) and move it up, then remove input shaft,
upper cover, and valve spool assembly (23).
t The valve spool is fitted into the body with an
extreme small clearance, so be careful not to
apply any sideways force as it will become
impossible to remove it. When removing the
valve spool from the housing, never use any
excessive force.
11. Remove upper cover assembly (22) from input

shaft and valve spool assembly (23), then remove
shim (24) and spacer (25).
* Check the number and thickness of the shims,
,
G9@ I F56103496
569FO69
12. Remove seal (26) and snap ring (271, then remove
spacer (281, seal (29), and seal ring (30) from up-
per cover (19).
I F56103497
19 569FO70
* Seal (29) and seal ring (30) may form one unit.
3 18
13. Remove snap ring (31), thrust washer (321, thrust
bearing (33), thrust washer (34), and wave washer
31
(35) from input shaft (18). 32
35 34
'32
F56103498
31 F56103499
30-214 HD325-6
0
14. Using pin @ (o 3.0 mm, length min. 16 mm), re-

move needle roller (36) from input shaft (18). ! n
* To prevent damaging the input shaft, carry out
the operation on a wooden block.
3/8 569FO76
15. Set valve spool (37) facing down, then remove

torsion bar (38) and spacer (39) from input shaft
and valve spool assembly (23).
* Do not remove needle roller (40) from the tor-
sion bar.
F56103501
i
-
16. Set valve spool (37) facing down, then rotate in-
put shaft (18) until drive ring (41) comes out.
17. Set valve spool (37) facing down, then rotate in-
put shaft (18) clockwise until ball (42) comes out.
* Ball (42) may come out, so be careful not to
lose it.
* Do not remove ball retaining spring (43) un-

less replacing it. When removing it, make the
end horizontal, grip it with pliers, then pull it
up until it comes completely away from valve
spool (37). Be careful not to damage the con-
trol edge or outside circumference ofthe valve
spool.
F56103503
J
HD325-6 30-215
0
ASSEMBLY OF STEERING
VALVE ASSEMBLY
Ir Before assembling, wash all parts in clean petro-
r
leum base solvent, then dry with air. Never wipe
with a cloth.
* Check careful that there are no pieces of paint re-
maining on the edge of the lapped surface.
* Unless there are special instructions, do not coat
any part with oil when assembling. 32
1. Set thrust washer (34), thrust bearing (33), and

thrust washer (32) to input shaft (18) in order, and F56103504 F56103505
install snap ring (31).
-Lr Thrustwasher (32) is larger than thrust washer
(34).
2. Install wave washer (35) to thrust bearing (33) and
thrust washer (34).
3. Install ball (42) on inside of valve spool (37).
B
37
@
42
.:56103507
4. Rotate counterclockwise so that ball and groove

of input shaft (18) are meshed, and insert input
shaft (18) in valve spool (37).
-k Keep the spool horizontal when carrying out
the operation.
F56103508
5. Fit middle of torsion bar (38) between thrust

washer (34) and valve spool (37).
* The positioning of the valve spool and input
shaft is carried out by fitting the torsion bar.
569FO73
30-216 HD325-6
0
6. Check spline of drive ring (41) and input shaft

(18), then align spline of valve spool (37), and
install drive ring (41).
sr If the drive-ring and input shaft spline do
not mesh, rotate the input shaft slightly to
mesh them and install drive ring.
* Fit the torsion bar securely.
* Turn the input shaft until it will not turn in
the direction out from the spool (clockwise
direction). When doing this, if the drive ring
is assembled correctly, a clearance of 8 - 9
mm will be obtained between the thrust I F56103510
washer and valve spool.
* If the drive ring is not assembled correctly,
the steering valve will not work properly.
569FO74
7. Measure diameter e of needle roller (40) of tor-

sion bar (38) at several places, and check that 38
the difference is less than 0.025 mm. Q
8. Set spacer (39) to torsion bar (38), and insert
I 23
valve spool and input shaft assembly (23).
a II
40
40
569FO75 F56103511
9. Using pin @ (outside diameter: 3 mm), align pin

holes of torsion bar (38) and input shaft (18).
10. Using pin 0, knock in needle roller (36) 0.8 mm
from end face of input shaft.
* Check that needle roller (36) is not protrud-
ing from the input shaft.
569FO76
HD325-6 30-217
0
11. Install spacer (25) on input shaft and valve spool.

Sr There is a lip at one end on the inside of the
spacer. Install with the lip surface facing
wave washer.
12. Install input shaft and valve spool assembly (23)

to valve body (1 I).
* The clearance is extremely small, so if any
sideways force is applied when assembling,
it will not work properly.
13. Set shim (24) on thrust washer (321, coat new F56103513
seal (B) with grease, fix it in groove of upper
cover (19), align match mark of upper cover
(191, then install, and tighten mounting bolts
(20) tempo-rarily.
* When installing, be careful that seal (B)
does not come out of the groove.
14. Set tool Tl in position, and install so that valve

body and upper cover are centered.
15. Tighten mounting bolts (20), and remove tool

Tl.
-Mounting bolt:
27.0 k 2.5 Nm I2.75 If: 0.25 kgm}
16. Measure width .Qof groove of drive link (12) at L. CJ CWH01044

several places along whole length, and check
that difference is less than 0.025 mm
T
569FO77
17. Pull input shaft (18) down and hold it so that it

cannot rotate, then mesh drive link (12) with
valve spool spline, and install. Rotate spool so
that valve body is level with end face of spool. F56103517
30-218 HD325-6
0
18. Align drive link (12) and pin (401, and install.
19. Using depth gauge @, measure mountina

height “h” of end face of valve spool and valve
body.
DWHD0129
* Mounting height h = Within 0.063 mm (im-

proper shim adjustment)
If mounting height h = 0.064 mm or more,
repeat items 12 - 20 and adjust the shims to
make h = within 0.063 mm.
20. Install ball (13).
21. Set rod (17) to spring (161, and fit to valve body
(I I), then install roller (15) and rod (14). F56103518
22. Fit seal to valve body.
569FO80
23. Before installing rotor, inspect rotor as follows.

I) Set pin side of end cover assembly (2) fac-
ing up, and spline side of rotor of rotor set
(9) facing down, and check that the rotor ro-
tates freely inside the stator.
F56103519
HD325-6 30-2 19
0
2) Measure thickness of rotor and stator, and

checkthat the difference is less than 0.18 mm.
3) Using feeler gauge 0, check that clearance
of rotor from stator is less than 0.18 mm.
- DWH00130
24. Using guide pin 8, install wear plate (IO), rotor

assembly (9), and manifold (8).
25. Fit seal to end cover assembly (2).
26. Set sleeve (3) and end cover assembly (2) in posi-
tion, tighten mounting bolts (I) uniformly, install
sleeve, then remove end cover assembly.
569FO82
27. Fit washer (6) to end cover assembly (2), then in-
stall commutator (5).
* Install the commutator so that the concave
portion is facing the end cover assembly.
Concavity of
commutator
I F56103522
I
DWH00131 I Set in a straight line
* Align the position so that the hole on the oval

part of the commutator forms a straight line
with one of the holes in the end cover assem-
bly.
tlWH00132
30-220 HD325-6
0
DISASSEMBLY AND ASSEMBLY DEMAND VALVE
REMOVAL OF DEMAND VALVE

ASSEMBLY
pin.
g Loosen the oil filler cap slowly to release the

1. Remove hose (I), then remove check valve (2).
2. Remove hoses (3) and (4).
3. Remove tubes (5), (6) and (7). I
566FO6668
4. Remove demand valve assembly (8).
&I kg Demand valve assembly: 25 kg
INSTALLATION OF DEMAND
VALVE ASSEMBLY
moval.
l Refilling with oil (Hydraulic tank)
Sr Refill oil to the specified level and run the en-
gine to circulate the oil through the system.
la Hydraulic tank: 129 e
l Bleed the air

Bleeding air from hydraulic cylinder (for steering).
30-222 HD325-6
0
DISASSEMBLY AND ASSEMBLY DEMAND VALVE
DISASSEMBLY OF DEMAND
VALVE ASSEMBLY
1. Remove cover (2) from demand valve assembly,
then remove sprig (3).
Sr Spring is under load of 147.1 N I15 kg), so
remove gradually with long bolts.
2. Remove plate (4), screw in bolt (Dia. = 8 mm, Pitch

= 1.25) to seat (5), and pull out seat, then remove
spring (6) and poppet (7).
3. Remove plug (8), then pull out demand spool (9).

T5695152
4. Remove plate (IO), screw in bolt (Dia. = 8 mm,

Pitch = 1.25), to orifice (1 I), then remove orifice.
5. Remove relief valve assembly (12).
ASSEMBLY OF DEMAND VALVE

ASSEMBLY
1. Fit O-ring install relief valve assembly (12).
QEG Relief valve assembly:
83.4 + 14.7 Nm j8.5 + 1.5 kgm)
2. Fit O-ring and back-up ring, assemble orifice (1 I),

then install plate (IO).
4 569F093A-K
3. Assemble demand spool (9), fit O-ring, then in-

stall plug (8).
4. Fit O-ring and back-up ring on seat (5), and as-

semble popper (7), spring (6) and seat (5), then
install plate (4).
5. Assemble plate and spring (3), then install cover

(2) on demand valve assembly.
HD325-6 30-223
0
DISASSEMBLY AND ASSEMBLY RELIEF VALVE
DISASSEMBLY OF RELIEF
VALVE ASSEMBLY
1. Remove cover (I), and loosen nut, then remove
screw (2).
2. Loosen nut (3), the remove holder (4).
3. Remove retainer (6), spring (7) and popper (8)

from sleeve (5).
4. Remove plug (9), and remove valve (IO) and

spring (1 I), then remove seat (12) by pushing out.
ASSEMBLY OF RELIEF VALVE 569 F094
ASSEMBLY
1. Fit O-ring and back-up ring, install seat (12).
2. Assemble spring (11) and valve (IO), then install

plug (9).
3. Assemble poppet (8), spring (7) and retainer (6)

in sleeve (5).
4. Fit O-ring, and install holder (4), the tighten nut

(3).
m Holder: 39.2 i. 9.8 Nm (4 k 1 kgm}
Nut: 73.6 * 4.9 Nm I7.5 f 0.5 kgm1
5. Install screw (2), tighten nut, and fit O-ring, then

install cover (1).
m Cover: 34.3 + 4.9 Nm I3.5 f 0.5 kgm}
30-224 HD325-6
0
DISASSEMBLY AND ASSEMBLY HOIST VALVE
REMOVAL OF HOIST VALVE

ASSEMBLY
a Raise the dump body and lock with the safety
pin.
A Loosen the oil filler cap slowly to release the

1. Drain hydraulic tank oil.
2. Disconnect hoist cable (I).
3. Disconnect positioner cable (2).
4. Remove bracket (3) and spring (4).
5. Remove tubes (5), (6), and (7).
6. Remove hoist valve assembly (8).
&I kg Hoist valve assembly: 40 kg
INSTALLATION OF HOIST
VALVE ASSEMBLY
moval.

+ Refill oil to the specified level and run the en-
gine to circulate the oil thorough the system.
HD325-6 30-225
0
DISASSEMBLY OF HOIST
VALVE ASSEMBLY
1. Remove lever (1).
2. Remove main relief valve (3) from body (2):
3. Check valve
Remove plug (4), spring (5), and check valve (6)
from body (2).
4. Remove rotary seal assembly (7).
5. Rotary seal assembly 566FO667’
1) Remove cover (8), then loosen bolt (9), move

lever (IO), and remove key (11).
2) Remove plate (12), then remove dust seal (13),
oil seal (14), shaft (15), and bearing (16).
6. Spool assembly
1) Remove case (17).
2) Remove plug (18), spring (19), spacer (20), and
ball (21) from case (17).
3) Remove plug (22) from case.
4) Remove bolt (23), then remove detent (24),
collar (25), retainer (26), spring (27), retainer
(28), and joint (29).
5) Remove case (30). i
7 566FO6672
6) Remove joint (32) from spool assembly (31).
* Disconnect the joint with the spool still in-
stalled inside the valve body.
7) Remove spool (33) from body (2).
7. Remove plugs (34), (35), (36), and (37) from body.
36
566FO6673
30-226 HD325-6
0
ASSEMBLY OF HOIST VALVE

ASSEMBLY
l Clean all parts, correct all burrs, and check for dirt
or damage.
l Coat the sliding surfaces of all parts with engine
oil before installing.
1. Install plugs (37), (36), (35), and (34) to body.

B Plug (36): 137.3 f 9.8 Nm {I4 k 1 kgm)
m Plug (34): 68.6 * 9.8 Nm {7 k 1 kgm}
Spool assembly
1) Assemble spool (33) in body (2).
2) Install joint (32) to spool (33).
* Install the joint with the spool installed
inside the valve body.
m Joint: 66.2 + 7.4 Nm 16.75 k 0.75 kgm)
3) Install case (30) to body.
4) Assemble joint (29), retainer (28), spring (27),
retainer (26), collar (25), and detent (24), then
install bolt (23).
5) Install plug (22) to case (17).
m Plug: 11.3 + 1.5 Nm Il.15 f 0.15 kgm)
6) Assemble ball (21), spacer (20), and spring (19)
to case (17), and install plug (18).
w Plug: 49.0 f 9.8 Nm I5 rtr1 kgm}
7) Install case (17).
3. Rotary seal assembly

1) Press fit bearing (16), oil seal (14), and dust
seal (13) to rotary case.
& Bearing, oil seal, dust seal:
Grease (G2-LI)
2) Assemble key (11) and lever (IO) while insert-

ing shaft (15).
3) Align notch position of lever (IO) and spool
(30), and secure with bolt (9).
4) Secure rotary seal assembly (7) to body (2)
with bolt.
5) Install plate (12) and cover (8).
4. Check valve
Assemble check valve (6) and spring (5) to body
(21, then install plug (4).
B Plug: 367.8 If: 24.5 Nm 137.5 + 2.5 kgm)
& Plug: Thread tightener (LT-2)
5. Install main relief valve assembly (3).

w Main relief valve assembly:
30.9 rf:3.4 Nm I3.15 f 0.35 kgm}
6. Install lever (I).
HD325-6 30-227
0
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
REMOVAL OF STEERING
CYLINDER ASSEMBLY
1. Remove grease tube (I).
2. Remove bottom pin (2). m
-k Support with a transmission jack.
* Start the engine, operate the steering to the
left, and retract the piston rod, then discon-
nect the cylinder bottom from the frame.
3. Disconnect head hose (3).
4. Disconnect bottom hose (4).
5. Remove grease tube (5).
6. Remove head pin (6). m
7. Remove steering cylinder assembly (7).
L+lkg Steering cylinder assembly: 45 kg
INSTALLATION OF STEERING
CYLINDER ASSEMBLY
moval.
a
Ir When connecting the pin, assemble the rub-
ber boot (8).
F56103587
& Bushing stopper bolt (16):

QZI Bushing stopper bolt (16):
549.2 f 58.8 Nm I56.0 i: 6.0 kgm}
l Refilling with oil (hydraulic tank)

Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
again.
F56103588A-K
I 566FO6779
30-228
0
DISASSEMBLY OF STEERING
CYLINDER ASSEMBLY
1. Set cylinder assembly (I) in tool Ul.
2. Raise lock of cylinder head nut, and using tool

U2, remove cylinder head assembly (2).
3. Pull out cylinder head and piston rod assembly

(3) from cylinder (4) and remove.
* When the piston rod assembly is pulled out
from the cylinder, oil will come out, so catch
it in a container.
4. Remove cylinder (4) from tool Ul.
F56103590K
5. Disassembly of piston rod assembly

1) Set piston rod assembly (3) in tool Ul.
2) Using tool U4, remove nut (5).
3) Remove piston assembly (6) and cylinder

head assembly (7) from rod (8).
-
! F56103592
HD325-6 30-229
0
6. Disassembly of piston assembly

1) Remove wear ring (9) from piston (IO).
2) Remove wear ring (I 1) from Piston (IO).
‘“*’ 569FO5260
7. Disassembly of cylinder head assembly I 1

1) Remove snap ring (12), then remove dust seal
(13).
2) Remove rod packing (14).
3) Remove busing (15) from cylinder head (16).
4) Remove O-ring (17) and backup ring (18).
16 18 569FO5261
30-230 HD325-6
0
ASSEMBLY OF STEERING
CYLINDER ASSEMBLY
1
before installing. -14
1. Assembly of cylinder head assembly

1) Using push tool, press fit bushing (15) in cyl-
inder head (16).
2) Install rod packing (14).
* Be careful to install the rod packing fac-
ing in the correct direction. I 16 1’8 569FO5261
3) Assemble backup ring (18) and O-ring (17) in

order.
* Do not try to force the backup ring into
position.
Warm it in warm water (50 - 60°C) before
fitting it.
4) Using tool U9 install dust seal (13) to cylinder
head (161, then install snap ring (12).
2. Assembly of piston assembly

1) Using tool UIO, expand piston ring (I I).
* Set the piston ring on the expand the ring.
2) Remove piston ring from tool UIO , and as-
semble to piston (IO).
CWHO1048 569FO5262
3) Using toll U12, compress piston ring.

4) Assemble wear ring (9).
CWH01049 CWH01050
11
10 9
JFL
569FO5260
HD325-6 30-23 1
0
3. Assemblv of piston rod assembly 1

1) Assemble cylinder head assembly (7) and pis-
ton assembly (6) to piston rod (8).
-
F56103592
2) Using tool U4, tighten nuts (5).

& Nut: Thread tightener (LT-2)
m 1.078.7 f 107.9 Nm {llO+ 11.0 kgm}
3) Remove piston rod assembly (3) from tool Ul.
4. Set cylinder (4) in toll Ul.
5. Assemble cylinder head and piston rod assem-

bly (3) in cylinder (4).
I- F56103590K
6. Using tool U2, tighten cylinder head assembly (2).

m Cylinder head nut:
568.8 + 56.9 Nm I58 k 5.8 kgm1
30-232 HD325-6
0
DISASSEMBLY AND ASSEMBLY HOIST CYLINDER
REMOVAL OF HOIST CYLINDER

ASSEMBLY
100 mm) between the frame
&h Frt. a block (approx.
and the body.
g After stopping engine, operate dump body con-

trol lever 2 - 3 times to release remaining pres-
sure.
a Loosen oil filler cap slowly to release pressure

inside hydraulic tank.
1. Remove positioner cable and bracket (I). m

\ ’
* The positioner is on the left side only.
I 566FO6674
2. Remove bottom mounting pin (2). m

* Fit a nylon rope around the hoist cylinder as-
sembly, then sling using a forklifttruck (5ton).
* After disconnecting the hoses, fit blind plugs
to prevent the oil from leaking out.
4. Remove holder (5).
5. Remove hoist cylinder assembly (6).
& kg Hoist cylinder assembly: 140 kg
I I / F56103602
INSTALLATION OF HOIST
CYLINDER ASSEMBLY Block

moval.
m
* Adjust the body positioner.
adjusting body positioner.
DEH00133
M
a When aligning the position of the pin hole,
run the engine at low idling. Never insert
your fingers in the pin hole-
* Refilling with oil

* Refill with engine oil (EOIO-CD) to the speci-
fied level, startthe engine, and raise and lower
the body 2-3 times to circulate the oil through
the system. Then check the oil level again.
HD325-6 30-233
0
DISASSEMBLY OF HOIST
CYLINDER ASSEMBLY
. Be careful not to damage the rod packing, dust
seal, piston ring, and wear ring.
1. Set cylinder assembly to tool Ul.
2. Using tool U2, remove crown (I) from cylinder I

(2).
* After loosening the crown, remove the grease
nipple from the rod head, then pull put the
crown.
- CWHOlOSl
3. Remove cylinder II and rod assembly from cylin-

der I(2).
I - DWH00134
4. Remove piston nut (3), then lift off rod (5) from
cylinder II (4).
569F05264A-K 566FO6677
5. Remove cylinder head assembly (6) from cylin-

der II (4).
6 4 7
6. Remove wear ring (7).
30-234 HD325-6
0
CYLINDER HEAD
DISASSEMBLY AND ASSEMBLY PISTON
DISASSEMBLY OF CYLINDER HEAD

ASSEMBLY
1) Remove O-ring, then remove dust seal (8) and

rod packing (9).
2) Remove bushing (IO).
566FO6679
7. Remove snap ring (I 1) from cylinder II (4), then

remove piston assembly (12).
4
I 569FO5267-1 K
DISASSEMBLY OF PISTON ASSEMBLY
Remove piston ring (13) and wear ring (14) from

piston assembly (12).
13 566FO6680
1
8. Remove snap ring (15) from cylinder II (41, then
remove dustseal (16), rod packing (171, and bush-
ing (18).
1‘5 18
566FO6681
HD325-6 30-235
0
ASSEMBLY OF HOIST
CYLINDER ASSEMBLY
U6
Ir Clean all parts, and check for dirt or damage. Coat
before installing.
1. Using tool U6, press fit bushing (18) to cylinder II

(4).
2. install rod packing (17).

* Check the direction of assembly for the rod
packing when installing.
3. Using tool U8 fit dust seal (16) and install snap

ring (15).
15
566FO6685 566FO6683 r--J CWH01053
ASSEMBLY OF PISTON ASSEMBLY
I) Using tool UIO, expand piston ring (13), and

assemble to piston (12).
* Set the piston ring on tool UIO, and turn
the handle 8 - 10 times to expand the ring.
2) Set tools Ull in position, and compress pis-
ton ring (13).
3) Using tools Ull, install wear ring (14).
L CWH01054 I CWH01055
566FO6680
30-236 HD325-6
0
4. Assemble piston assembly (12) to cylinder ll (4),

and install snap ring (11).
569FO5267-1 K
5. Install wear ring (7) to cylinder II (4).
566FO6687
ASSEMBLY OF CYLINDER HEAD ASSEMBLY
I) Using tool U5, press fit bushing (IO).
, /
CWH01056
2) Assemble rod packing (9) to cylinder head (6).

Ir Check the direction of assembly for the
rod packing when installing.
566FO6689
HD325-6 30-237
0
3) Using tool U7 install dust seal (8).
6. Assemble cylinder head (6) to cylinder II (4).
566FO6678
7. Raise rod (5) and assemble to cylinder II (4).

* Align the stud bolt at the tip of the rod with
the bolt hole in the piston assembly.
kd 566FO6677
8. Tghten mounting nut (3) of piston assembly (12).

& Stud bolt: Thread tightener (Loctite #262)
w Mounting bolt:
274.6 ? 29.4 Nm I28 ?Z3 kgm}
+ Remove all oil and grease from the assembly
portion of the nuts and blots.
569F05264A-K
30-238 HD325-6
0
9. Assemble cylinder II and rod assembly to cylin-

der I(2).
I \ DWH00134
10. Using tool U2 install crown (I) to cylinder I (21,

and fit grease nipple.
w Crown: 4,413.2 1441.3 Nm I450 +_45 kgm}
HD325-6 30-239
0
DISASSEMBLY AND ASSEMBLY BODY
REMOVAL OF BODY ASSEMBLY

a Stop the machine on level ground, and fix the
stone remover bar to the body with a pin.
1. Remove hoist cylinder bottom pin (I).

* Using tool I, sling the body assembly.
* Pull the hoist cylinder with lever block @ to
prevent it from falling when pin (I) is pulled
out.
2. Remove body hinge pin (2).
3. Remove body assembly (3).
kg
rE?J Body assembly: 8,000 kg
* Tie ropes to the left and right sides of the body
assembly, and support the body to prevent it
from turning when it is raised.
F56103612
30-240 HD325-6
0
DISASSEMBLY AND ASSEMBLY BODY
INSTALLATION OF BODY
ASSEMBLY
moval.
a
f Check the number and thickness of the shims,
. Procedure of adjusting shim of body assembly

3
1. Adjusting shim at body mount F56103614A-K
I) insert spacer (5) (height: 40 mm) to tip of body.
2) Inspect clearance between top surface of
frame (6) and rubber pads (I) @, @I, @ at 6
places on left and right.
3) If any clearance is found, add shim (2) to ad-
just clearance.
* Standard shim thickness @, @, 0: 2 mm
4) Remove spacer (5).
‘t F56103615A-K
2. Adjusting shim at front mount

1) Lower body, and measure height of rubber
pad (3).
2) If it is greater than standard height, or any
clearance from body is found, add shim (4) to
adjust to standard height.
* Standard shim thickness: 6 mm
* Standard height H: 51 mm
HD325-6 30-241
0
DISASSEMBLY AND ASSEMBLY FRONT DRIVE CONTROLLER
CONTROLLER ASSEMBLY
4h Always turn the starting switch to the OFF posi-
tion.

3. Remove transmission controller assembly (3).
INSTALLATION OF
TRANSMISSION CONTROLLER 566FO6797
566FO6796
ASSEMBLY
moval.
REMOVAL OF SUSPENSION
CONTROLLER ASSEMBLY
a Always turn the starting switch to the OFF posi-
tion.

2. Remove suspension controller assembly (5).
INSTALLATION OF
ASSEMBLY
. Carry out installation in the reverse order to re

CONTROLLER ASSEMBLY
HD325-6W

2. Remove front drive controller assembly (7).
DRIVE CONTROLLER
ASSEMBLY
HD325-6W
. Carry out installation in the reverse order to re- 566FO6799
moval.
30-242 HD325-6
0
40 MAINTENANCE STANDARD
Outprt shaft.. ................................................. 40- 2

Torque converter valve ................................ 40- 3
Torque converter ......................................... .40- 4
Transmission.. ............................................... 40- 6
ECMV(Electronic Control Modulation Valve). . ..40-IO
Front axle ...................................................... 40-I 1
Differential .................................................... 40-I 2
Final drive (Rear) .......................................... 40-14
Final drive (Front) (HD325-6W) ............... ..40-14- 1
Front brake (HD325-6,405-6) ...................... .40-15
Front brake (HD325-6W). .......................... .40-15-l
Rear brake ..................................................... 40-I 6
Parking brake ............................................... 40-17
Rear axe1 support ......................................... 40-18
Steering linkage ............................................ 40-19
Front suspension cylinder ........................... 40-21
Rear suspension cylinder.. .......................... -40-22
Parking brake chamber ............................... .40-23
Slack adjuster ............................................... 40-24
Hydraulic pump ............................................ 40-25
Demand valve ............................................... 40-28
Cross-over relief valve ................................ .40-28
Hoist valve .................................................... 40-29
Steering cylinder .......................................... 40-30
Hoist cylinder.. .............................................. 40-31
HD325-6 40-l
0
MAINTENANCE STANDARD OUTPUT SHAFT
OUTPUT SHAFT
.75 kgm
566F06050A
Unit: mm
No.lCheck item 1 Criteria Remedy
Standard Tolerance Standard Clearance

Clearance between size Shaft Hole clearance limit
1 flywheel and bearing
80 -00.013 -0a.030 0.013- 0.02
- 0.030
2 Clearance between shaft 40 -0.009 -00.012 0.025- 0.10 Replace

and bearrng -0.025 - 0.003
3 Clearance between bearing 120 -00.015 -0.006 0.009- 0.09

and cover -0.028 - 0.028
4 C$$rhF; between bearing 65 +0.012 -0o.015 0.007- 0.025

-0.007 - 0.027
,
Standard size Repair limit
5 Wear of oil seal contact Repair or
surface of couplrng 94.7 replace
g5 - L87
Standard backlash Backlash limit

6 Backlash at spline
0.099 - 0.202 0.4
Dimension at
e e Repair limit(e)
smallest widt:e
Replace
Original
Deformation of rubber dimension2
7
cushion eo 75 67
ti
561FO3184
External Without cranks
40-2 HD325-6
MAINTENANCE STANDARD TORQUE CONVERTER VALVE
TORQUE CONVERTER VALVE
Unit: mm
No. Check item Criteria Remedy
Standard size Standard clearance Clearance limit

1 Clearance between main
relief valve spool body 0.067
32 0.035 - 0.061
2 Clearance between main 0.056

relief valve spool and piston 22 0.020 - 0.051
Clearancebetween torque con- 32 0.035 - 0.061 0.067

3 verter relief valve spool and body
-
4 Clearance between lock-up 32 0.035 - 0.061 0.067
valve spool and body
Standard size I Repair limit I

Replace
5 Main relief valve spring I
6
7
-
8
18.4N
{I .88kgI
HD325-6 40-3
MAINTENANCE STANDARD TORQUE CONVERTER
Unit: mm
Thickness of seal rin
Width of seal ring
HD325-6
MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
HD325-6
HD325-6W
HD405-6
SVH00514
40-6 HD325-6
0
Unit: mm
Nom Check item Criteria Remedy
Free Installed Installed Free Installed

1 No.1 clutch spring (12~~s) length length lord length lord
62.9N 53.4N
54 45 50.76
(6.41 kg1 (5.449kg)
83.8N 71.2N
2 No.4 clutch spring (12pcs) 54 42 50.76
18.54kgI I7.259kg)
No.5 clutch spring (12~~s) 78.3N 66.5N

3 77 66 72.38
{7.98kg} (6.783kg)
76.9N 65.4N
4 No.6,7 clutch spring (24~~s) 58 48 54.52
17.84kgI I6.664kgI
Overall thickness of three Standard size Tolerance Repair limit

5 discsand two plates for No.1
clutch 25 f0.22 24.2
Overall thickness of four discs

6 and three plates for No.2 clutch 35 f0.26 33.9
-
Overall thickness of three discs
7 and two plates for No.3 clutch 25 +0.22 24.2
Overall thickness of three discs

8 and two plates for No.4 clutch 25 f0.22 24.2
-
Overall thickness of five discs
9 and four plates for No.5 clutch 45 f0.30 43.7
Replace
10 and three plates for No.6 clutch 35 f0.26 33.9

11 and three plates for No.7 clutch 35 +0.26 33.9
-
12 Thickness of disc 5.0 -10.1 4.73
13 Thickness of plate 5.0 fO.l 4.8
Width -0.01
Wear of seal ring 2.56 -0.03 2.26
14 on transmission
input shaft
Thickness 1.7 kO.1 1.55
-
-0.01
Wear of seal ring Width 3.0 - 0.03 2.7
on transmission
15
input shaft
Thickness 3.1 +0.1 2.95
Width -0.01
Wear of seal ring 4.0 -0.03 3.6
16
on No.1 carrier
Thickness 4.6 kO.12 4.45
HD325-6 40-7
- Unit: mm
No
-
18
19
cover f0.15 3.85
-
Backlash between No.1 sun
20 gear and No.1 planetary gear 0.13 - 0.36
Backlash between No.1 plan-

21 0.15 - 0.39
etary gear and No.2 ring gear

-
23 etary gear and No.4 ring gear 0.17 - 0.39

Replace
Backlash between No.5 planetary


27 gear and No.6 planetan/ gear 0.14 - 0.35



Deformation of internal teeth

31 of disc Repair limit:0.3
Thickness of thrust washer Standard size Tolerance Repair limit

32 (No. 1,4,5,6,7 planetan/
gear)
2 * 0.1 1.5
40-8 HD325-6
Unit: mm
Nc Check item Criteria Remedy
Location Standard clearance Clearance limit

I I
No.1 gear train 0.25 - 0.90 I 1.5
3: Side clearance of planetary No.4 gear train 0.25 - 0.90 1.5

gear Replace thrst
washer or
No.5 gear train 0.25 - 0.90 1.5 carrier
No.6 gear train 0.25 - 0.90 1.5
No.7 gear train 0.25 - 0.90 1.5
Standard value I Amount of wear

34 Stepped wear of seal ring
contact surface - Max. 0.5
Replace
Standard value Repair limit
Oil seal contact surface of
35
output shaft
120 119.9
-
Tolerance Standard Clearancie
Clutch No. Standard
size Shaft 1 Hole clearance limit
No.1 -0.5 +0.089 0.5 -

outside 395 -0.7 0 0.789 0.87
-
Inside 375 -0.125 +0.089 0.1250.303 0.33
-0.214 0
No.2.,3 -0.5 +0.081 0.5 -
Outside 275 -0.7 0 0.781 0.86
If there are
250 -0.5 +0.072 0.5 - seizure
-0.7 0 0.772 0.85 stripes or any
other damage
I - I I
No.2.,3 -0.085 -0.063 0.085 - on the

inside 170 -0.148 0 1.211 0.23
surface,corect
Clearance between the damage.
36 No.4 -0.5 +0.089 0.5 -
cylinder and piston outside 375 -0.7 0 0.789 0.87 If the part is
within the
-
Inside 325 -0.125 +0.089 0.1250.303 0.33 clearance
-0.214 0 limit,it can be
No.5 -0.5 +0.089 0.5 - used again.
outside 375 -0.7 0 0.789 0.87
If the damage
- is serious,
Inside 325 -0.125 +0.089 0.1250.303 0.33 replace.
-0.214 0
No.5 -0.5 - 0.089 0.5 -
outside 375 -0.7 0 0.789 0.87
-
Inside 325 -0.125 +0.089 0.1250.303 0.33
-0.214 0
No.7 -0.5 +0.089 0.5 -

outside 375 -0.7 0 0.789 0.87
Inside 325 -0.125 +0.089 0.125 -

-0.214 0 0.303 0.33
HD325-6 40-9
MAINTENANCE STANDARD ECMV
ECMV(Electronic Control Modulation Valve)
561FO3188
Unit: mm
- -r
-
/ Stagrd / Shaz’t 3ral Standard Clearance
Clearance between flow clearance limit
sensor valve and valve
0.064
0.062
0.063
I Replace
I Standard size I Repair limit
Installed Installed Installed
4 Fill switch spring Free length length load Free length load
41.7N
14.8 37.6N
15 (4.25kg)
(Nar?ral) (Nomal) {3.83kg}
-
Flow sensor valve return 4.9N 4.4N
5 33.5 29.5 33.1
spring {0.5kgI 10.45kgI
10.6N 9.5N
Pressure control valve 11.7
6 spring 16.2 (Nomal)
{l.O8kg) 15.8 (0.97kgI
(Nomal)
40-10 HD3256
MAINTENANCE STANDARD FRONT AXEL
FRONT AXLE
HD325-6
HD405-6
thread
926.7+98.1Nm
j. \ I / .?I .(94.5*10kml
When not coat ina thread:
1201.3*122.6Nm
(122.5* 12.5bml
bm 382.5*39.2Nm
, (39*4kPml
SWH00823
Unit: mm
Criteria Remedy
NO Check item
Standard size Tolerance Repair limit

Correct or
1 replace
Wear of oil sliding surface -
220 -:.115

Wear of outside diameter
2 of portion of shaft inserted
into bearing 129.83 Correct
130 :;:;;t
-
Wear of outside diameter 126 -0.012
3 of portion of shaft inserted 119.86
-0.047
into bearing
HD325-6 40-11
0
MAINTENANCE STANDARD DIFFERENTIAL
DIFFERENTIAL
(Standard differntial)
HD325-6
HD325-6W
HD405-6
Unit: mm

, Wear of oil seal contact Repair or
surface of coupling replace
110 -:.0*7 109.9
2 Thickness of side gear Replace

5.0 -00.05 4.5
thrust washer
Backlash of bevel gear and

3 oinion 0.3 - 0.4 Adjust
I-
40-12 l-ID3256
0
MAINTENANCE STANDARD DIFFERENTIAL
DIFFERENTIAL
HD325-6
HD325-6W
HD4056
i i
I SDH00335
Unit: mm

Wear of coupling oil seal Correct or
1 contact surface replace
110 -Lo*-/ 109.9
2 Thickness of side gear

6.0 -EL050 5.5
thrust washer
3 Thickness of disc + 0.3 2.8 Replace

3.3
I I I
4 Thickness of plate 2.1 f 0.1 1.9

I I I I
Backlash of bevel gear and 0.3 - 0.4 Adjust

5
pinion
HD3256 40-13
0
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE (REAR)
‘I
thread
926.7*98.1Nm 926.7*98.1Nm
{94.5~lOkpml (94.5*10kpm)
When not coating thread: When not coating thread:
1201.3*122.6Nm 1201.3*122.6Nm
(122.5*12.5b.l (122.5*12.5km) SWH00824
Unit: mm
I I I
Check item Criteria Remedy
Backlash between Standard size Repair limit

I planetary gear and sun
gear 0.19 -0.45 0.8 Replace
2 Backlash between plan-

0.21- 0.65 1.0
etary gear and ring gear I I
3 Curvature of drive shaft Repair limit: 1.5TIR Correct or

replace

4 Thickness of spacer Replace
36 i 0.1 35.5
Wear of outside dimaeter Standard size Repair limit

5 of portion of axe1 tube in-
serted into bearing 2oo -0.015
199.8 Correct
- 0.061
Wea.r of outside diameter of 220 -0.015
6 portron of axel tube In- 219.8
serted into bearing - 0.061
40-14 HD325-6
0
FINAL DRIVE (FRONT)

HD325-6W
li3.0*12.3Nm
(11.25*1.25kPml
SVH00836
HD325-6 40-14-l
0
Unit: mm
0.19 - 0.54
0.40 - 0.70
40-14-2 HD325-6
0
MAINTENANCE STANDARD FRONT BRAKE
FRONT BRAKE
HD325-6
HD405-6
94.5 + 10.5kp $%El56+6kgm
566FO6057
Unit: mm

, Wear of padtremaining Replace
thickness of wear material) 19.5 3.0
- Ratio of surface:lO% Replace

2 Missing portion of pad
Correct or
3 Face runout of disc(Note 1) 0.15 0.50
replace
4 Wear of disctthickness of 30 Less than 27 Replace

disc)
Open crack in direction Replace

5 Damage to disc surface -
Ecentric wear,marked damage
Correct
(No.2)
Notel: If there is excessive face runout of the disc, check the front wheel bearing also.
Note2: If the depth of the scratch exceed 1.5mm
l
If the whole pad is worn, the disc has been rubbed by mistake by the pad rear plate, the rear
l
plate metal is melted to the disc, or there is portrusion

If there are vertical scratches other than concentric scratches
l
HD325-6 40-15
0
MAINTENANCE STANDARD FRONT BRAKE
HD325-6W
549*59Nm v+
(56*6luml \
8 SVH00837
Unit: mm

1 Backlash between outer
gear and plate 0.21 - 0.64 2.2
2 Backlash between inner

I I
3 Thickness of plate
2.4 2.15
-
A Thickness of disc 5.1 4.6
Replace
5 Thickness of damper 6.9 5.1

Warping of disc friction
6
surface Max.0.45 0.7
Warping of plate and

7 damper friction surface Max.O.50 0.7
I I I
6 Assembled thickness of
plate and disc 33.9 30.4
40-15-l HD325-6
0
MAINTENANCE STANDARD REAR BRAKE
REAR BRAKE
I561 :6kgm
566FO6058
Unit: mm

1 Backlash between outer
gear and plate
0.52 - 0.90 1.5
2 Backlash between inner

-
3 Thickness of plate
2.4 2.15
4 Thickness of disc 5.1 4.6

- Replace
5 Thickness of damper I 6.9 I 5.1 I

6 zr;lA;g of disc friction
Max.0.45 0.7
Wraping of plate and

7 damper friction surface Max.0.50 0.7

Assembled thickness of
8 plate and disc
123.9 114.4
-
Wear of oil seal contact Repair or
9 430 o--0.015
surface replace
-
HD325-6
40-16
MAINTENANCE STANDARD PARKING BRAKE
PARKING BRAKE
I / \ 7..---
1 2
566FO6059
Unit: mm
No Check item Criteria Remedy
I
-
Standard backlash I Repair limit Repair or
1 Face runout of disc replace
0.4 I 0.8
-
Rebuild
(Thickness of
Min.20 ;;;;d~rt not
2 Thickness of disc 25 20mm)
I Max.20
Replace
Thickness of pad
3 21.5 11.5
(including thickness of plate)
-
Standard size Repair limit Standard Clearance
of plate clearance limit
Clearance between plate and 22.3 Correct or

4 -:.3 replace
brake assembly
Standardvalue of
Repair limit 1.0 * 0.4 1.5
brakeassembly
+0.4
23 -0.1
HD325-6 40-17
MAINTENANCE STANDARD REAR AXLE SUPPORT
REAR AXLE SUPPORT
E-E F-F
G-G
566FO6060
Unit: mm

Clearance between rod size Shaft Hole clearance limit
1 mounting pin and boss
+ 0.046 - 0.030 -
60 +0.030
+0.076 0 0.122 0.6
Clearance between inner 0.12 -

2 and outer for bushing - 0.6 Replace
0.25
clearance between suspen-

0.030 -
3 sion cylinder
pin and frame moounting
or axel 60 -0.030
-0.076 +0.046
0 0.122 0.6
0.12 -
4 Clearance
and between
outer for bushinginner - 0.25 0.6
40-18 HD325-6
MAINTENANCE STANDARD STEERING LINKAGE
STEERING LINKAGE
&5 56+6b ‘3
Qa 18+2k$ ‘1
7 6
6 D-D
E-E 566FO6061
HD325-6 40-19
MAINTENANCE STANDARD STEERING LINKAGE
566FO6062
Unit: mm
No. Check item

I Criteria Remedy
-
Inner and outer ring clear- size Shaft Hole clearance limit
1 antes between the kcuckle _
arm and arm bushing 0.12 -
135 - - 0.7
0.25
Clearance between steering

2
cylinder bushing and pin
Clearance between the tie

3 rod bushing and pin
-
Clearance between inner 0.10 -
4 70 0.20 0.4 Replace
and outer rings for bushing
Clearance between the cen- -0.025 +0.030 0.225 -

5 ter lever bushing and pin 55 - 0.064 +0.200 0.364 1.0
Clearance between arm - 0.025 +0.039 0.025 -

6 bushing and pin 60 - 0.064 0 0.103 0.6
Clearance between inner and 0.12 -

7 - - - 0.25 0.6
outer rings for the bushing
Clearance between pin and

lock plate Clearance must be 0
MAINTENANCE STANDARD FRONT SUSPENSION CYLINDER
566FO6063
- Unit: mm

size Shaft Hole clearance limit
1
Clearance between piston Replace
rod and bushing -0.043 bushing
+0.240 0.043 -
160 -0.106 0.346 0.4
0
-
Clearance between piston +0.540 0.403 - Replace
2 rod and bushing 160 -0.043 0.646 0.7
-0.106 +0.360 bushing
-
Clearance between -0.05 +0.115 0.05 - Replace wear
3 cylinder and wear ring 200 0.375 0.8 ring
-0.26 0
I I I
Measurins method:
Place the spring on a flat bench and Repair limit
measure the amount that the spring
curves.
4 Elasticity of leaf spring Max.0.3mm
Replace
SVH0075
Measuring method:
Measure protrusion and elongation of
stopper. Elongation:
All the conditions below must be fulfilled.
Max.5mm
Rod stopper Protrusion:
5 Deformation of stopper Max.2mm
No cracks
SVH00875
HD325-6 40-21
MAINTENANCE STANDARD REAR SUSPENSION CYLINDER
REAR SUSPENSION CYLINDER

HD325-6
HD325-6W
HD405-6
SOH00336
Unit: mm
I I I
Standard Tole lnce Standard Clearance

, Clearance between piston
rod and bushing - 0.043 - 0.240 0.43 -
160 -0.106 0 0.346 0.4
Replace
2 Clearance between piston -0.043 - 0.540 0.403 -
rod and bushing 160 -0.106 0.360 0.646 0.7
3 Clearance between -0.050 -0.115

cylinder and wear ring 200 0.8
- 0.260 0
40-22 HD325-6
0
MAINTENANCE STANDARD PARKING BRAKE CHAMBER
PARKING BRAKE CHAMBER

7.25k1.75 kgm
426F191 A
Unit: mm

Clearance between
1 cylinder and piston
Hole:159
ShatY158.65 0.35
Clearance between piston Hole: 38.8

2 insert center boss Shafb38.04 0.76
Replace
I
Installed Installed Installed
Piston spring Free length Free length
3 length load load
7355f490N
260
{750*50kg}
4 Play of rod in axial direction 2.1

- 1 Ajust
I
5 Installed dimension of rod 128
I
-
40-23
MAINTENANCE STANDARD SLACK ADJUSTER
SLACK ADJUSTER
m
I 6+0.5kgm
566FO6065
Unit: mm

, Clearance between body size Shaft Hole clearance limit
and piston Replace
-0.030 +0.074
80 0 0.03 - 0.15 0.25
-0.076
40-24
MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
SAL(1 I-014 (For emergency steering)
1
2
\
b=
11.55 1 kgm
A-A
42AFOll OO-2K
Unit: mm

-
Standard clearance Clearance limit
1 Side clearance
0.10-0.15 0.19
Clearance between inside di-

2 ameter of plain bearing and 0.06 - 0.144 0.20 Replace
outside dimeter of gear shaft
Standard size Tolerance

3 Depth to knock in pin
10 - 00.5
4 Rotating torque of splined
shaft 2.0 - 4.9Nm (0.2 - 0.5kgm)
Speedfrpm) Delivery pressure Standard delivery Delivery amount

Delivery amount MPa(kg / cm21 amount @/min.) limit (Urnin. -
EOIO-CD
45 - 55’C 3500 20.6{210) 47 43
40-25
SAR(3b80 (For torqueconverter, transmission)
-\
28.5 f 3 kgm
A-A
425F134-1K
Unit: mm
Standard clearance Clearance limit

I Side clearance
0.10 -0.15 0.19
Clearance between inside di-

2 ameter of plain bearing and 0.06 - 0.149 0.20
outside dimeter of gear shaft Replace
Standard size Tolerance

14
- 00.5
4 Rotating torque of splined

6.9 -11.8Nm (0.7 - 1.2 kgm}
shaft
Delivery pressure Standard delivery Delivery amount
Delivery amount Speed(rpm) MPa(kg/cm*) amount (elmin.) limit (e/min.)
- -
EOIO-CD
45 - 55°C 2500 3.9 1401 188 172
HD325-6
40-26
SAR(3b063+050 (For steering and hoist)
m 2i.5 f 3 kgm C&l 8 f 2 kgm w 2i.5 + 3 kgm
A-A
569FO5081-1 K
Unit: mm

-
I Model Standard clearance Clearance limit
1 Side clearance
Ei 0.10-0.15 0.019
Replace
Clearance between inside

diameter of plain bearing
2 Ei 0.06 -0.149 0.20
and outside dimeter of
gear shaft
I Model Standard size Tolerance
-
Roating torque of spling
4 shaft 13.7 -23.5Nm {1.4- 2.4 kgm)
Delivery Standard Deliven/

pressure delivery amount
Model Speed(rpm) MPa limit
Delivery amount amount
{kg I cm? (Urnin.) @/min.)
EOIO-CD
45 - 55°C SAR(3)-050 112 102
2500 20.6{210}
SAR(3)-063 145 134
HD325-6 40-27
MAINTENANCE STANDARD DEMAND VALVE
DEMAND VALVE
ci3=
,9.5-12.5kgm
569F05084-K
Unit: mm
Standard size
I Repair limit
, Spool return spring Installed Installed Installed

Free length Free length
langth load load
Replace
130.4N 120.6N
172.2 140
(13.3kg) (12.3kgI
2 Check valve spring 3.38N 3.09N
42.2 33.5
{0.345kgI (0.315kgI
CROSS-OVER RELIEF VALVE
569F05085-K
40-28 HD325-6
MAINTENANCE STANDARD HOIST VALVE
HOIST VALVE
W15.5+2.5kgm 7 iz0.5kgm
w 37.5+2.5kgm
Unit: mm
Relif valve poppet spring Installed Installed Installed Replace

Free length langth load Free length load
42.0 258.9N 39.4 206.9N

49.3
I26.4kgI {21.lkg}
HD325-6 40-29
MAINTENANCE STANDARD STEERING CYLINDER
STEERING CYLINDER
m 568.8* 56.9Nm
-(58*5.8kml
(Width across f lats:50mm)
SWHOO626
Unit: mm
I
Standard Tolerance _ Standard Clearance
Clearance between piston size Shaft Hole clearance limit
Replace
1 rod and bushing 0.551 bushing
50 -0.025 +0.164 0.032 -
- 0.087 +0.007 0.251
Clearance between piston

2 rod support shaft and 40 +0.039 1.0
bushina 0
Replace
Clearance between cylinder bot-
3 40 +0.039 1.0
tom support shaft and bushing 0
-
40-30 HD3256
MAINTENANCE STANDARD HOIST CYLINDER
HOIST CYLINDER
~I;2f;;;.4Nm
(Width, across f lats:Zlmm)
1111 I
SWH00826
Unit: mm
Clearance between
cylinder and bushing
rod and bushing
HD3256
90 OTHERS
Air piping diagram
(HD325-6: 6001 and up, HD405-6 : 2001 and up) ................................................................. 90-1-2
(HD325-6W: 5485 – 6000) ..................................................................................................... 90-1-4
(HD325-6W: 6001 and up) .................................................................................................... 90-1-6
Air circuit diagram
(HD325-6W: 5485 – 6000) ..................................................................................................... 90-1-8
(HD325-6, 6W: 6001 and up, HD405-6 : 2001 and up) ....................................................... 90-1-10
Diagram for electrical circuit inside cab (1/3 – 3/3)
(HD325-6: 5680 – 6000, HD325-6W: 5706 – 6000, HD405-6: 1055 – 2000) ............... 90-3 – 90-7
Diagram for electrical circuit inside cab (1/4 – 4/4)
(HD325-6, 6W: 6001 and up, HD405-6 : 2001 and up) .......................................... 90-7-2 – 90-7-8
Diagram for electrical circuit outside cab (1/2 – 2/2)
(HD325-6: 5680 – 6000, HD325-6W: 5706 – 6000, HD405-6: 1055 – 2000) ............. 90-9 – 90-11
Diagram for electrical circuit outside cab (1/2 – 2/2)
(HD325-6, 6W: 6001 and up, HD405-6 : 2001 and up) ...................................... 90-11-2 – 90-11-4
Automatic retard speed control system
Electrical circuit diagram ....................................................................................................... 90-13
Automatic shift controller
(HD325-6: 5680 – 6000, HD325-6W: 5706 – 6000, HD405-6: 1055 – 2000) ........................ 90-15
Automatic shift controller
(HD325-6, 6W: 6001 and up, HD405-6 : 2001 and up) ....................................................... 90-15-2
Automatic suspension system
System circuit diagram (1/2 – 2/2)
(HD325-6: 5680 – 6000, HD325-6W: 5706 – 6000, HD405-6: 1055 – 2000) ......... 90-17 – 90-19
System circuit diagram
(HD325-6, 6W: 6001 and up, HD405-6 : 2001 and up) .................................................... 90-19-2
Payload meter (Printer type)
Electrical circuit diagram
(HD325-6: 5680 – 6000, HD325-6W: 5706 – 6000, HD405-6: 1055 – 2000) ...................... 90-21
Payload meter II (Card type)
(HD325-6: 5680 – 6000, HD325-6W: 5706 – 6000, HD405-6: 1055 – 2000) ...................... 90-23
Payload meter (Printer • Card type)
(HD325-6, 6W: 6001 and up, HD405-6 : 2001 and up) .................................................... 90-23-2
Electrical circuit diagram for transmission controller system
(HD325-6, 6W: 6001 and up, HD405-6 : 2001 and up) ........................................................ 90-201
Electrical circuit diagram for transmission controller system (1/2 – 2/2)
(HD325-6, 6W: 6001 and up, HD405-6 : 2001 and up) ......................................... 90-203 – 90-205
Oil filter caution system ..................................................................................................... 90-205-2
Front drive system
Electrical component layout
(HD325-6W: 5706 – 6000) .................................................................................................... 90-207
(HD325-6W: 6001 and up) ................................................................................................... 90-209
(HD325-6W: 5706 – 6000) .................................................................................................... 90-211
(HD325-6W: 6001 and up) ................................................................................................... 90-213
HD325-6 90-1
C
THE FOLDOUTS WERE NOT AVAILABLE AT TIME OF RELEASE.
OIL FILTER CAUTION SYSTEM
OIL FILTER CAUTION SYSTEM DIAGRAM
HD325-6 90-205-2
C
DataKom Publishing Corporation
440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
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Manual de Oficina Sebm015114 - HD325 - 405-5 - 0502

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Manual de Oficina Sebm015114 - HD325 - 405-5 - 0502

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SEBM015114

MACHINE MODEL SERIAL NUMBER

• HD325-6, HD405-6 mounts the SAA6D140E-2 or SAA6D140E-3 engine.

( ) Page to be deleted Discard

Pages having no marks are those previously re-

LIST OF REVISED PAGES

b 00-1 (14) 01-7-1 (7) 10-34 (3) 10-75 10-105

30-206 (2) 40-8 90-201 (7)

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

¤ Heavy parts (25 kg or more) must be lifted

• If a part cannot be smoothly removed from the

★ The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

¤ Before carrying out the following work, release

For details, see TESTING AND ADJUSTING,

Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets,

• Used in places requiring an imme-

• Features: Resistance to heat and

Adhesive: • Used as adhesive or sealant for

Polyethylene • Used as sealant for machined

Holtz • Used as heat-resisting sealant for

• Quick hardening type adhesive

• Quick hardening type adhesive

Loctite Polyethylene • Resistance to heat, chemicals

• Used as adhesive or sealant for

• Used as sealant for various

• Features: Silicon based, resist-

• Ftures: Silicon based, quick hard-

Three bond • Used as heat-resisting sealant for

• Used as lubricant for sliding por-

SYG2-400LI • General purpose type

SYG2-400CA • Used for normal temperature,

Molybdenum 400 g • Used for places with heavy load

STANDARD TIGHTENING TORQUE

Thread diameter Width across

6 10 13.2 0 1.4 1.35 0 0.15

27 41 1320 0 140 135 0 15

Thread diameter Width across

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque

TIGHTENING TORQUE FOR 102 ENGINE SERIES

ELECTRIC WIRE CODE

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal