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

Shop Manual: 1550 pages
Operation and Maintenance Manual: 391 pages
Serial Numbers:
HD325-7 – 7001-7025
HD325-7 – 7101 and up
HD405-7 – 3001-3035
HD405-7 – 7101 and up
Manual: Shop Manual, Operation and Maintenance Manual
00 Index and foreword
Index
Foreword and general information
01 Specification
Specification and technical data
10 Structure, function and maintenance standard
Engine and cooling system
Power train, Part 1
Power train, Part 2
Steering system
Brake system
Undercarriage and frame
Hydraulic system
Cab and its attachments
Electrical system
20 Standard value table
Standard service value table
30 Testing and adjusting
Testing and adjusting
40 Troubleshooting
General information on troubleshooting
Troubleshooting by failure code, General
Troubleshooting by failure code
Troubleshooting of electrical system (E-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of mechanical system (S-mode)
50 Disassembly and assembly
General information on disassembly and assembly
Engine and cooling system
Power train
Steering system
Brake system
Undercarriage and frame
Hydraulic system
Body
Cab and its attachments
Electrical system
90 Diagrams and drawings
Hydraulic diagrams and drawings
Electrical diagrams and drawings
HOW TO READ THE SHOP MANUAL
Composition of the shop manual
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION

This section describes the structure and operation of each component with respect to each system. “STRUCTURE AND FUNCTION” is helpful in not only understanding the structure of each component but performing troubleshooting.

20 STANDARD VALUE TABLE

This section describes the standard values for new machine and failure criteria for testing and adjusting, and troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge troubles in troubleshooting.

30 TESTING AND ADJUSTING

This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described in “STANDARD VALUE TABLE”.

40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY OF THE KOMATSU HD325-7 DUMP TRUCK

This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.

90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
Symbols
Important safety and quality portions are marked with the following symbols so that shop manual is used effectively.