Komatsu HD325-8E0, HD405-8E0 Dump Truck Service Repair Manual

Shop Manual: 3244 pages
Operation and Maintenance Manual: 474 pages
Field Assembly Manual: 83 pages
Serial Numbers:
HD325-8E0 – 55001 and up
HD405-8E0 – 55001 and up
Manual: Shop Manual, Operation and Maintenance Manual, Field Assembly Manual
HOW TO READ THE SHOP MANUAL
– Some of the attachments and options described in this shop manual may not be available in some areas. If they are required, consult your Komatsu distributor.
– The materials and specifications are subject to change without notice.
– Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual for the machine which has the same engine model.
– Actual machine may differ from the images which are contained in this manual. A typical model is shown in the illustrations of this 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

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.

60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION

This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which cannot be separately classified in the appendix.

90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.