🏷️ Basic Information Identification Make: Komatsu Model: HD325-5 Product Type: Factory Service Repair Manual Machine Type: Dump Truck Codes Serial Number Coverage Start: 2001 👋 Introduction Market Position Segment: Heavy-duty mining and construction haul trucks Application: Off-highway heavy hauling in demanding environments Competitive Analysis Competitors: Caterpillar 773 series, Bell B40D/B50D, Volvo A40F Key Features Durability: Known for robust construction and reliability in harsh conditions Payload Capacity: Designed for high payload capacity and efficient material movement Operator Comfort: Cab designed for operator productivity and comfort over long shifts 📋 Manual Details Coverage Areas Primary Coverage: Komatsu HD325-5 Dump Truck Page Count Estimated Pages: 1000+ Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, diagnostics, and repair Powertrain: Transmission, drive shafts, differentials, final drives Hydraulics: Hoisting system, steering system, brake system, hydraulic circuit diagrams Electrical: Starter, alternator, batteries, lighting, sensors, ECUs, wiring diagrams Chassis: Frame, suspension (front and rear), steering linkage Braking System: Service brakes, parking brake, retarder system Bodywork And Cab: Cab structure, mounting, interior components, body panels Air Conditioning: Refrigeration cycle, components, servicing Cooling System: Radiator, fan, water pump, coolant specifications Fuel System: Fuel tank, pump, filters, injectors Procedures Included Maintenance: Scheduled maintenance, lubrication points, fluid changes Diagnostics: Troubleshooting guides, diagnostic codes, fault finding procedures Repair: Component removal, disassembly, assembly, and installation Overhaul: Engine, transmission, hydraulic pump and motor overhauls Calibration: Sensor calibration, system adjustments Testing: Component performance testing, system operational checks Torque Specifications: Engine, powertrain, and chassis fastener torque values Technical Depth Depth: Comprehensive from basic adjustments to complete rebuilds Detail Level: Detailed step-by-step instructions with diagrams and illustrations Diagnostic Tools: Information on required special tools and diagnostic equipment 📊 Manual Specifications File Format Format: PDF Searchability: Searchable text for quick information retrieval Print Quality Quality: High-resolution scans for clear text and sharp images Printable: Printable for physical reference Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Manufacturer: Komatsu Model: S6D140E-2 Type: Direct injection, turbocharged, aftercooled diesel engine Displacement: 20.36 L (1242.6 cu in) Performance Gross Power Hp: 450 HP (336 kW) @ 2000 RPM Peak Torque Lb-Ft: 1314 lb-ft (1781 Nm) @ 1400 RPM Fuel System Injection Type: Common Rail (likely based on era, manual will confirm specific system) Fuel Type: Diesel Fluid Specifications Engine Oil Type: API CD/CE/CF-4 or higher (e.g., SAE 15W-40, refer to manual for exact spec) Coolant Type: Ethylene glycol-based antifreeze (50% solution, refer to manual for Komatsu specific type) 🔧 Transmission Standard Type: Komatsu Automatic Transmission Model Designation: AT3700 (Specific model may vary, manual will confirm) Gear Selection: Electronically controlled, automatic gear shifting Number Of Gears: 6 Forward / 1 Reverse (Typical for this class) Features Retarder: Integrated transmission retarder for downhill speed control Shift Logic: Advanced shift logic for optimal performance and fuel efficiency Fluid Specifications Transmission Fluid Type: Komatsu genuine oil or equivalent ATF (refer to manual for exact specification and part number) 📐 Dimensions Exterior Length Mm: 9770 mm (32 ft 3 in) Width Mm: 3400 mm (11 ft 2 in) Height Mm: 3505 mm (11 ft 6 in) Wheelbase Mm: 4500 mm (14 ft 9 in) Cargo Body Capacity M3: 21.0 m³ (27.5 cu yd) SAE heaped Weights Operating Weight Kg: Approx. 63,000 kg (138,891 lbs) Payload Capacity Kg: 32,000 kg (70,548 lbs) Front Axle Load Kg: 24,930 kg (54,961 lbs) (Max) Rear Axle Load Kg: 70,070 kg (154,477 lbs) (Max) 🛡️ Safety Features Ratings Rollover Protection: ROPS (Roll-Over Protective Structure) as standard Fall Protection: FOPS (Falling-Object Protective Structure) available/optional Active Features Braking System: Dual circuit, oil-immersed, multi-disc brakes; Hydro-dynamic retarder Steering System: Hydrostatic power steering with auto-emergency steering function Passive Features Cab Design: Reinforced safety cab structure Lighting: Standard work lights, stop lights, turn signals 💡 Technology Features Infotainment System Type: Basic operator display and controls (not automotive-style infotainment) Features: Engine monitoring, transmission status, hydraulic pressure indicators, warning lights. Driver Assistance Features: Automatic transmission, retarder system, load-sensing hydraulics. Connectivity Features: Diagnostic ports for service and data logging. 🔧 Maintenance Service Intervals Engine Oil Change: Refer to manual (typically 250-500 hours depending on operating conditions) Hydraulic Oil Change: Refer to manual (typically 1000-2000 hours) Transmission Oil Change: Refer to manual (typically 1000-2000 hours) Air Filter Replacement: Based on vacuum indicator or hours (refer to manual) Fluid Specifications Hydraulic Fluid Type: Komatsu genuine hydraulic oil (e.g., 6909-21-1060) or equivalent ISO VG 32/46 (refer to manual) Gear Oil Type: Refer to manual for differential and final drive oil specifications (e.g., GL-5) Grease Type: Refer to manual for lubrication points (e.g., Lithium Complex EP Grease) Known Issues Common Wear Points: Suspension articulation joints, brake disc wear, hydraulic hose integrity Powertrain Reliability: Generally robust, but transmission control solenoids can require service over time. Electrical Components: Sensors and wiring in...