🏷️ Basic Information Identification Make: Komatsu Model: HD325-5 Product Type: Workshop Service Repair Manual Applicable Serial Numbers: SN: 2001 and up Codes Manual Identifier: HD325-5 Workshop Service Repair Manual 👋 Introduction Market Position Vehicle Segment: Heavy-Duty Off-Highway Articulated Dump Truck Competitive Analysis Key Competitors: Caterpillar (e.g., 730C), Bell Trucks, Volvo Construction Equipment, John Deere Key Features Design Philosophy: Robust construction, reliability, high payload capacity, and maneuverability in challenging terrain. Manual Value Proposition: Essential resource for maintaining operational efficiency and longevity of the HD325-5, reducing downtime and repair costs. 📋 Manual Details Coverage Areas Primary Coverage: Complete Service and Repair for Komatsu HD325-5 Dump Truck Page Count Estimated Page Count: Hundred's of pages (exact number not provided, but implied to be extensive) Manual Type Manual Classification: Factory Service Repair Manual Language Primary Language: English (assumed based on product description) Format Digital Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine, Transmission, Drivetrain, Axles, Differentials Chassis: Suspension System (Front and Rear), Steering System, Braking System (Service, Parking, Retarder), Frame and Body Components Hydraulic System: Hoist System, Steering Hydraulics, Brake Hydraulics, Hydraulic Pump and Valve Operation Electrical System: Starting System, Charging System, Lighting System, Instrumentation, Control Systems, Wiring Diagrams Operator Station: Cab Components, Controls, HVAC System Procedures Included Maintenance: Routine Maintenance Checks, Lubrication Schedules, Filter Replacements, Fluid Level Checks and Replenishment Troubleshooting: Diagnostic Procedures, Fault Code Interpretation, Symptom-Based Troubleshooting Guides Repair: Component Removal and Installation, Overhaul Procedures for Engine, Transmission, Hydraulics, etc. Diagnostics: Electrical System Diagnostics, Hydraulic System Testing, Engine Performance Testing Specifications Data: Torque Specifications, Clearances, Component Dimensions, Pressure Readings Technical Depth Depth Of Coverage: Comprehensive: from basic maintenance to complete component overhauls and advanced diagnostics. Diagnostic Capability: Detailed diagnostic flowcharts and testing procedures for all major systems. Rebuild Procedures: In-depth rebuild instructions for critical components like engines, transmissions, and hydraulic cylinders. 📊 Manual Specifications File Format Digital File Type: PDF (Portable Document Format) Searchability: Typically searchable text within PDF for efficient information retrieval. Print Quality Output Quality: High resolution for clear diagrams, illustrations, and text. Printable. Binding Type Physical Format Analogous: N/A (Digital Download) Paper Type Physical Format Analogous: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Make: Komatsu Engine Model: Likely a SAA6D125E-3 or similar industrial diesel engine (specific model not provided in product info, but common for this class). Engine Type: Inline 6-cylinder, Turbocharged, Aftercooled Diesel Performance Gross Horsepower: Approximately 330-335 HP (Varies by specific configuration and regulations, requires manual verification). Peak Torque: Estimated around 900-950 lb-ft (Requires manual verification). Fuel System Fuel Injection: Direct Injection, Common Rail (Likely electronic control) Fuel Type: Diesel Fuel Cooling System Cooling Type: Water-Cooled with Fan Emission Controls Emission Standards: EPA Tier III / EU Stage IIIA (Likely for this generation, requires manual verification) 🔧 Transmission Standard Transmission Type: Komatsu Advanced Transmission with Electronic Control (K-ATESS) Number Of Gears: 6 Forward, 3 Reverse (Typical for this model) Features Shift Control: Automatic shift selection with manual override capability Transmission Fluid Type: Komatsu genuine transmission oil or equivalent Dexron III/VI (Specific part number in manual) Torque Converter: Lock-up torque converter for improved fuel efficiency in higher gears 📐 Dimensions Exterior Overall Length: Approx. 32 ft 10 in (10,010 mm) (Requires manual verification) Overall Width: Approx. 10 ft 8 in (3,240 mm) (Requires manual verification) Overall Height: Approx. 11 ft 7 in (3,530 mm) to top of cab (Requires manual verification) Cargo Body Capacity Heaped: Approx. 21.0 cubic yards (16.0 cubic meters) (Requires manual verification) Payload Capacity: Approx. 35.3 US tons (32,000 kg) (Requires manual verification) Weights Operating Weight: Approx. 50,700 lbs (23,000 kg) (Requires manual verification) Front Axle Load Max: Specifics in manual. Rear Axle Load Max: Specifics in manual. 🛡️ Safety Features Ratings Rollover Protection: ROPS (Roll-Over Protective Structure) Cab, FOPS (Falling Object Protective Structure) Canopy often standard. Active Features Braking System: Full hydraulic, dual-circuit, oil-immersed disc brakes on all wheels. Parking brake, secondary brake, and automatic retarder. Visibility: Large cab windows, optional rearview camera, powerful work lights. Passive Features Seatbelt: Operator seatbelt (likely three-point). Cab Design: Ergonomically designed for operator comfort and safety, with noise reduction. 💡 Technology Features Infotainment Cab Features: Basic operator controls, digital instrumentation display, potentially radio preparation. Driver Assistance Operational Aids: Transmission control system (K-ATESS) for optimized shifting and fuel economy, diagnostic display for system status. Connectivity Telematics Support: While not always standard on this generation, provisions for telematics systems (e.g., Komtrax) may be present or installable, detailed in manual. 🔧 Maintenance Service Intervals Engine Oil Change: Typically 500 hours (Refer to manual for exact interval and oil type). Hydraulic Oil Change: Typically 2000 hours (Refer to manual for exact interval and oil type). Transmission Oil Change: Typically 1000 hours (Refer to manual for exact interval and oil type). Fluid Specifications Engine Oil Spec: API CI-4 or CH-4, SAE 15W-40 (Confirm with manual for exact Komatsu specification)....