Komatsu HD325-6 HD405-6 HD465-5 HD605-5 HD785-5 DUMP Truck Service Repair Manual

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🏷️ Basic Information Identification Make: Komatsu Model: HD325-6, HD405-6, HD465-5, HD605-5, HD785-5 Product Type: Service Repair Manual Codes Product Identifier: Komatsu HD325-6 HD405-6 HD465-5 HD605-5 HD785-5 DUMP Truck Service Repair Manual 👋 Introduction Market Position Category: Heavy-duty Off-Highway Articulated Dump Trucks Application: Mining, Construction, Quarrying, Heavy Earthmoving Operations Competitive Analysis Key Competitors: Caterpillar (e.g., 730, 735), Volvo CE (e.g., A30F, A35F), Bell Equipment, John Deere Key Features Durability And Reliability: Known for robust construction and reliability in harsh environments. Performance: High payload capacities, powerful engines, and efficient drivetrain systems for demanding work. Operator Comfort: Designed with operator comfort and safety in mind, featuring advanced cab suspension and ergonomic controls. 📋 Manual Details Coverage Areas Models Covered: Komatsu HD325-6, HD405-6, HD465-5, HD605-5, HD785-5 Dump Trucks Regions Of Operation: Global (Specifications may vary by region) Page Count Estimated Page Count: Over 1000 pages (Comprehensive, exact count varies by model and edition) Manual Type Type: Official Factory Service and Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine, Transmission, Drive Axles, Differentials, Final Drives Hydraulics: Hoisting, Steering, Braking, Cooling Fan, Implement Hydraulics Electrical: Starting System, Charging System, Lighting, Instrumentation, Control Systems, ECSS (Electronically Controlled Suspension System) Chassis And Frame: Frame, Suspension (Front and Rear), Steering System Components Braking System: Service Brakes (Inboard, Wet-Disc), Parking Brake, Retarder System Body And Cab: Operator's Cab, Dump Body, Fenders, Guards Cooling System: Radiator, Fan, Hoses, Thermostat Lubrication System: Engine Oil System, Transmission Oil System, Axle Lubrication Procedures Included Maintenance: Scheduled Maintenance, Lubrication Charts, Fluid Checks and Replacements, Filter Replacements Disassembly And Assembly: Complete component-level disassembly and reassembly procedures for all major systems. Troubleshooting: Diagnostic charts, common problems, symptom-based troubleshooting guides, error code interpretation. Repair And Rebuild: Detailed instructions for component repair, overhaul, and rebuilding of engines, transmissions, hydraulic pumps, cylinders, etc. Technical Specifications: Torque values, clearances, pressure settings, flow rates, electrical specifications. Testing And Adjustment: Procedures for testing and adjusting hydraulic systems, engine performance, braking systems, and electrical components. Technical Depth Depth: Comprehensive from basic daily checks to complete engine and transmission overhauls. Diagnostics Level: Advanced diagnostic procedures including electrical schematics, hydraulic circuit diagrams, and fault finding trees. Rebuild Level: Detailed instructions for complete component rebuilds with specifications for wear limits and tolerances. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Searchability: Fully searchable text content for quick information retrieval. Printability: Printable pages for field use or workshop reference. Print Quality Image Resolution: High-resolution diagrams and illustrations for clarity. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Hd325 6 Engine Model: Komatsu SAA6D125E-2 Engine Type: Turbocharged, Aftercooled, Direct Injection, Diesel Displacement: 19.0 L (1159 cu. in.) Gross Horsepower: 353 HP (263 kW) @ 2000 RPM Net Horsepower: 330 HP (246 kW) @ 2000 RPM Primary Engine Hd405 6 Engine Model: Komatsu SAA6D140E-3 Engine Type: Turbocharged, Aftercooled, Direct Injection, Diesel Displacement: 23.1 L (1410 cu. in.) Gross Horsepower: 473 HP (353 kW) @ 2000 RPM Net Horsepower: 446 HP (333 kW) @ 2000 RPM Primary Engine Hd465 5 Engine Model: Komatsu SAA6D140E-3 Gross Horsepower: 523 HP (390 kW) @ 2000 RPM Net Horsepower: 493 HP (368 kW) @ 2000 RPM Primary Engine Hd605 5 Engine Model: Komatsu SAA6D140E-3 Gross Horsepower: 523 HP (390 kW) @ 2000 RPM Net Horsepower: 493 HP (368 kW) @ 2000 RPM Primary Engine Hd785 5 Engine Model: Komatsu SAA6D170E-3 Engine Type: Turbocharged, Aftercooled, Direct Injection, Diesel Displacement: 27.0 L (1647 cu. in.) Gross Horsepower: 773 HP (576 kW) @ 2000 RPM Net Horsepower: 738 HP (550 kW) @ 2000 RPM Performance Engine Management: Electronically Controlled Engine Management System (ECM) Fuel System Fuel Type: Diesel Fuel Fuel Injection: High-pressure Common Rail Fuel Injection System Fluid Specifications Engine Oil Grade: API CJ-4 or ACEA E9 (Check specific model/year for exact specification) Coolant Type: Komatsu Super Coolant (Ethylene Glycol based) or equivalent with extended life additives 🔧 Transmission Standard Type: Planetary Gear Type, Full Automatic, Komatsu Traction System (KTS) Gears: 6 Forward / 1 Reverse (Varies by model) Control: Electronically Controlled Automatic Transmission Optional Availability: N/A (Typically standard across these heavy-duty models) Features Shift Control: Automatic gear selection based on load, speed, and grade Retarder: Integrated transmission retarder for downhill speed control Fluid Specifications Transmission Fluid Grade: Komatsu Genuine TO-30, Allison TES 295, or equivalent (Consult manual for specific model requirements) 📐 Dimensions Exterior Hd325 6 Length: Approx. 9.98 m (32 ft 9 in) Width: Approx. 3.48 m (11 ft 5 in) Height: Approx. 3.93 m (12 ft 11 in) Exterior Hd405 6 Length: Approx. 10.56 m (34 ft 8 in) Width: Approx. 3.58 m (11 ft 9 in) Height: Approx. 4.05 m (13 ft 3 in) Exterior Hd465 5 Length: Approx. 10.56 m (34 ft 8 in) Width: Approx. 3.58 m (11 ft 9...

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Tags: Dump Truck Engines HD325-6 HD405-6 HD465-5 HD605-5 HD785-5 Komatsu Misc

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Description

🏷️ Basic Information

Identification

Make:

Komatsu

Model:

HD325-6, HD405-6, HD465-5, HD605-5, HD785-5

Product Type:

Service Repair Manual

Codes

Product Identifier:

Komatsu HD325-6 HD405-6 HD465-5 HD605-5 HD785-5 DUMP Truck Service Repair Manual

👋 Introduction

Market Position

Category:

Heavy-duty Off-Highway Articulated Dump Trucks

Application:

Mining, Construction, Quarrying, Heavy Earthmoving Operations

Competitive Analysis

Key Competitors:

Caterpillar (e.g., 730, 735), Volvo CE (e.g., A30F, A35F), Bell Equipment, John Deere

Key Features

Durability And Reliability:

Known for robust construction and reliability in harsh environments.

Performance:

High payload capacities, powerful engines, and efficient drivetrain systems for demanding work.

Operator Comfort:

Designed with operator comfort and safety in mind, featuring advanced cab suspension and ergonomic controls.

📋 Manual Details

Coverage Areas

Models Covered:

Komatsu HD325-6, HD405-6, HD465-5, HD605-5, HD785-5 Dump Trucks

Regions Of Operation:

Global (Specifications may vary by region)

Page Count

Estimated Page Count:

Over 1000 pages (Comprehensive, exact count varies by model and edition)

Manual Type

Type:

Official Factory Service and Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine, Transmission, Drive Axles, Differentials, Final Drives

Hydraulics:

Hoisting, Steering, Braking, Cooling Fan, Implement Hydraulics

Electrical:

Starting System, Charging System, Lighting, Instrumentation, Control Systems, ECSS (Electronically Controlled Suspension System)

Chassis And Frame:

Frame, Suspension (Front and Rear), Steering System Components

Braking System:

Service Brakes (Inboard, Wet-Disc), Parking Brake, Retarder System

Body And Cab:

Operator's Cab, Dump Body, Fenders, Guards

Cooling System:

Radiator, Fan, Hoses, Thermostat

Lubrication System:

Engine Oil System, Transmission Oil System, Axle Lubrication

Procedures Included

Maintenance:

Scheduled Maintenance, Lubrication Charts, Fluid Checks and Replacements, Filter Replacements

Disassembly And Assembly:

Complete component-level disassembly and reassembly procedures for all major systems.

Troubleshooting:

Diagnostic charts, common problems, symptom-based troubleshooting guides, error code interpretation.

Repair And Rebuild:

Detailed instructions for component repair, overhaul, and rebuilding of engines, transmissions, hydraulic pumps, cylinders, etc.

Technical Specifications:

Torque values, clearances, pressure settings, flow rates, electrical specifications.

Testing And Adjustment:

Procedures for testing and adjusting hydraulic systems, engine performance, braking systems, and electrical components.

Technical Depth

Depth:

Comprehensive from basic daily checks to complete engine and transmission overhauls.

Diagnostics Level:

Advanced diagnostic procedures including electrical schematics, hydraulic circuit diagrams, and fault finding trees.

Rebuild Level:

Detailed instructions for complete component rebuilds with specifications for wear limits and tolerances.

📊 Manual Specifications

File Format

Digital Format:

PDF (Portable Document Format)

Searchability:

Fully searchable text content for quick information retrieval.

Printability:

Printable pages for field use or workshop reference.

Print Quality

Image Resolution:

High-resolution diagrams and illustrations for clarity.

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine Hd325 6

Engine Model:

Komatsu SAA6D125E-2

Engine Type:

Turbocharged, Aftercooled, Direct Injection, Diesel

Displacement:

19.0 L (1159 cu. in.)

Gross Horsepower:

353 HP (263 kW) @ 2000 RPM

Net Horsepower:

330 HP (246 kW) @ 2000 RPM

Primary Engine Hd405 6

Engine Model:

Komatsu SAA6D140E-3

Engine Type:

Turbocharged, Aftercooled, Direct Injection, Diesel

Displacement:

23.1 L (1410 cu. in.)

Gross Horsepower:

473 HP (353 kW) @ 2000 RPM

Net Horsepower:

446 HP (333 kW) @ 2000 RPM

Primary Engine Hd465 5

Engine Model:

Komatsu SAA6D140E-3

Gross Horsepower:

523 HP (390 kW) @ 2000 RPM

Net Horsepower:

493 HP (368 kW) @ 2000 RPM

Primary Engine Hd605 5

Engine Model:

Komatsu SAA6D140E-3

Gross Horsepower:

523 HP (390 kW) @ 2000 RPM

Net Horsepower:

493 HP (368 kW) @ 2000 RPM

Primary Engine Hd785 5

Engine Model:

Komatsu SAA6D170E-3

Engine Type:

Turbocharged, Aftercooled, Direct Injection, Diesel

Displacement:

27.0 L (1647 cu. in.)

Gross Horsepower:

773 HP (576 kW) @ 2000 RPM

Net Horsepower:

738 HP (550 kW) @ 2000 RPM

Performance

Engine Management:

Electronically Controlled Engine Management System (ECM)

Fuel System

Fuel Type:

Diesel Fuel

Fuel Injection:

High-pressure Common Rail Fuel Injection System

Fluid Specifications

Engine Oil Grade:

API CJ-4 or ACEA E9 (Check specific model/year for exact specification)

Coolant Type:

Komatsu Super Coolant (Ethylene Glycol based) or equivalent with extended life additives

🔧 Transmission

Standard

Type:

Planetary Gear Type, Full Automatic, Komatsu Traction System (KTS)

Gears:

6 Forward / 1 Reverse (Varies by model)

Control:

Electronically Controlled Automatic Transmission

Optional

Availability:

N/A (Typically standard across these heavy-duty models)

Features

Shift Control:

Automatic gear selection based on load, speed, and grade

Retarder:

Integrated transmission retarder for downhill speed control

Fluid Specifications

Transmission Fluid Grade:

Komatsu Genuine TO-30, Allison TES 295, or equivalent (Consult manual for specific model requirements)

📐 Dimensions

Exterior Hd325 6

Length:

Approx. 9.98 m (32 ft 9 in)

Width:

Approx. 3.48 m (11 ft 5 in)

Height:

Approx. 3.93 m (12 ft 11 in)

Exterior Hd405 6

Length:

Approx. 10.56 m (34 ft 8 in)

Width:

Approx. 3.58 m (11 ft 9 in)

Height:

Approx. 4.05 m (13 ft 3 in)

Exterior Hd465 5

Length:

Approx. 10.56 m (34 ft 8 in)

Width:

Approx. 3.58 m (11 ft 9 in)

Height:

Approx. 4.05 m (13 ft 3 in)

Exterior Hd605 5

Length:

Approx. 10.56 m (34 ft 8 in)

Width:

Approx. 3.58 m (11 ft 9 in)

Height:

Approx. 4.05 m (13 ft 3 in)

Exterior Hd785 5

Length:

Approx. 11.32 m (37 ft 2 in)

Width:

Approx. 3.99 m (13 ft 1 in)

Height:

Approx. 4.18 m (13 ft 9 in)

Cargo Hd325 6

Payload Capacity:

32 Tonnes (35.3 US Ton)

Body Volume Heaped:

24.0 m³ (31.4 cu. yd.)

Cargo Hd405 6

Payload Capacity:

40 Tonnes (44.1 US Ton)

Body Volume Heaped:

28.0 m³ (36.6 cu. yd.)

Cargo Hd465 5

Payload Capacity:

45 Tonnes (49.6 US Ton)

Body Volume Heaped:

31.1 m³ (40.7 cu. yd.)

Cargo Hd605 5

Payload Capacity:

60 Tonnes (66.1 US Ton)

Body Volume Heaped:

40.3 m³ (52.7 cu. yd.)

Cargo Hd785 5

Payload Capacity:

77.5 Tonnes (85.4 US Ton)

Body Volume Heaped:

52.0 m³ (68.0 cu. yd.)

Weights Hd325 6

Operating Weight:

Approx. 24,000 kg (52,910 lb)

Weights Hd405 6

Operating Weight:

Approx. 32,000 kg (70,550 lb)

Weights Hd465 5

Operating Weight:

Approx. 36,000 kg (79,370 lb)

Weights Hd605 5

Operating Weight:

Approx. 45,000 kg (99,210 lb)

Weights Hd785 5

Operating Weight:

Approx. 65,000 kg (143,300 lb)

Weights

Front Axle Load:

Varies with payload and load distribution

Rear Axle Load:

Varies with payload and load distribution

Tire Size:

Commonly 29.5R25, 33.25R29, 37.00R33 (Varies by model and configuration)

Wheel Bolt Pattern:

Heavy-duty multi-piece wheel construction

🛡️ Safety Features

Ratings

Osha Compliance:

Designed to meet or exceed relevant safety standards for heavy equipment operation.

Active Features

Braking System:

Inboard, wet-disc brakes for superior stopping power and durability; integrated retarder.

Steering System:

Hydrostatic power steering for precise control.

Visibility:

Large cab windows, optional lighting packages, and mirror configurations for enhanced visibility.

Traction Control:

Komatsu Traction System (KTS) for improved traction on slippery surfaces.

Passive Features

Operator Cab:

ROPS (Roll-Over Protective Structure) and FOPS (Falling Object Protective Structure) certified cab.

Seat Belt:

Retractable seat belts.

Emergency Stop:

facilmente accessible emergency stop buttons.

Service Access:

Ground-level service access points and safety interlocks.

💡 Technology Features

Infotainment

Cab Features:

Focus is on operational efficiency and comfort, not traditional infotainment. Features include advanced operator displays and controls.

Driver Assistance

System Integration:

Integration of engine, transmission, and brake systems for optimized performance and safety.

Monitoring Systems:

Komatsu's advanced monitoring system (e.g., VHMS - Vehicle Health Monitoring System) provides real-time operational data and diagnostics.

Connectivity

Telematics:

Optional telematics systems for remote fleet management, tracking, and diagnostics.

🔧 Maintenance

Service Intervals

Daily Checks:

Engine oil level, coolant level, hydraulic oil level, brake fluid, tire pressure and condition, visual inspection for leaks and damage.

Engine Oil Change:

Typically every 250-500 operating hours, depending on operating conditions and oil analysis.

Engine Oil Filter Replacement:

Replace with every engine oil change.

Transmission Oil Change:

Typically every 1000-2000 operating hours, or as indicated by oil analysis.

Transmission Filter Replacement:

Replace with every transmission oil change.

Hydraulic Oil Filter Replacement:

Typically every 500-1000 operating hours.

Air Filter Element Replacement:

As needed, based on operating environment (indicated by air cleaner restriction indicator).

Fuel Filter Replacement:

Typically every 500 operating hours.

Fluid Specifications

Hydraulic Oil Grade:

Komatsu Genuine Hydraulic Oil, ISO VG 32 or VG 46 (Check specific model requirements)

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid (For any separate brake fluid reservoirs, if applicable)

Grease Type:

Komatsu Genuine Grease, or equivalent Lithium-based EP grease NLGI #2.

Fluid Capacities Hd325 6

Engine Oil Capacity:

Approx. 50 L (13.2 US gal)

Transmission Oil Capacity:

Approx. 68 L (17.9 US gal)

Hydraulic Oil Capacity:

Approx. 170 L (44.9 US gal)

Fluid Capacities Hd405 6

Engine Oil Capacity:

Approx. 75 L (19.8 US gal)

Transmission Oil Capacity:

Approx. 95 L (25.1 US gal)

Hydraulic Oil Capacity:

Approx. 260 L (68.7 US gal)

Known Issues

Common Wear Items:

Brake pads and discs (due to wet, multi-disc design), hydraulic hoses and seals, articulation joints, suspension components.

Common Electronic Faults:

Sensor failures (engine, transmission, hydraulic pressure), wiring harness issues, communication errors between ECUs.

Preventive Maintenance Importance:

Adherence to the service manual's recommended maintenance schedule is critical for preventing major failures and ensuring longevity.

📚 Vehicle History

Brand Heritage

Company Origin:

Komatsu Ltd. is a Japanese multinational corporation that manufactures construction, mining, and industrial machinery.

Reputation:

Renowned for producing durable, reliable, and high-performance heavy equipment.

Model Evolution

Dump Truck Lineup:

The HD series represents Komatsu's commitment to the articulated dump truck market, with continuous development in engine technology, drivetrain efficiency, and operator comfort over generations.

Series Designation:

The 'HD' designation stands for Heavy-Duty, and the numerical suffix generally indicates the nominal payload capacity (in tonnes).

Production

Manufacturing Locations:

Komatsu equipment is manufactured globally, with significant production facilities in Japan, the USA, and other regions.

Production Years:

The specific '5' and '6' designations indicate particular generations. For example, HD465-5, HD605-5, HD785-5 likely represent a common development period, while HD325-6 and HD405-6 represent a subsequent evolution, possibly incorporating updated emissions standards and features.

🏆 Awards & Recognition

Recognitions

Industry Accolades:

Komatsu equipment is consistently recognized for its durability, reliability, and productivity in the heavy-duty sector. Specific awards may be model or region-dependent and not always publicly documented for individual service manuals.

Ratings

Performance Benchmarks:

Highly competitive in benchmarks for fuel efficiency, payload hauling, and cycle times within their respective classes.

Certifications

Emissions Standards:

Models of this generation would have been developed to meet Tier II or Tier III emissions standards prevalent at the time of their release. Specific compliance may vary by region and model year.