This comprehensive manual provides in-depth information essential for maintaining, assembling, disassembling, and servicing your Komatsu HD325-6 and HD405-6 dump trucks. It empowers you to achieve peak performance through effective, economical, and safe machine operation and maintenance.

The manual consists of three distinct sections: a Service Repair Manual, a Field Assembly Manual, and an Operation & Maintenance Manual. The Service Repair Manual contains detailed specifications, diagrams, and real-life photo illustrations, guiding you through every step of repair, servicing, maintenance, and troubleshooting procedures. This manual equips you to effectively identify issues and understand how to repair and maintain your machine independently.

The Operation & Maintenance Manual clearly outlines procedures for operation, handling, lubrication, maintenance, checking, and adjustments. It serves as an invaluable resource for operators and maintenance personnel, ensuring optimal performance, economic operation, and safety.

The Field Assembly Manual provides a comprehensive guide for the safe and effective assembly of your Komatsu HD325-6 and HD405-6 dump trucks. This section includes step-by-step assembly procedures, parts installation instructions, adjustment guidelines, and post-assembly maintenance procedures.

This manual covers a wide range of topics, including:

**Service Repair Manual:**

* General information
* Structure and Function
* Testing and Adjusting
* Disassembly and Assembly
* Maintenance Standards
* Additional Information

**Operation & Maintenance Manual:**

* Safety Information
* Intended Use
* Location of Plates and Serial Number Tables
* Safety Labels
* General Precautions
* Operation Precautions
* Maintenance Precautions
* Tire Precautions
* General View
* Component explanations
* Operation Procedures
* Determining and Maintaining Travel Road
* Transportation
* Cold Weather Operation
* Long-Term Storage
* Troubleshooting
* Maintenance Guides
* Service Outlines
* Wear Parts
* Fuel, Coolant, and Lubricant Recommendations
* Standard Tightening Torques
* Replacement Schedule for Safety Critical Parts
* Maintenance Schedule Chart
* Service Procedures
* Specifications
* Options and Attachments
* Payload Meter Handling
* Dump Body Selection
* Tachograph (TCO 15-6)
* Revo Tachograph (TCO 15-7)
* Differential Lock Operation
* ABS and ABS/ASR Operation
* Auto-Greasing System Handling
* ARSC (Automatic Retarder Speed Control)
* ASR-II (Automatic Spin Regulator II)
* Oil Filter Precautions
* Index

**Field Assembly Manual:**

* Lifting up the Chassis Assembly
* Installing the Front Axle
* Installing Front Tires
* Installing Rear Tires
* Installing Right Front Light Assembly
* Installing Guards
* Installing Catwalk and Guard
* Assembling Right Platform
* Installing Mirrors
* Installing Body Pins
* Adjusting Body Shims
* Installing Body Accessories
* Installing Body Guards
* HD325-6 Preparation Work
* Split Body Assembly
* Body Welding
* Body Protector Welding
* HD405-6 Preparation Work
* Split Body Assembly
* Body Welding
* Body Protector Welding
* Appendix: Field Assembly Inspection Report

This manual is a valuable resource for anyone looking to maintain, repair, or assemble a Komatsu HD325-6 or HD405-6 dump truck. Its comprehensive coverage, detailed illustrations, and step-by-step instructions make it an essential tool for achieving peak performance and maximizing the life of your equipment.

The Komatsu HD325-6 and HD405-6 are heavy-duty rigid frame dump trucks designed for demanding off-road applications in mining, quarrying, and construction. These models are recognized for their robust construction, high payload capacity, and powerful engine performance. The HD325-6 boasts a payload capacity of 120 tons (109 US tons), while the HD405-6 boasts a payload capacity of 140 tons (127 US tons). Both models are powered by Komatsu's highly efficient and durable SAA6D170E-6 engine, delivering high torque and horsepower while meeting stringent emissions standards. The trucks are equipped with robust drivetrains, featuring heavy-duty axles and transmissions designed for smooth operation and long service life. Their ergonomic operator cabins provide a comfortable and productive working environment, featuring intuitive controls and excellent visibility.

These rigid dump trucks are built with a focus on safety and operator comfort. The HD325-6 and HD405-6 are equipped with advanced safety features including automatic braking systems, stability control, and a comprehensive warning system. The trucks also feature a comfortable and spacious cabin with a well-designed operator seat and ample legroom. The intuitive control layout and easy-to-read instrument panel enhance operational efficiency and reduce operator fatigue. The robust construction and durable components ensure long-term performance and minimize downtime. The Komatsu HD325-6 and HD405-6 are renowned for their reliability and productivity, making them indispensable assets in demanding off-road environments. They are designed to withstand the toughest challenges and deliver consistent performance over long working cycles.