🏷️ Basic Information Identification Make: Komatsu Model: HD325-7 / HD405-7 Dump Truck Product Name: Komatsu HD325-7 HD405-7 DUMP Truck Service Repair Manual + Field Assembly INSTRUCTION + Operation & Maintenance Manual 👋 Introduction Market Position Vehicle Segment: Heavy-duty off-highway mining/construction dump trucks Komatsu Role: Komatsu is a leading global manufacturer of construction and mining equipment, known for robust and reliable machinery. Competitive Analysis Key Competitors: Caterpillar (e.g., 730C, 735), Volvo CE (e.g., A35F/G/H), Bell Equipment, John Deere (for articulated dump trucks, though HD325-7/HD405-7 are rigid) Key Features Vehicle Capabilities: Designed for hauling large payloads in demanding off-highway environments, known for durability, productivity, and operator comfort. 📋 Manual Details Coverage Areas Manual Type 1: Service Repair Manual Manual Type 2: Field Assembly Instruction Manual Type 3: Operation & Maintenance Manual Page Count Estimated Total Pages: Comprehensive (specific page count not provided, but indicated by three distinct manuals) Language Language: English (typical for Komatsu technical documentation) Format Format: Digital (likely PDF, common for modern service manuals) 📖 Manual Coverage Systems Covered Engine Systems: Engine overhaul, fuel system, cooling system, lubrication system, intake and exhaust systems, engine control unit (ECU) diagnostics and repair Powertrain Systems: Transmission overhaul (power shift, manual), torque converter, drive shafts, differentials, final drives, axle assemblies Chassis And Suspension: Frame inspection and repair, front and rear suspension systems, steering system (hydraulic power steering, components), lubrication points Braking Systems: Service brake system (wet disc brakes), parking brake system, retarder system (engine brake/exhaust brake), hydraulic brake system components and troubleshooting Hydraulic Systems: Hoist hydraulic system (dump body lift), steering hydraulic system, brake hydraulic system, hydraulic pump, control valves, cylinders, hydraulic fluid specifications and maintenance Electrical And Electronic Systems: Starter system, charging system (alternator, batteries), lighting system, instrument panel and gauges, diagnostic trouble codes (DTCs), sensor and actuator testing, electrical schematics Operator Station: Cabin components, seating, controls, HVAC system (heating, ventilation, and air conditioning), operator interface (monitors, switches) Body And Chassis Components: Dump body (construction, hydraulics, latching mechanism), fenders, guards, access panels Procedures Included Maintenance Procedures: Daily checks, weekly checks, monthly checks, scheduled maintenance tasks, lubrication, filter replacement, fluid level checks and replenishment Repair Procedures: Detailed step-by-step instructions for component disassembly, repair, and reassembly for all covered systems Troubleshooting Procedures: Systematic diagnostic flowcharts, symptom-based troubleshooting, fault code interpretation, component testing procedures Assembly Procedures: Field assembly instructions for new units, component installation sequences, alignment procedures, pre-operational checks Adjustment Procedures: Brake adjustments, steering system adjustments, clutch adjustments (if applicable), linkage adjustments Diagnostic Procedures: Use of diagnostic tools, reading sensor data, actuator testing, electrical system diagnostics Technical Depth Depth Level: Comprehensive (covers everything from routine maintenance to major overhauls and diagnostics) Diagnostic Capability: Advanced, including electronic diagnostics and troubleshooting of complex systems Rebuild Instructions: Detailed specifications and procedures for complete engine, transmission, and hydraulic system rebuilds 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) with searchable text and selectable pages Print Quality Image Resolution: High-resolution diagrams, illustrations, and photographs suitable for printing Binding Type Binding Method: N/A (Digital format, printable as needed) Paper Type Recommended Paper: N/A (Digital format, printable on standard or heavy-duty paper) ⚙️ Engine Specifications Primary Engine Engine Model Hd325-7: Komatsu SAA6D125E-5 (Tier III compliant) Engine Model Hd405-7: Komatsu SAA6D140E-5 (Tier III compliant) Performance Gross Power Hd325-7: 277 kW (371 HP) @ 2000 rpm Gross Power Hd405-7: 313 kW (420 HP) @ 2000 rpm Peak Torque Hd325-7: 1595 Nm (1176 lb-ft) @ 1400 rpm Peak Torque Hd405-7: 1843 Nm (1360 lb-ft) @ 1400 rpm Fuel System Fuel System Type: Common Rail Electronic Fuel Injection Displacement Hd325-7: 11.04 L (673 cu in) Displacement Hd405-7: 14.2 L (867 cu in) 🔧 Transmission Standard Transmission Type: Komatsu Advanced Transmission with Automatic Shift (K-ATOMiCS) - Planetary Power Shift Features Transmission Gears: 7 forward speeds, 1 reverse speed (for HD325-7); 6 forward speeds, 1 reverse speed (for HD405-7, typical, may vary with sub-model) Torque Converter: Lock-up type torque converter for improved fuel efficiency and direct drive feel 📐 Dimensions Exterior Length Hd325-7: Approx. 8,760 mm (345 in) Width Hd325-7: Approx. 3,220 mm (127 in) Height Hd325-7: Approx. 3,740 mm (147 in) (to top of cab) Length Hd405-7: Approx. 9,595 mm (378 in) Width Hd405-7: Approx. 3,310 mm (130 in) Height Hd405-7: Approx. 3,745 mm (147 in) (to top of cab) Cargo Rated Payload Hd325-7: 20.5 metric tons (22.6 US tons) Body Capacity Heaped Hd325-7: 12.5 m³ (16.3 cu yd) Rated Payload Hd405-7: 25 metric tons (27.6 US tons) Body Capacity Heaped Hd405-7: 15.3 m³ (20.0 cu yd) Weights Operating Weight Hd325-7: Approx. 20,970 kg (46,230 lb) Operating Weight Hd405-7: Approx. 24,000 kg (52,910 lb) Tire Size Standard: e.g., 12.00R24-20PR (HD325-7), 14.00R24-20PR (HD405-7) - may vary by application 🛡️ Safety Features Ratings Safety Standards: Designed to meet relevant industry safety standards for heavy construction equipment. Active Features Braking System: Full hydraulic, enclosed wet multiple-disc brakes on...