Komatsu HD325-6 (SN:05680-), HD325-6W (SN:05706-), HD405-6 (SN:01055-) Rigid Dump Trucks (Japan) Workshop Manual (SEBM015115)

Illustrated factory Workshop Manual for Komatsu Rigid Dump Trucks Models HD325-6, HD325-6W and HD405-6.

This manual will assist you in diagnosing, repairing, and adjusting for your rigid dump truck.
You can use a Windows, Mac, or Android device to view this manual. You only need to have a PDF reader installed.

Covered Models (Japan):
   HD325-6 (SN: 05680-)
   HD325-6W (SN: 05706-)
   HD405-6 (SN: 01055-)

Format: PDF, 1461 pages
Language: English
Table of Contents:
   SAFETY
   FOREWARD
      GENERAL
      HOW TO READ THE SHOP MANUAL
      HOISTING INSTRUCTIONS
      METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
      COATING MATERIALS
      STANDARD TIGHTENING TORQUE
      ELECTRIC WIRE CODE
      CONVERSION TABLE
      UNITS
   GENERAL
      GENERAL ASSEMBLY DRAWING
      SPECIFICATIONS
      WEIGHT TABLE
      LIST OF LUBRICANT AND WATER
   STRUCTURE AND FUNCTION
      RADIATOR, TORQUE CONVERTER, OIL COOLER, AFTER COOLER
      POWER TRAIN SKELETON
      OUTPUT SHAFT
      DRIVE SHAFT
      TORQUE CONVERTER, TRANSMISSION AND BRAKE COOLING HYDRAULIC PIPING
      HYDRAULIC CIRCUIT DIAGRAM FOR TORQUE CONVERTER, TRANSMISSION AND BRAKE COOLING
      TORQUE CONVERTER, TRANSMISSION AND BRAKE COOLING HYRDAULIC CIRCUIT SCHEMATICS
      TORQUE CONVERTER
      TORQUE CONVERTER VALVE
      LOCKUP SOLENOID VALVE
      TRANSMISSION
      TRANSMISSION VALVE
      ECMV (ELECTRONIC CONTROL MODULATION VALVE)
      FRONT AXLE
      REAR AXLE
      DIFFERENTIAL
      FINAL DRIVE
      FRONT BRAKE
      REAR BRAKE
      PARKING BRAKE
      WHEELS
      REAR AXLE SUPPORT
      STEERING SYSTEM
      STEERING WHEEL
      STEERING LINKAGE
      SUSPENSION SYSTEM
      SUSPENSION CYLINDER
      AIR PIPING
      AIR CIRCUIT DIAGRAM
      AIR GOVERNOR
      AIR DRYER
      SAFETY VALVE
      CHECK VALVE
      DOUBLE CHECK VALVE
      HAND BRAKE VALVE
      BRAKE VALVE
      EMERGENCY BRAKE CONTROL VALVE
      PARKING BRAKE CONTROL VALVE
      RELAY VALVE
      PARKING BRAKE RELAY VALVE
      FRONT BRAKE CHAMBER
      REAR BRAKE CHAMBER
      PARKING BRAKE CHAMBER
      SLACK ADJUSTER
      FRONT DRIVE HYDRAULIC CIRCUIT DIAGRAM
      FRONT DRIVE PISTON PUMP
      FRONT DRIVE PISTON MOTOR
      CHARGE PUMP OIL FILTER
      HYDRAULIC PIPING
      HYDRAULIC CIRCUIT DIAGRAM
      HYDRAULIC CIRCUIT SCHEMATICS
      DUMP BODY CONTROL
      HYDRAULIC TANK, FILTER
      DEMAND VALVE
      STEERING CONTROL VALVE
      CROSS-OVER RELIEF VALVE
      HOIST VALVE
      DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB
      DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB
      FRONT BRAKE CUT-OFF VALVE
      OVERRUN PREVENTION VALVE
      EXHAUST BRAKE VALVE
      HORN VALVE
      WIPER SWITCH
      WIPER RELAY
      AIR CONDITIONER
      ENGINE CONTROL SYSTEM
      EXHAUST BRAKE
      AUTOMATIC RETARD SPEED CONTROL SYSTEM (OP)
      AUTOMATIC SHIFT CONTROL SYSTEM
      AUTOMATIC EMERGENCY STEERING SYTEM
      AUTOMATIC SUSPENSION SYSTEM
      PAYLOAD METER (PRINTER TYPE)
      ELECTRICAL CIRCUIT DIAGRAM
      PRINCIPLE OF CALCULATION
      FEATURES OF EQUIPMENT
      PAYLOAD METER II (CARD TYPE)
      MACHINE MONITOR SYSTEM
      OIL FILTER CAUTION SYSTEM (IF EQUIPPED)
      FRONT DRIVE SYSTEM
      WHEEL DRIVE CONTROLLER
      ECMV
      SENSORS, SWITCHES
   TESTING AND ADJUSTING
      STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
      STANDARD VALUE TABLE FOR CHASSIS
      STANDARD VALUE TABLE FOR ELECTRICAL PARTS
      TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
      ADJUSTING VALVE CLEARANCE
      MEASURING COMPRESSION PRESSURE
      MEASURING BLOW-BY
      ADJUSTING ALTERNATOR BELT TENSION
      ADJUSTING FAN BELT TENSION
      MEASURING ENGINE SPEED
      MEASURING ENGINE OIL PRESSURE
      MEASURING BOOST PRESSURE
      MEASURING EXHAUST TEMPERATURE
      MEASURING EXHAUST GAS COLOR
      TESTING AND ADJUSTING FUEL INJECTION TIMING
      AIR BLEEDING FROM FUEL SYSTEM
      CHECKING FOR LEAKAGE IN FUEL SYSTEM
      MEASURING FUEL PRESSURE
      REALEASING REMAINING PRESSURE IN FUEL SYSTEM
      HANDLING EQUIPMENT IN FUEL CIRCUIT
      REDUCED CYLINDER MODE OPERATION
      HANDLING OF ENGINE CONTROLLER HIGH CONTROLLER HIGH TENSION CIRCUIT
      ADJUSTING ENGINE STOP MOTOR CABLE
      ADJUSTING ACCELERATOR PEDAL
      ADJUSTING ENGINE SPEED SENSOR
      ADJUSTING TRANSMISSION SPEED SENSOR
      TESTING HYDRAULIC PRESSURE OF TORQUE CONVERTER VALVE
      TESTING ECMV OIL PRESSURE
      TESTING TORQUE CONVERTER STALL SPEED
      TESTING BRAKE PRESSURE
      BLEEDING AIR FROM BRAKE CIRCUIT
      TESTING AND ADJUSTING PARKING BRAKE PERFORMANCE
      TESTING WEAR OF FRONT BRAKE PAD
      TESTING WEAR OF FRONT BRAKE DISC
      TESTING WEAR OF REAR BRAKE DISC
      TESTING REAR BRAKE CAUTION SYSTEM
      TESTING AND ADJUSTING SUSPENSION CYLINDER
      TESTING AND ADJUSTING SET PRESSURE OF AIR GOVERNOR
      ADJUSTING HOIST LEVER LINKAGE
      ADJUSTING BODY POSITIONER
      TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING, HOIST CIRCUIT
      AIR BLEEDING FROM STEERING CYLINDER
      BLEEDING AIR FROM FRONT DRIVE HYDAULIC CIRCUIT
      ADJUSTING ELECTRONIC MONITOR
      SETTING ROTARY SWITCH
      METHOD OF DELETING DATA FROM TRANSMISSION CONTROLLER MEMORY
      METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM
      PM CLINIC CHECK SHEET
      TROUBLESHOOTING
   DISASSEMBLY AND ASSEMBLY
      METHOD OF USING MANUAL
      PRECAUTIONS WHEN CARRYING OUT OPERATION
      SPECIAL TOOL LIST
      SKETCHES OF SPECIAL TOOLS
      STARTING MOTOR
      ALTERNATOR
      ENGINE OIL COOLER
      FUEL INJECTION PUMP ASSEMBLY
      FUEL SUPPLY PUMP
      AIR COMPRESSOR
      AIR CONDITIONER COMPRESSOR
      AIR CONDITIONER CONDENSER
      WATER PUMP
      AFTERCOOLER
      EXHAUST BRAKE CYLINDER
      TURBOCHARGER
      NOZZLE HOLDER
      FUEL INJECTOR
      CYLINDER HEAD
      ENGINE
      RADIATOR, TORQUE CONVERTER OIL COOLER
      RADIATOR, FRONT DRIVE COOLER (HD325-6W)
      FRONT DRIVE OIL COOLER (HD325-6W)
      OUTPUT SHAFT
      TORQUE CONVERTER, TRANSMISSION (HD325-6, 405-6)
      TORQUE CONVERTER, TRANSMISSION (HD325-6W)
      TORQUE CONVERTER VALVE
      TORQUE CONVERTER, TRANSMISSION
      TORQUE CONVERTER
      PTO (HD325, 405-6)
      PTO (HD325-6W)
      TRANSMISSION
      TRANSMISSION CONTROL VALVE (ECMV ASSEMBLY)
      DIFFERENTIAL
      DIFFERENTIAL GEAR
      FRONT WHEEL (HD325, 405-6)
      FRONT WHEEL (HD325-6W)
      REAR WHEEL
      FRONT BRAKE CALIPER PAD
      FRONT BRAKE CALIPER
      FRONT WHEEL HUB
      FRONT FINAL DRIVE CLUTCH, CARRIER (HD325-6W)
      FRONT FINAL DRIVE, BRAKE (HD325-6W)
      FRONT DRIVE SHAFT (HD325-6W)
      REAR FINAL DRIVE CARRIER
      REAR FINAL DRIVE
      REAR BRAKE
      PARKING BRAKE PAD
      PARKING BRAKE CALIPER
      FRONT SUSPENSION CYLINDER (HD325, 405-6)
      FRONT SUSPENSION CYLINDER (HD325-6W)
      VARIABLE DAMPING SELECTOR VALVE
      REAR SUSPENSION
      AIR GOVERNOR
      BRAKE VALVE
      PARKING BRAKE CHAMBER
      FRONT BRAKE CHAMBER (HD325, 405-60
      REAR BRAKE CHAMBER
      FRONT BRAKE CHAMBER
      REAR BRAKE CHAMBER
      SLACK ADJUSTER
      TRANSMISSION LUBRICATION, RETARDER BRAKE PUMP (HD325, 405-6)
      TRANSMISSION LUBRICATION, RETARDER BRAKE PUMP (HD325-6W)
      BRAKE COOLING PUMP (HD325, HD405-6)
      BRAKE COOLING PUMP (HD325-6W)
      HOIST, STEERING PUMP
      FRONT DRIVE PUMP (HD325-6W)
      EMERGENCY STEERING MOTOR PUMP
      TRAVEL DRIVE MOTOR (HD325-6W)
      TRAVEL MOTOR (HD325-6W)
      STEERING VALVE
      DEMAND VALVE
      RELIEF VALVE
      HOIST VALVE
      STEERING CYLINDER
      HOIST CYLINDER
      BODY ASSEMBLY
      TRANSMISSION CONTROLLER
      SUSPENSION CONTROLLER
      FRONT DRIVE CONTROLLER
   MAINTENANCE STANDARD
      OUTPUT SHAFT
      TORQUE CONVERTER VALVE
      TORQUE CONVERTER
      TRANSMISSION
      ECMV (ELECTRONIC CONTROL MODULATION VALVE)
      FRONT AXLE
      DIFFERENTIAL
      FINAL DRIVE (REAR)
      FINAL DRIVE (FRONT) HD325-6W
      FRONT BRAKE (HD325-6, 405-6)
      FRONT BRAKE (HD325-6W)
      REAR BRAKE
      PARKING BRAKE
      REAR AXLE SUPPORT
      STEERING LINKAGE
      FRONT SUSPENSION CYLINDER
      REAR SUSPENSION CYLINDER
      PARKING BRAKE CHAMBER
      SLACK ADJUSTER
      HYDRAULIC PUMP
      DEMAND VALVE
      CROSS-OVER RELIEF VALVE
      HOIST VALVE
      STEERING CYLINDER
      HOIST CYLIN