Komatsu HD325-6, HD325-6W & HD405-6 Dump Truck 2001 Shop Manual (P/N SEBM015108)

Komatsu shop manual SEBM015108, February 2001 print, covers the HD325-6 (2WD), HD325-6W (4WD), and HD405-6 off-highway dump trucks. It contains chassis specifications, structure and function, testing and adjusting, disassembly and assembly, maintenance standards, and circuit diagrams.

PDF Search, Bookmarks and Diagram Limitations

Search and diagram access: Text search works through most chapters, but the section 90 electrical sheets are not searchable. Embedded bookmarks cover the main sections; some later-serial diagram links open a missing-foldouts notice. Small wiring labels require zooming. Two enlarged diagram views, PDF pages 1292 and 1315, are partly unreadable because their images are damaged; the corresponding overview sheets remain available.

The ZIP download contains one printable PDF with 1,320 pages, including one cover page, six revision-list pages, one missing-foldouts notice, and one revision-proposal form. These pages are already included in the total.

Powertrain, Brake and Hydraulic Workshop Procedures

These selected contents outline the main workshop coverage rather than reproduce the full contents list. Further topics include air-dryer operation and electrical wire-color codes.

• Powertrain repair: Torque converter and transmission removal, separation, overhaul and reassembly, ECMV service, clutch-pressure testing, and torque-converter stall testing.

• Axles and final drives: Standard and differential-lock assembly procedures, rear final-drive overhaul, and HD325-6W front final-drive clutch, carrier, brake, and shaft service.

• Brake service: Front and rear brake work, parking-brake caliper and chamber repair, slack-adjuster service, pressure testing, wear checks, and circuit bleeding.

• Steering and hoist hydraulics: Pump, valve, and cylinder repair, hydraulic pressure testing, steering-cylinder bleeding, and dump-body removal and installation.

• Suspension service: Front and rear cylinder removal, disassembly and assembly, nitrogen charging and adjustment, and variable damping selector valve service.

• Electrical diagnosis: Connector locations, pin tables, service codes, controller self-diagnostics, and troubleshooting for transmission, suspension, payload meters, monitor systems, and optional ABS/ASR equipment.

Written for service personnel carrying out workshop repairs, this manual covers work requiring the specified lifting equipment, fixtures, and test instruments.

Engine Work and Serial-Specific Coverage

Engine procedures include valve-clearance adjustment, compression and blow-by measurement, and boost and oil-pressure checks. Earlier SAA6D140E-2 machines have fuel-injection timing procedures; later SAA6D140E-3 machines have common-rail fuel-system checks, low-pressure fuel measurement, and reduced-cylinder diagnostic operation.

The removal and installation section covers the injection pump, turbocharger, nozzle holders, cylinder head, and complete engine assembly for the applicable configuration.

For detailed internal engine overhaul information, Komatsu directs the reader to the separate 6D140-2 or 140-3 Series Engine Shop Manual. Those engine manuals are not included.

Drivetrain and HD325-6W Front Drive

Step-by-step procedures cover the output-shaft/flywheel connection, torque converter, wet lock-up clutch, transmission, and ECMV (Electronic Control Modulation Valve). Differential procedures distinguish standard assemblies from units with differential lock.

The HD325-6W has dedicated coverage for its front-drive piston pump and motor, front final-drive clutch/carrier, front drive shaft, and travel motor. Control-system material explains the front-drive ECMV, 4-wheel-drive controller, steering-angle sensor, high-pressure oil-pressure sensor, clutch-pressure sensor, and wheel-speed sensor.

Forcing the torque converter into the transmission can damage its seal ring, while final-drive and brake procedures identify holding-tool precautions needed to protect floating seals.

Suspension Controls and Fault Isolation

The automatic suspension section explains Soft, Medium, and Hard damping modes and the controller and sensor logic used to select them.

Troubleshooting chapters address engine, transmission, suspension, payload meter printer/card systems, automatic retarder speed control, hydraulic/mechanical systems, the monitor panel, and the later electronic engine controller. Optional ABS/ASR coverage includes ECU self-diagnosis, fault-memory clearing, and system-checker sheets.

Problem/cause charts and connector tests support fault isolation before components are disassembled. Replacement transmission-controller procedures also explain how model and network settings must match the machine.

After steering-cylinder or piping repair, trapped air can damage the piston seal through compression and combustion; the manual provides a specific bleeding procedure.

Circuit Diagrams and Missing Foldouts

Diagram coverage includes the torque-converter/transmission/brake-cooling hydraulic circuit, HD325-6W front-drive hydraulic circuit, air circuit, earlier-serial inside- and outside-cab wiring, automatic suspension system circuit, and A/C refrigerant circuit.

Later-serial foldout limitation: Several section 90 sheets listed for HD325-6/HD325-6W serial 6001 and up and HD405-6 serial 2001 and up are absent. These include cab wiring, automatic shift, automatic suspension, payload-meter, and additional transmission-controller foldouts. Related system descriptions and troubleshooting diagrams remain included.

Tools, Inspection Standards and Workshop Preparation

Tool references identify the 799-203-8001 multi-tachometer and 799-101-5002 hydraulic tester. Suspension equipment includes the 792-610-1100 pump/joint kit and 792-610-1200 gas-charge kit; transmission clutch-pressure equipment includes assemblies 792-415-1200 and 792-415-1100.

Output-shaft work lists the 790-101-2102 puller with the 790-101-1102 30-ton pump. Dimensioned special-tool sketches accompany the tool lists.

Maintenance-standard tables give inspection and repair limits for dismantled components. General reference tables cover tightening torques for metric fasteners, flared nuts, split-flange bolts, and O-ring boss joints.

For work around a raised dump body, pressurized steering/hoist circuits, suspension cylinders, brake systems, or the later common-rail fuel circuit, follow the manual's machine-support, pressure-release, and electrical-isolation precautions before starting hands-on repair.

Selected Adjustment and Capacity Data

Engine adjustment: At normal temperature, SAA6D140E-2 valve clearances are 0.43 mm intake and 0.80 mm exhaust. SAA6D140E-3 values are 0.35 mm intake and 0.57 mm exhaust.

Serial-specific fluid data: Earlier machines list 41 L specified/37 L refill for the engine oil pan and 106 L specified for the cooling system. Later machines list 56 L specified/52 L refill and 89 L specified/89 L refill, respectively. Brake-cooling gear-pump delivery is listed as 472 L/min for the earlier group and 450 L/min at 2,000 rpm for the later group.

Chassis capacities: Specified capacities include 195 L for the transmission case, including the front-drive case where applicable; 165 L for the hydraulic tank; 50 L for the differential case; and 17 L per final drive. The fluid tables distinguish specified capacity from routine service refill quantity.

Pressure-test examples: With oil at 60–80°C, torque-converter main relief pressure is 3.285 ± 0.14 MPa at low idle and 3.58 ± 0.15 MPa at high idle. The steering table lists 19.61 MPa (+0.49/−0.39) at full throttle with oil at 45–55°C. Hoist relief pressure is 20.59 ± 0.49 MPa at full throttle with oil at 45–55°C, measured at the end of the body-raising stroke.