Komatsu HD325-6/HD405-6 Dump Truck Manual (EN)

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GEN00020-00 (Replaces SEAW000301) Field Assembly Manual -6 -6 DUMP TRUCK SERIAL NUMBERS HD325-6 5680 and up HD405-6 1055 and up This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, revisions may be made to this publication.

It is recommended that customers contact their distributor for information on the latest revision. Copyright 2005 Komatsu Printed in U.S.A. Komatsu America Corp. January 2005

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CONTENTS

CONTENTS HD325-6/HD405-6 LIFTING UP CHASSIS ASSEMBLY ....................................................................................................... 2 INSTALLING FRONT AXLE ................................................................................................................... 4 INSTALLING FRONT TIRES .................................................................................................................. 6 INSTALLING REAR TIRES ..................................................................................................................... 8 INSTALLING RIGHT FRONT LIGHT ASSEMBLY................................................................................

10 INSTALLING GUARDS ........................................................................................................................ 12 INSTALLING CATWALK AND GUARD ............................................................................................... 14 ASSEMBLING RIGHT PLATFORM ...................................................................................................... 16 INSTALLING MIRRORS ....................................................................................................................... 18 INSTALLING BODY PINS ....................................................................................................................

20 ADJUSTING BODY SHIMS ................................................................................................................. 22 INSTALLING BODY ACCESSORIES ................................................................................................... 26 INSTALLING BODY GUARDS ............................................................................................................. 28 HD325-6 PREPARATION WORK ......................................................................................................................... 30 ASSEMBLY OF SPLIT BODY ...............................................................................................................

32 WELDING BODY .................................................................................................................................. 34 WELDING BODY PROTECTOR ........................................................................................................... 40 HD405-6 PREPARATION WORK ......................................................................................................................... 44 ASSEMBLY OF SPLIT BODY ...............................................................................................................

46 WELDING BODY .................................................................................................................................. 48 WELDING BODY PROTECTOR ........................................................................................................... 54 APPENDIX FIELD ASSEMBLY INSPECTION REPORT 1 HD325, 405-6

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LIFTING UP CHASSIS ASSEMBLY

3 HD325, 405-6 Order of work Work procedure 1. Prepare 2 cranes. 2. Install slings to the points shown in the fig- ure and lift up the chassis assembly. 3. Remove the stands 4. Lower the chassis assembly. • Work on a level and firm place. • Weight of chassis assembly: Approx. 18 tons When using mobile cranes • Front side: 45 tons • Rear side: 25 tons • Protect the front bumper. • Take care that the rear side will not interfere with the grease tubes, etc. • Secure the left front suspension cylinder with wires so that it will not be extended by its weight. • Place supports higher than 800 mm under the parts to which the stands were installed. (3 layers of a block 300 mm square, etc.)

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INSTALLING FRONT AXLE

5 HD325, 405-6 Order of work Work procedure 1. Remove each mounting pin from the frame. 2. Fix the suspension cylinder. 3. Secure the A-arm. 4. Secure the steering cylinder. 5. Secure the tie rod. 6. Connect the brake hose/suspension control hose (5 pieces). • Since different pins are used for different parts, classify them so that they will not be mixed up. • Observe the tightening torque shown in the figure. • Observe the tightening torque shown in the figure. • Check the numbering of the hose on the axle side and the block on the frame side. (1, 2, 3, 4, and 5 from the front end)

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