Komatsu HD325-7, HD405-7 Dump Truck Operation and Maintenance Manual (EEAM030600)
These HD325-7 and HD405-7 trucks live in hard haul-road work—quarries, mines, and heavy construction—running loaded most of the day. This Operation and Maintenance Manual is what I use to set up a sane service rhythm, so the truck is ready when the shift starts and doesn’t surprise you mid-haul. For example, if a driver reports sluggish pulling on grades and higher fuel burn, I’ll go back to this book to verify the basic checks and scheduled inspections before I start chasing more complicated faults.
Applications & Use Cases
- Plan preventive maintenance so filters, joints, and key wear points are inspected before they become breakdowns.
- Set up daily and weekly walk-arounds for operators, focusing on leaks, loose hardware, tire condition, and abnormal noises.
- Trace early signs of drivetrain or brake issues by following the recommended inspection order instead of guessing.
- Align service timing across a fleet, so multiple trucks come in together for planned downtime.
- Verify operating practices—idling, warm-up, and shutdown—so operators don’t shorten component life.
FAQ
Q: Can I keep this manual on a tablet in the service truck?
A: Yes, it’s well-suited to digital use; you can zoom diagrams and search terms while you’re parked beside the machine.
Q: Is it worth printing parts of it?
A: I’d print the daily checks and key service routines, laminate them, and keep them in the cab and workshop.
Safety Note
Always lock out, tag out, and secure the truck on level ground before performing any inspection or service.
📘 Show Index
Komatsu HD325-7, HD405-7 Dump Truck Index:
- FOREWORD
- BEFORE READING THIS MANUAL
- SAFETY INFORMATION
- Noise emission levels
- Vibration levels
- INTENDED USE
- USE OF MACHINE
- DIRECTIONS OF MACHINE
- VISIBILITY FROM OPERATOR’S SEAT
- LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
- PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE
- EPA REGULATIONS, ENGINE NUMBER PLATE
- SERVICE METER POSITION
- TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
- MACHINE SERIAL NUMBER PLATE (according directive 2006/42/EC)
- Declaration according Directive 2006/42/EC Annex I point 1.7.4.2 (c)
- FOREWORD
- SAFETY
- OPERATION
- MAINTENANCE
- SPECIFICATIONS
- ATTACHMENTS, OPTIONS
- INDEX
- COLOPHON
- SAFETY
- SAFETY
- SAFETY LABELS
- POSITION FOR ATTACHING SAFETY LABELS
- SAFETY LABELS
- GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE
- PRECAUTIONS BEFORE STARTING OPERATION
- PREPARATIONS FOR SAFE OPERATION
- FIRE PREVENTION
- PRECAUTIONS WHEN GETTING ON OR OFF MACHINE
- DO NOT GET CAUGHT IN DUMP BODY
- PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES
- UNAUTHORIZED MODIFICATION
- PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS
- PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING
- PRECAUTIONS FOR OPERATION
- PRECAUTIONS FOR JOBSITE
- STARTING ENGINE
- OPERATION
- TRANSPORTATION
- TOWING
- PRECAUTIONS FOR MAINTENANCE
- PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE
- PRECAUTIONS FOR INSPECTION AND MAINTENANCE
- TIRES
- DISMANTLING THE MACHINE END OF SERVICE LIVE
- OPERATION
- GENERAL VIEW
- GENERAL VIEW OF MACHINE
- GENERAL VIEW OF CONTROLS AND GAUGES
- EXPLANATION OF COMPONENTS
- MACHINE MONITOR
- OTHER FUNCTIONS OF MACHINE MONITOR
- SWITCHES
- CONTROL LEVERS AND PEDALS
- BODY PIVOT PIN
- LOCATION OF FIRE EXTINGUISHER
- DUST INDICATOR
- BATTERY DISCONNECT SWITCH
- FUSES
- POWER SOURCE
- RELAY LOCATIONS
- CAR RADIO
- CAR STEREO
- AIR CONDITIONER
- OPERATION
- CHECK BEFORE STARTING ENGINE
- STARTING ENGINE
- OPERATIONS, CHECKS AFTER STARTING ENGINE
- STOPPING ENGINE
- CHECKS AFTER STOPPING ENGINE
- MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING
- SHIFTING GEAR
- TRAVELLING DOWNHILL
- STEERING THE MACHINE
- LOADING OPERATIONS
- DUMP OPERATIONS
- PRECAUTIONS FOR OPERATION
- PARKING MACHINE
- CHECKS AFTER COMPLETION OF WORK
- LOCKING
- HANDLING TIRES
- DETERMINING AND MAINTAINING TRAVEL ROAD
- DETERMINING TRAVEL ROAD
- MAINTAINING TRAVEL ROAD
- TRANSPORTATION
- PRECAUTIONS WHEN TRANSPORTING
- STEPS FOR TRANSPORTATION
- METHOD OF SECURING MACHINE
- METHOD OF LIFTING MACHINE
- COLD WEATHER OPERATION
- PRECAUTIONS FOR LOW TEMPERATURE
- PRECAUTIONS AFTER COMPLETION OF WORK
- AFTER COLD WEATHER
- LONG-TERM STORAGE
- BEFORE STORAGE
- DURING STORAGE
- AFTER STORAGE
- PRECAUTIONS BEFORE TRAVELLING AFTER LONG-TERM STORAGE
- TROUBLESHOOTING
- AFTER RUNNING OUT OF FUEL
- IF TRANSMISSION HAS TROUBLE
- METHOD OF LOWERING DUMP BODY IN EMERGENCY
- METHOD OF TOWING MACHINE
- IF BATTERY IS DISCHARGED
- OTHER TROUBLE
- MAINTENANCE
- GUIDES TO MAINTENANCE
- OUTLINE OF SERVICE
- HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC
- OUTLINE OF ELECTRIC SYSTEM
- WEAR PARTS
- RECOMMENDED FUEL, COOLANT, AND LUBRICANT
- USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
- RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL
- STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
- PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
- MAINTENANCE SCHEDULE CHART
- MAINTENANCE SCHEDULE CHART
- EXPLANATION OF LUBRICATION CHART DECAL
- SERVICE PROCEDURE
- INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)
- WHEN REQUIRED
- CHECK BEFORE STARTING
- EVERY 250 HOURS SERVICE
- EVERY 500 HOURS SERVICE
- EVERY 1000 HOURS SERVICE
- EVERY 2000 HOURS SERVICE
- EVERY 4000 HOURS SERVICE
- EVERY 8000 HOURS SERVICE
- EVERY 15000 HOURS SERVICE
- SPECIFICATIONS
- ATTACHMENTS, OPTIONS
- SELECTING DUMP BODY
- HANDLING AIR SUSPENSION SEAT
- SEAT ADJUSTMENT
- REMOVAL AND INSTALLATION OF HEADREST
- HANDLING AUTOMATIC SPIN REGULATOR (ASR)
- EXPLANATION OF COMPONENTS
- ACTUATION OF ASR SYSTEM
- PRECAUTIONS WHEN USING
- BLEEDING AIR FROM ASR CIRCUIT
- HANDLING ABS
- EXPLANATION OF COMPONENTS
- ABS SYSTEM CHECK AFTER STARTING ENGINE
- OPERATION OF ABS
- PRECAUTIONS WHEN USING
- HANDLING PAYLOAD METER II (CARD TYPE)
- METHOD OF USING ACCURATELY
- GENERAL LOCATIONS
- CONTENT OF DISPLAY (CONTROLLER, EXTERNAL DISPLAY LAMPS)
- EXTERNAL DISPLAY LAMPS
- DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER
- OPERATION OF SWITCHES
- PROBLEM AND WARNING DISPLAY (ERROR CODE)
- WHEN ERROR CODE F-09 IS DISPLAYED (PROCEDURE FOR REPLACING BATTERY)
- OPERATION WHEN ERROR CODE F.CAL IS DISPLAYED OR CONTROLLER HAS BEEN REPLACED
- ARSC (AUTOMATIC RETARDER SPEED CONTROL)
- EXPLANATION OF COMPONENTS
- METHOD OF OPERATION
- USE OF REAR VIEW MONITOR
- NAME AND FUNCTION OF EACH PART OF REAR VIEW MONITOR
- SETTING OF REAR VIEW MONITOR
- CAUTIONS WHEN USING REAR VIEW MONITOR
- EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER
- SOCKET FOR ENGINE HEATER
- CONNECTING EXTERNAL POWER SOURCE
- RESTARTING ENGINE
- HANDLING EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER
- HANDLING DUMPING COUNTER
- METHOD OF DISPLAYING, RESETTING DUMPING COUNTER
- HANDLING MACHINES EQUIPPED WITH KOMTRAX
- INDEX
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- COLOPHON
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