GEN00020-00

(Replaces SEAW000301)

Field Assembly
Manual

-6
DUMP TRUCK
-6
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
 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

HD325, 405-6
1
LIFTING UP CHASSIS ASSEMBLY

Process drawing

HD325, 405-6
2
 Order of work Work procedure

1. Prepare 2 cranes. • 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

2. Install slings to the points shown in the fig- • Protect the front bumper.
ure and lift up the chassis assembly. • Take care that the rear side will not interfere
with the grease tubes, etc.

3. Remove the stands • Secure the left front suspension cylinder with
wires so that it will not be extended by its
weight.

4. Lower the chassis assembly. • Place supports higher than 800 mm under the
parts to which the stands were installed. (3
layers of a block 300 mm square, etc.)

HD325, 405-6
3
INSTALLING FRONT AXLE

Process drawing

HD325, 405-6
4
 Order of work Work procedure

1. Remove each mounting pin from the frame. • Since different pins are used for different
parts, classify them so that they will not be
mixed up.

2. Fix the suspension cylinder.

3. Secure the A-arm.

4. Secure the steering cylinder. • Observe the tightening torque shown in the
figure.

5. Secure the tie rod. • Observe the tightening torque shown in the
figure.

6. Connect the brake hose/suspension control • Check the numbering of the hose on the axle
hose (5 pieces). side and the block on the frame side. (1, 2, 3,
4, and 5 from the front end)

HD325, 405-6
5
INSTALLING FRONT TIRES

Process drawing

HD325, 405-6
6
 Order of work Work procedure

1. Install the right front tire.

1 569-22-62841, 12 pieces, Clamp
2 569-22-62870, 24 pieces, Nut

• Fix clamps 1 with nuts 2. • Reduce the sideways runout of the tire to be-
• Fix the clamps in the numerical order low 5 mm.
shown in the figure.
• Tighten the nuts to the following torque.
• When LM-G is applied to the threads and
nut seats
84 – 105 kg·m (Target: 94.5 kg ·m)
• When nothing is applied to the threads
and nut seats
110 – 135 kg·m (Target: 123.0 kg·m)

HD325, 405-6
7
INSTALLING REAR TIRES

Process drawing

HD325, 405-6
8
 Order of work Work procedure

1. Install the rear tires. • Remove paint, dirt, sand, rust, oil, grease, etc.
1 566-30-74120, 2 pieces, Spacer from the contact faces of the wheel assembly
2 566-81-14111, 2 pieces, Ring and rear axle.
3 569-22-62830, 6 pieces, Clamp
4 569-22-62841, 16 pieces, Clamp
5 569-22-62870, 38 pieces, Nut

1) Install the inside wheel assembly and fix • Reduce the sideways runout of the tire to be-
clamps 569-22-62830 No. 1, 2, and 3 low 5 mm.
shown in the figure with nuts 569-22-
62870.
• Tighten the nuts to the following
torque.
• When LM-G is applied to the threads
and nut seats
84 – 105 kg·m (Target: 94.5 kg·m)
• When nothing is applied to the
threads and nut seats
110 – 135 kg·m (Target: 123.0 kg·m)

2) Install spacer 566-30-74120, outside • Reduce the sideways runout of the tire to be-
wheel assembly, and ring 566-81-14111, low 5 mm.
then fix 3 clamps 569-22-62841.

3) Tighten nuts 569-22-62870 in the numeri-

cal order shown in Fig. 1.
Observe the tightening torque shown in
1) above.

4) Install the extension.

Tightening torque: 0.3 ± 0.05 kgm

HD325, 405-6
9
INSTALLING RIGHT FRONT LIGHT ASSEMBLY

Process drawing

Connection of wiring harness between headlight and chassi

CN32, CN33, CN34, CN35, CNB36, CN37

HD325, 405-6
10
 Order of work Work procedure

1. Install the front light to the front support.

Connect the wiring harness between the light
and chassis. (For the connectors, see the fig-
ure.)

HD325, 405-6
11
INSTALLING GUARDS

Process drawing

Table 1
ROPS specification 566-89-6A990

ROPS + MUFFLER specification 566-84-6A790

ROPSLESS specification 566-46-6A980

ROPSLESS + MUFFLER specification 566-84-6A770

HD325, 405-6
12
 Order of work Work procedure

1. Install the bracket to the right of the rear sup-

port.
Install the guard to the right underside of the
rear support.
• The parts for installation are installed to
the chassis temporarily when shipped.

2. Install the guard to the left underside of the

cab.
• The parts for installation are installed to
the chassis temporarily when shipped.

HD325, 405-6
13
INSTALLING CATWALK AND GUARD

Process drawing

HD325, 405-6
14
 Order of work Work procedure

1. Install the catwalk assembly to the left side

of the cab.
• The parts for installation are installed to
the cab temporarily when shipped.

2. Install the guard to the catwalk.

• The parts for installation are installed to
the catwalk temporarily when shipped.

HD325, 405-6
15
ASSEMBLING RIGHT PLATFORM

Process drawing

HD325, 405-6
16
 Order of work Work procedure

1. Install the platform to the side of the right

platform.
• The bolts and washers are installed to the
platform temporarily when shipped.

2. Install the guards to the right platform.

• The parts for connecting the guards are
installed to 566-54-6A751 temporarily
when shipped.
• The parts for installation of the guards
are installed to the platform temporarily
when shipped.

HD325, 405-6
17
INSTALLING MIRRORS

Process drawing

HD325, 405-6
18
 Order of work Work procedure

1. Install the mirror assembly to the guard of

the right platform.
• The parts for installation are installed to
the mirror assembly temporarily when
shipped.

2. Install the undermirrors to the guards on both

sides.

3. Install the mirror assembly to the left side of

the cab.
• The parts for installation are installed to
the mirror assembly temporarily when
shipped.

HD325, 405-6
19
INSTALLING BODY PINS

Process drawing

HD325, 405-6
20
 Order of work Work procedure

1. Install the hinge pins (on both sides).

1 566-97-46170, 2 pieces, Pin
2 566-74-11270, 4 pieces, Shim
3 566-74-11280, 16 pieces, Shim
4 281-70-15290, 2 pieces, Plate
5 01010-81425, 4 pieces, Bolt
6 01643-31445, 4 pieces, Washer

2. Fix the hoist cylinders (on both sides).

7 566-97-46180, 2 pieces, Pin
8 07020-00675, 2 pieces, Fitting
9 281-70-15290, 2 pieces, Plate
- 01010-81425, 4 pieces, Bolt
q 01643-31445, 4 pieces, Washer

HD325, 405-6
21
ADJUSTING BODY SHIMS

Process drawing

HD325, 405-6
22
 Order of work Work procedure

1. Body rest (Front mount) • For adjustment of the shims, see H3-120.
1 569-74-61520, 2 pieces, Pad
2 569-74-61580, 16 pieces, Shim
3 01010-81650, 8 pieces, Bolt
4 01643-31645, 8 pieces

2. Body pad (Bottom mount) • For adjustment of the shims, see H3-120.
5 569-74-61511, 6 pieces, Pad
6 569-74-61531, 18 pieces, Shim (t = 1.0)
7 569-74-61541, 6 pieces, Shim (t = 3.2)
8 569-74-61840, 3 pieces, Shim (t = 1.0)
9 569-74-61850, 7 pieces, Shim (t = 1.0)
- 569-74-61860, 9 pieces, Shim (t = 1.0)
q 569-74-61870, 2 pieces, Shim (t = 1.0)
w 01010-81645, 24 pieces, Bolt
e 01643-31645, 24 pieces, Bolt

HD325, 405-6
23
 Process drawing

HD325, 405-6
24
 Order of work Work procedure

1. Adjusting the body mount shim

Adjust the body mount shim according to the
following procedure.
(1) Bottom mounts (Rubber mounts of body
bottom plate)
A. Insert a spacer 40 mm thick in the
body end.
B. Measure distance δ between the cen-
ter of the body mount and the frame
(6 places on both sides).
C. Insert shims (δ1 - 38), (δ2 - 38), and
(δ3 - 38) thick in the points of δ1, δ2,
and δ3 respectively.
D. Install the bottom mounts and re-
move the spacers.
E. Lower the body and check that all of
the 6 bottom mounts are in contact
with the frame top.
F. Finish adjustment of the bottom
mounts.

(2) Front mounts (Rubber mounts of body • After the body is installed, the discrepancy be-
front plate) tween the protector and cab must be 25 mm
A. After the above adjustment of the or less. If the discrepancy exceeds 25 mm,
bottom mounts, measure distances adjust it to below 25 mm with the shims of
A1 and A2 between the body front hinge pin (566-97-46170).
mount and frame rear support.
B. Set the thicknesses (quantity) of
shims (569-74-61580) to (A1 - 51) mm
and (A2 - 51) mm respectively.
C. Install the shims having the thick-
nesses calculated in B above and
then install rubber pad (569-74-
61520).
D. Lower the body and check that the
total thickness of the rubber pad is
51 mm. If the total thickness is not
51 mm, adjust it to 51 mm with the
shims. (Deflection: 1 mm)
E. Finish adjustment of the front mount.

HD325, 405-6
25
INSTALLING BODY ACCESSORIES

Process drawing

HD325, 405-6
26
 Order of work Work procedure

1. Install the safety pins.

1 569-74-61670, 2 pieces, Pin
2 569-74-61470, 2 pieces, Pin

2. Install the poke ejector.

3 566-74-6A620, 2 pieces, Bar
4 01011-82405, 2 pieces, Bolt
5 01640-22540, 8 pieces, Washer
6 01580-12419, 4 pieces, Nut

3. Install the mudguard.

7 566-74-41512, 2 pieces, Plate
8 566-74-41521, 2 pieces, Plate
9 01010-81235, 12 pieces, Bolt
- 01643-31232, 12 pieces, Washer
q 01580-11210, 12 pieces, Nut

HD325, 405-6
27
INSTALLING BODY GUARDS

Process drawing

HD325, 405-6
28
 Order of work Work procedure

1. Install the spill guard and platform guard to

the body.
1 566-74-41431, 1 piece, Guard
2 566-74-41460, 1 piece, Guard (L)
3 566-74-41470, 1 piece, Guard (R)
4 01010-81225, 20 pieces, Bolt
5 01643-31232, 20 pieces, Washer
6 566-74-41480, 2 pieces, Plate
7 01010-81225, 8 pieces, Bolt
8 01643-21232, 8 pieces, Washer

HD325-6
9 566-74-41442, 1 piece, Guard
- 566-74-41451, 1 piece, Guard
q 01010-81225, 20 pieces, Bolt
w 01643-31232, 20 pieces, Washer

HD405-6
e 569-83-65920, 1 piece, Guard
r 569-83-65930, 1 piece, Guard
t 01010-81440, 16 pieces, Bolt
y 01643-31445, 16 pieces, Washer
u 01010-81435, 8 pieces, Bolt
i 01643-31445, 8 pieces, Washer

HD325, 405-6
29
PREPARATION WORK
HD325-6
Process drawing

HD325, 405-6
30
 Order of work Work procedure

1. Select a place for work. • Secure an area of 169 m2 (13 m x 13 m) on the

floor or ground.
• The gradient of the floor or ground must not
exceed 0.05 m in 10 m.

2. Arrange the welder, generator, and tools.

3. Lift off the body (in the normal position). • Place the body on proper wood blocks.

4. Remove the left side of the body and protec- • Cut off the angle bar and plate used to secure
tor stored in the split body. the left of the body and protector with gas.
At this time, hang the left side of the body
and protector with a crane so that they will
not fall after cut off. Cut off the left side of
the body first, then the protector.

5. Remove the paint from the parts to be • Remove the paint from the range of 15 mm
welded. through along the fitting line of the body.
Burn the paint with a gas burner or scrape it
with a grinder.

6. Turn over the split body.

7. Install the stands and the split body on the

ground of the assembly shop as shown in
the figure at right.

HD325, 405-6
31
ASSEMBLY OF SPLIT BODY

Process drawing

HD325, 405-6
32
 Order of work Work procedure

1. Set the right side of the split body on the

stand.

2. Set the left side of the split body on the stand • If both sides are not matched accurately, ad-
so that the clearance will be even. just them with hydraulic cylinders.
• When setting the right side, utilize the hang-
ing plate on the underside of the side plate
3. Secure the body with the following parts, uti- and the exhaust port.
lizing plates 566-83-6H190 (at 5 places). (See
page 38, 39.)
01011-820100, Bolt, 5 pieces
01643-32060, Washer, 5 pieces
01580-12016, Nut, 5 pieces
581-74-11630, Tube, 5 pieces

4. Adjust the large end of the bottom plate, • If the split parts are deviated from each other
large end of the front plate, and ribs flush excessively, correct them with hydraulic cyl-
with each other. inders.
• When correcting them, check that the mount-
ing bolts are loosened.

5. Secure the body by tack welding.

6. Remove the cross ribs (7 pieces) tack-welded

to the bottom plate and install them by tack
welding, matching them to the ribs of the
bottom plate. When installing the ribs, re-
move the mudguard mounting plate (566-74-
6EB90, Plate).

HD325, 405-6
33
WELDING BODY

Process drawing

HD325, 405-6
34
 Order of work Work procedure

1. Weld the front plate. (See page 38, 39.) • Apply arc welding to the front plate in verti-
cal position. Observe the welding condition
shown in Table 1.
2. Weld the bottom plate on the level. (See page • Put a stand under the rear part of the bottom
38, 39.) plate to keep the bottom plate on the level.
After welding the ribs, secure the mudguard
mounting plate removed before by tack weld-
ing at the angle of the plate installed to the
bottom plate, then weld it.
Check the mounting hole pitch with mating
plate (566-74-41521).

3. Remove the stands (4 pieces) for transporta- • Perform back-step welding to connect beads
tion installed to the bottom plate. and start welding.

4. After finishing the welding work, remove the

spatters and finish the beads with a grinder.

5. Check the welded parts for a defect.

(1) Check the deposited metal.
(2) Check for an undercut, overlap, and spat-
ter.
(3) Check the leg length of weld for short-
age (Insufficient leg length is not permit-
ted.)

HD325, 405-6
35
WELDING BODY

Process drawing

Table 1
CO2 gas arc welding Arc welding Remarks
Welding position Flat (F) Flat, vertical (V) (1) Do not apply CO2 gas
Welding rod JIS Z3312YGW11 JIS Z3212D5016 welding when wind
or equivalent or equivalent velocity is higher than
d1.2, 1.6 d4.0, 5.0 2 – 3 (m/sec).
(2) Remove moisture,
Welding current (A) 320 – 350, 380 – 420 130– 160, 220– 260
dust, and paint from
Preheating/Postheating Unnecessary Unnecessary surfaces to be welded.
Gas shielding rate (l/min) 25 – 35 —

HD325, 405-6
36
 Order of work Work procedure

6. Turn over the body.

Install a sling to the body hinge holes of the
bottom plate to turn over the body.

Keeping the body in the position shown at • Put wood blocks under the front and rear parts
left (lifted with a crane), weld the inside of of the bottom plate.
the front plate. Then, lower the body and • Connect the ground cable for welding to the
weld the inside of the bottom plate. body securely.
• Apply CO2 gas shielded arc welding as stan-
dard. If it is difficult to apply, however, apply
arc welding.
• Drying time of arc welding rod
1 Temperature: 150 – 200ºC
2 Time: 120 minutes

HD325, 405-6
37
 Process drawing

HD325, 405-6
38
 Process drawing

HD325, 405-6
39
WELDING BODY PROTECTOR

Process drawing

CO2 gas arc welding Arc welding Remarks

Welding position Flat (F) Flat, vertical (V) (1) Do not apply CO2 gas
Welding rod JIS Z3312YGW11 JIS Z3212D5016 welding when wind
or equivalent or equivalent velocity is higher than
d1.2, 1.6 d4.0, 5.0 2 – 3 (m/sec).
(2) Remove moisture,
Welding current (A) 320 – 350, 380 – 420 130 – 160, 220 – 260
dust, and paint from
Preheating/Postheating Unnecessary Unnecessary surfaces to be welded.
Gas shielding rate (l/min) 25 – 35 —

HD325, 405-6
40
 Order of work Work procedure

1. Weld the protector. • If any plate is used to secure the protector,

(1) Place the protector on the tops of the side remove it with a gas cutting device or a
plate and front plate with a crane. grinder.
• Capacity of crane: Min. 2 tons
• Lift of crane: Min. 7 m
• Breaking strength of wire rope, chain,
chain block: Min. 2 tons
(2) Position the protector so that the end of
the body side plate will be in parallel with
the protector side plate.
(3) Cut the front and side plates of the pro-
tector with gas so that the top of the body
side plate and will be in parallel with the
top of the protector.
Note:
Since the protector and front plate are
distorted by welding as shown below, the
front and side plates of the protector
must be cut with gas so that the clear-
ance will be minimized at the time of
welding. (Reduce the clearance to be-
low 3 mm.)
(4) After positioning, tack-weld the front
panel of the protector.

HD325, 405-6
41
WELDING BODY PROTECTOR

Process drawing

HD325, 405-6
42
 Order of work Work procedure

(5) Weld the protector. (See page 38, 39.) • Apply CO2 gas shielded arc welding as stan-
• Welding order: Weld the side plate dard. If it is difficult to apply, however, apply
first. arc welding.
• Welding symbol: Shown in the weld-
ing instruction drawing. • Drying time of arc welding rod
• Welding condition: Shown in weld- (1) Temperature: 150 – 200ºC
ing condition table on the previous (2) Time: 120 minutes
page.
• Perform welding according to
KES04.343, General, 2nd Grade.

(6) Finishing
Remove the spatters and finish the beads
with a grinder. Cut the hanging plate
welded to the top of the body with gas
and finish the marks of weld with a
grinder.

(7) Check the welded parts for defects.

1 Crack of weld bead (visual check)
2 Undercut, overlap, and spatter
3 Leg length of weld for shortage (In-
sufficient leg length is not permitted.)

(8) After cooling, paint the welded parts.

1 Mix the base and hardener of the
paint well at the ratio of 5:1 as speci- • Put on mask, goggles, gloves, etc. to protect
fied. yourself from paint mist.
2 After painting, clean the paint spray
gun with paint thinner before the
paint is hardened.
[Undercoat paint]
RETAN GP primer
RETAN GP hardener
RETAN GP thinner
[Top coat paint]
NAX MIGHTYLAC II KB natural yellow
NAX MIGHTYLAC II KB hardener
NAX MIGHTYLAC II KB thinner

HD325, 405-6
43
PREPARATION WORK
HD405-6
Process drawing

HD325, 405-6
44
 Order of work Work procedure

1. Select a place for work. • Secure an area of 169 m2 (13 m x 13 m) on the

floor or ground.
• The gradient of the floor or ground must not
2. Arrange the welder, generator, and tools. exceed 0.05 m in 10 m.

3. Lift off the body (in the normal position). • Place the body on proper wood blocks.

4. Remove the left side of the body and protec- • Cut off the angle bar and plate used to secure
tor stored in the split body. the left of the body and protector with gas.
At this time, hang the left side of the body
and protector with a crane so that they will
not fall after cut off. Cut off the left side of
the body first, then the protector.

5. Remove the paint from the parts to be • Remove the paint from the range of 15 mm
welded. through along the fitting line of the body.
Burn the paint with a gas burner or scrape it
with a grinder.

6. Turn over the split body.

7. Install the stands and the split body on the

ground of the assembly shop as shown in
the figure at right.

HD325, 405-6
45
ASSEMBLY OF SPLIT BODY

Process drawing

HD325, 405-6
46
 Order of work Work procedure

1. Set the right side of the split body on the

stand.

2. Set the left side of the split body on the stand • If both sides are not matched accurately, ad-
so that the clearance will be even. just them with hydraulic cylinders.
• When setting the right side, utilize the hang-
ing plate on the underside of the side plate
3. Secure the body with the following parts, uti- and the exhaust port.
lizing plates 566-83-6H190 (at 5 places). (See
page 52, 53.)
01011-82010, Bolt, 5 pieces
01643-32060, Washer, 5 pieces
01580-12016, Nut, 5 pieces
581-74-11630, Tube, 5 pieces

4. Adjust the large end of the bottom plate, • If the split parts are deviated from each other
large end of the front plate, and ribs flush excessively, correct them with hydraulic cyl-
with each other. inders.

• When correcting them, check that the mount-

ing bolts are loosened.

5. Secure the body by tack welding.

6. Remove the cross ribs (7 pieces) tack-welded

to the bottom plate and install them by tack
welding, matching them to the ribs of the
bottom plate. When installing the ribs, re-
move the mudguard mounting plate (566-74-
6EB90, Plate).

HD325, 405-6
47
WELDING BODY

Process drawing

HD325, 405-6
48
 Order of work Work procedure

1. Weld the front plate. (See page 52, 53.) • Apply arc welding to the front plate in verti-
cal position. Observe the welding condition
shown in Table 1.

2. Weld the bottom plate on the level. • Put a stand under the rear part of the bottom
(See page 52, 53.) plate to keep the bottom plate on the level.
After welding the ribs, secure the mudguard
mounting plate removed before by tack weld-
ing at the angle of the plate installed to the
bottom plate, then weld it.
Check the mounting hole pitch with mating
plate (566-74-41521).

3. Remove the stands (4 pieces) for transporta- • Perform back-step welding to connect beads
tion installed to the bottom plate. and start welding.

4. After finishing the welding work, remove the

spatters and finish the beads with a grinder.

5. Check the welded parts for a defect.

(1) Check the deposited metal.
(2) Check for an undercut, overlap, and spat-
ter.
(3) Check the leg length of weld for short-
age (Insufficient leg length is not permit-
ted.)

HD325, 405-6
49
 Process drawing

Table 1
CO2 gas arc welding Arc welding Remarks
Welding position Flat (F) Flat, vertical (V) (1) Do not apply CO2 gas
Welding rod JIS Z3312YGW11 JIS Z3212D5016 welding when wind
or equivalent or equivalent velocity is higher than
d1.2, 1.6 d4.0, 5.0 2 – 3 (m/sec).
(2) Remove moisture,
Welding current (A) 320 – 350, 380 – 420 130– 160, 220– 260
dust, and paint from
Preheating/Postheating Unnecessary Unnecessary surfaces to be welded.
Gas shielding rate (l/min) 25 – 35 —

HD325, 405-6
50
 Order of work Work procedure

6. Turn over the body.

Install a sling to the body hinge holes of the
bottom plate to turn over the body.

Keeping the body in the position shown at • Put wood blocks under the front and rear parts
left (lifted with a crane), weld the inside of of the bottom plate.
the front plate. Then, lower the body and • Connect the ground cable for welding to the
weld the inside of the bottom plate. body securely.
• Apply CO2 gas shielded arc welding as stan-
dard. If it is difficult to apply, however, apply
arc welding.
• Drying time of arc welding rod
(1) Temperature: 150 – 200ºC
(2) Time: 120 minutes

HD325, 405-6
51
 Process drawing

HD325, 405-6
52
 Process drawing

HD325, 405-6
53
WELDING BODY PROTECTOR

Process drawing

Table 1
CO2 gas arc welding Arc welding Remarks
Welding position Flat (F) Flat, vertical (V) (1) Do not apply CO2 gas
Welding rod JIS Z3312YGW11 JIS Z3212D5016 welding when wind
or equivalent or equivalent velocity is higher than
d1.2, 1.6 d4.0, 5.0 2 – 3 (m/sec).
(2) Remove moisture,
Welding current (A) 320 – 350, 380 – 420 130– 160, 220– 260
dust, and paint from
Preheating/Postheating Unnecessary Unnecessary surfaces to be welded.
Gas shielding rate (l/min) 25 – 35 —

HD325, 405-6
54
 Order of work Work procedure

1. Weld the protector. • If any plate is used to secure the protector,

(1) Place the protector on the tops of the side remove it with a gas cutting device or a
plate and front plate with a crane. grinder.
• Capacity of crane: Min. 2 tons
• Lift of crane: Min. 7 m
• Breaking strength of wire rope, chain,
chain block: Min. 2 tons
(2) Position the protector so that the end of
the body side plate will be in parallel with
the protector side plate.
(3) Cut the front and side plates of the pro-
tector with gas so that the top of the body
side plate and will be in parallel with the
top of the protector.
Note:
Since the protector and front plate are
distorted by welding as shown below, the
front and side plates of the protector
must be cut with gas so that the clear-
ance will be minimized at the time of
welding. (Reduce the clearance to be-
low 3 mm.)
(4) After positioning, tack-weld the front
panel of the protector.

HD325, 405-6
55
 Process drawing

HD325, 405-6
56
 Order of work Work procedure

(5) Weld the protector. (See page 52, 53.) • Apply CO2 gas shielded arc welding as stan-
• Welding order: Weld the side plate dard. If it is difficult to apply, however, apply
first. arc welding.
• Welding symbol: Shown in the weld-
ing instruction drawing.
• Welding condition: Shown in weld- • Drying time of arc welding rod
ing condition table on the previous (1) Temperature: 150 – 200ºC
page. (2) Time: 120 minutes
• Perform welding according to
KES04.343, General, 2nd Grade.

(6) Finishing
Remove the spatters and finish the beads
with a grinder. Cut the hanging plate
welded to the top of the body with gas
and finish the marks of weld with a
grinder.
(7) Check the welded parts for defects.
1 Crack of weld bead (visual check)
2 Undercut, overlap, and spatter
3 Leg length of weld for shortage (In-
sufficient leg length is not permitted.)
(8) After cooling, paint the welded parts.
1 Mix the base and hardener of the
paint well at the ratio of 5:1 as speci- • Put on mask, goggles, gloves, etc. to protect
fied. yourself from paint mist.
2 After painting, clean the paint spray
gun with paint thinner before the
paint is hardened.
[Undercoat paint]
RETAN GP primer
RETAN GP hardener
RETAN GP thinner
[Top coat paint]
NAX MIGHTYLAC II KB natural yellow
NAX MIGHTYLAC II KB hardener
NAX MIGHTYLAC II KB thinner

HD325, 405-6
57
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 1/4
Report No.

FIELD ASSEMBLY INSPECTION REPORT

After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance and quality.

Model-Type Machine Serial No. User Unit No. Engine Model Engine Serial No.
HD325-6
SAA6D140E-3
HD405-6
Service Meter Reading Date of Inspection
Attachment

1 2

Location of Machine at Inspection Manufacture

Model
Distributor’s Name

Serial No.

Customer’s Name Address: Signature: Delivery

Report
No. attached

Date:

Inspector’s Comments:

Inspector’s Name: KOMATSU USE ONLY :

C. Sheet Receiving Date :

Title
By :

Signature: Remark:

Check sheets filling instructions:

1. Use following indexes for entry of judgement

! ..... Normal ..... Correction made on abnormal point
..... Abnormal ..... Not applied

2. Enter actually measured values in parenthese, [ ].

Notes:

(1) Criteria are based on the standards when the machine is shipped out of the factory.

SUBMITTANCE OF THIS REPORT (AND CHECK SHEETS) TO COMATSU IS ONE OF THE CONDITIONS OF WARRANTY VALIDATION, COPY
FOR KOMATSU SHALL BE FORWARDED TO THE KOMATSU REGIONAL OFFICE TOGETHER WITH THE COPY OF DELIVERY SERVICE RE-
PORT.

GEN00020-00
Printed in Japan
A
 2/4

No. Inspection item Judgment procedure and standards Check Mainte- Remarks
nance
Check oil and water levels.

Engine oil level Level must be between (H) and (H - 10 mm).

1
(Check with engine stopped.)

Transmission oil level Level must be between (H) and (center between H and L).
2
(Check with engine at low idling.)

3 Hydraulic oil level Level must be within inspection window range.

Turn switch ON. (Basic items: Check lights and buzzers.)

Sound must be proper in volume and must not have beat

4 Function of horn
noise. (Sensory check)

Sound must be proper in volume and must not have beat

5 Function of backup buzzer
noise. (Sensory check)

When light switch is turned ON (1st, 2nd stage), front right

6 Function of clearance lamp and left clearance lamps and rear right, center, and left clear-
ance lamps (3 lamps) must light up.

When light switch is turned ON (2nd stage), 2 headlamps

7 Check of headlamps
(right and left) must light up.

When dimmer switch is operated with headlamps ON, lamps

Check of high beam
8 must change (2 lamps ← → 4 lamps). (Irradiating direction
(Function of dimmer switch)
must change.)

When turn signal lever is operated, front and rear turn sig-
9 Function of turn signal lamps
nal lamps must flash on correct side.

When hazard lamp switch is turned to ON, right and left

turn signal lamps and pilot (arrow) lamp inside operator’s
10 Function of hazard lamp
cab must flash. In this case, if key switch is turned to OFF,
pilot lamp must not flash.

When transmission shift lever is set to at R, backup lamps

11 Function of backup lamps
must light up.

When brake pedal is depressed, 3 red rear brake lamps

(right, center, and left) must light up.

When retarder lever is pulled, 2 red rear brake lamps (right

12 Function of brake lamps and left) must light up. Center lamp must not light up at
this time.

When light switch is ON and brake is turned ON, brightness

of brake lamp must change (become brighter).

Start engine.

13 Abnormal noise from engine No abnormal noise must be generated. (Sensory check)

14 Exhaust gas leakage Exhaust gas must not leak from exhaust shutter, etc.

Check that operation is correct (FLOAT – RAISE: 58.8 N{6.0

Operating effort of dump lever
15 kg}, FLOAT – LOWER: 68.6 N{7.0 kg}). Lever must not be
(Sensory check)
hitched during operation.

1 Check that order of operation from top is RAISE → HOLD

→ FLOAT → LOWER.

2 Check that dump body can be stopped at desired posi-

tion when lever is at HOLD.

3 Operate lever to RAISE position and check that it returns

16 to HOLD when released (When positioner is not installed).
Function of dump lever
4 Operate lever to LOWER position and check that it re-
turns to FLOAT when released.

5 Pressure must be adjusted at RAISE and LOWER posi-

tions.
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 3/4

No. Inspection item Judgment procedure and standards Check Mainte- Remarks
nance
Shock made when dump body When dump body is seated, unpleasant shock must not be
17 made. (Sensory check)
is lower to end

Operate lever to RAISE position and check that it does not

return to HOLD when released.
Function of body positioner
18 Operate lever to RAISE position to raise dump body and
(Overseas OP.)
check that it automatically returns to HOLD at a point 50 –
100 mm before end of H/T cylinder stroke.

When dump body is raised fully, it must not sway to right or

left. (Difference in dimension between right and left hoist
cylinders: Max. 7 mm)
Alignment of dump body on
19 When dump body is lower fully, it must come in contact
right and left
with mount evenly. (Contact area must be at least 80%.)

When dump body is lower fully, it must come in contact

with vibration stopper evenly.

Engine speed: Rated speed (2000rpm)

Body lifting speed
20 Standard common to HD325 and 405: 10.5 ± 1.5 sec, Mea-
(Oil temperature: 80ºC)
sured value: ( ) sec

Body lowering speed Engine speed: Low idling speed (650rpm)

21 (Lever at FLOAT,Oil tempera- Standard (HD325): 11.0±1.5 sec, Measured value:( )sec
ture: 50 – 70ºC) Standard (HD405): 15.0±1.5 sec, Measured value:( )sec

Function of dump body opera- Must light up when dump lever is set to any position other
22 tion caution lamp than FLOAT or while dump body is not seated.
* Centralized
operate.
warning lamp and warning buzzer must not

Hydraulic drift in 5 minutes must be 85 mm or less. (From

23 Hydraulic drift of dump body point where cylinder No. 2 is extended by 100 mm), Mea-
sured value: ( ) mm

Stop engine and check that dump body can be lifted with
Function of lifting dump body emergency steering motor.
24
with emergency starting motor * Do not operate emergency steering motor for more than
90 seconds continuously.

Stop truck on level ground and measure.

Length of suspension cylinder Length must be shorter than dimension A.

(Front) Dimension A: 233 (Position of label) ± 10 mm
25
with dump body Measured value: Left ( ) mm, Right ( ) mm
* Measure
empty.

Length of suspension cylinder Length must be shorter than dimension A.

(Rear) Dimension A: 191 ± 10 mm
26
Measure with dump body Measured value: Left ( ) mm, Right ( ) mm
* empty.
1 When dump lever is set to any position other than FLOAT,
display must change from [Soft] to [Hard].
Automatic suspension control
27
function (Opt.) 2 When service brake or emergency brake is turned ON,
Measure with dump body display must change from [Soft] to [Medium].
empty.
3 Display must show [Soft] in all cases other than 1 and
2 above.

Inspect each part.

Safety pin must be inserted without obstruction in right and

28 Function of safety pin
left stopper holes.

Safety pin must be removed from, installed to, and locked

29 Storage function of safety pin
at storage position securely.

Locknut must not be loosened.

Installation of dump control
30
linkage Boots (Rubber covers) of cable must not be twisted. (At
right side of cab, hoist valve, and positioner)
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 4/4

No. Inspection item Judgment procedure and standards Check Mainte- Remarks
nance
31 Front axle (Right) Mounting bolts (Mounting pins) must free from looseness.

Rear support light cover

32 Mounting bolts must be free from looseness.
(Right disconnecting point)

33 Inspection around engine No oil and water leakage.

Inspection around transmis-

34 No oil leakage.
sion

Inspection of hydraulic oil sys-

35 tem (tank, cylinder, pump, pip- No oil leakage.
ing)

Standard: Shown at left

Tire inflation pressure Measured value: Front left ( kPa { kg/cm2}),
(When dump body is empty) Front right ( kPa { kg/cm2})
18.00-33-32PR: 564±9.8kPa
{5.75±0.1kg/cm2} Standard: Shown at left
36 18.00-33-28PR: 491±9.8kPa Measured value: Rear left inside ( kPa { kg/cm2}),
{5±0.1kg/cm2} Rear right inside ( kPa { kg/cm2})
18.00-R33: 687±9.8kPa Standard: Shown at left
{7±0.1kg/cm2} Measured value: Rear left outside ( kPa { kg/cm2}),
Rear right outside ( kPa { kg/cm2})

1 Front left: Retighten.

Tightness of tire hub nuts
Tightening torque: 2 Front right: Retighten.
37 1079 – 1323 Nm{110 – 135kgm}
(Target: 1206 Nm{123kgm}) 3 Rear left: Retighten.
* When nothing is applied to
threads. 4 Rear right: Retighten.

38 Flaw of tires Tires must be free from flaw and tear.

Plated surfaces must be free from rust, harmful flaw, spat-

39 Hoist cylinders (Both sides)
ter, paint, etc.
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GEN00020-00