PDF Field Assembly Manual Komatsu HD325-8E0 HD405-8E0 Dump Truck - 1 MB
This field assembly instruction manual is the official guide for assembling the Komatsu HD325-8E0 and HD405-8E0 dump trucks on-site.
It provides crucial step-by-step procedures, torque specifications, and safety precautions.
Following this manual is essential for ensuring the structural integrity and operational safety of the machine from the very beginning.
A vital document for any assembly crew.
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--- Page 1 ---
GEN00189-04
DUMP TRUCK HD325 -8E0
HD405 -8E0
HD325- 55001
SERIAL NUMBERS and up
HD405- 55001
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4 Facility, jig and consumable parts list
No. Item Specifications Q'ty Where to use
61 Bar 1m 1
62 Sliver 1 For aligning holes
63 Big hammer 10 Ib 1
64 Shackle For 500 kg BD10 4
65 Shackle For 10 t BC40 4 For slinging dump body and chassis
66 Chain ATH-465-042 1 For general work
67 Nylon sling 250 mm width, 5 m length 1 For installation of R.H. platform
68 Nylon sling 60 mm width, 3 m length 2 For installation of support, and other small item
69 Nylon sling 100 mm width, 12 m length 1 For installation of front tires
70 Nylon sling 30 mm width, 2 m length 3 For installation of front axle
71 Nylon sling 100 mm width, 3 m length 1 For installation of front axle
72 Nylon sling (endless) 5.5 m length, 8 ton of proof load 2 For slinging dump body and chassis
73 Nylon sling (endless) 6.0 m length, 8 ton of proof load 2 For slinging dump body and chassis
74 Pin 60 x 250 mm 2 For slinging chassis, rear side (can be substituted by safety pin)
75 Jig for slinging dump body ATH-785-006 4 For installation of dump body
76 Lever block 3/4 tons LB008 3 For installation of F axle
77 Lever block 2 tons LB020 1 For installation of F axle
78 Wire 7 m 28 2 For slinging chassis
79 Wire 4 m 28 2 For installation of dump body
80 Wire 5 m 28 2 For installation of dump body
Damage protection material
81 (rubber plate, thick blanket etc.) L×W×H (700 mm×1100 mm×5 mm) 2 For slinging chassis
No. 78-80 can be substituted by following 4 items.
ATH-465-039 1 For installation of dump body
ATH-465-040 2 For slinging chassis
ATH-465-041 1 For slinging of half-separated dump body
Touch up paint list attached to dump body
No. Part name Unit Q'ty
1 Uni Grand 930 primer 4 kg 1
2 Thinner for NIPPON PAINT PCF 0.8 kg 1
3 SR3000 Natural yellow 16 kg 2
4 SR3000 Hardener 15 kg 1
5 Urethane thinner 205 17 L 1
6 Black gray Spray can 1
7 Heat resistance silver Spray can 1
8
8
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Field assembly instruction
Installation of R.H. platform mudguard HD405
No.0215
Installation of R.H. platform mudguard
(1)
䖩 䖩 䖩 䖩 䖩 䖩 䖩 䖩
(6), (7) (4), (5) (2), (3)
=ۻ8 places
1. Remove the mounting bolts from platform, and install the guard.
Part No. Part name Q'ty State of parts
(1) 566-54-8R392 GUARD,(R.H.) 1 Shipping as a single part (H38-L15700-F3)
(2) 566-54-8R380XC PLATE 1 Shipping as a single part (H38-L15700-F3)
(3) 01024-81230 BOLT 8 Install lightly to platform (L15700-F3)
(4) 283-54-11470XC PLATE 1 Install lightly to platform (L15700-F3)
(5) 01024-81230 BOLT 2 Install lightly to platform (L15700-F3)
(6) 124-54-26540 WASHER 2 Install lightly to platform (L15700-F3)
(7) 01024-81230 BOLT 2 Install lightly to R.H fender
Precautions Special tools Facility to be used
Name Q'ty Name Q'ty
Impact wrench 1 Stepladder 1
Socket 1
Others
18
--- Page 5 ---
Field assembly instruction
Installation of L.H. catwalk assembly
NO.0310
Installation of catwalk assembly
(6)
(7) Fix it by using a fastener
Fix it by using a (8), (9) for the handrail.
fastener for the step.
Detail of P part
A
(10)
Z2
P B A
View Z2
Z1
B
(1) 160 kg (2)
*Install it so that clearances (2 places) become as
shown in the figure below.
below
View Z1
(3) Catwalk
(5)
(4) Light box
1. Install the catwalk assembly.
Part No. Part name Q'ty State of parts
(1) X25-2686220 STEP SUB ASSY G. 1 Shipping as a single part (L18505-F3)
(2) 01024-81230 BOLT 4 Temporarily installed to (1)
(3) 01024-81240 BOLT 4 Temporarily installed to (1)
(4) 01024-81235 BOLT 4 Temporarily installed to (1)
(5) 01024-81230 BOLT 4 Installed to machine body STEP
(6) 561-54-86990XC CLAMP 1 Shipping as a single part (L18520-F3)
(7) 6143-11-5630 SPACER 1 Shipping as a single part (L18520-F3)
(8) 01643-31232 WASHER 2 Shipping as a single part (L18520-F3)
(9) 01580-11210 NUT 2 Shipping as a single part (L18520-F3)
(10) 01024-D1245 BOLT 2 Shipping as a single part (L18520-F3)
Precautions Special tools Facility to be used
Name Q'ty Name Q'ty
Impact wrench 1 Crane 25 tons 1
Socket 1 Lifting tool 1
Others
26
--- Page 6 ---
Field assembly instruction
Welding of exhaust pipe tube by actually
No.0435 positioning parts on machine
Welding of exhaust pipe tube by actually positioning parts on machine
* For the welding procedure and materials to be used
see dump body welding.
Precautions for assembly (cross section C-C)
1) Set the tube (6) and tube (1) to dimension A (119 mm) in the figure, and lock it with the nut (4)
(3 places).
2) The mating surface of the tube (1) does not protrude from the mating surface B of the exhaust
pipe (5).
3) The work of 1) and 2) above should be done after adjustment of the rubber mounting of the
dump body.
(6)
C
(3) Fix to make it A dimension with ATH - 465 – 027.
Cross section
C C-C
(4) (2) (1) (5)
Part No. Part name Q'ty State of parts
(1) 566-74-8L610 TUBE 1 Unit shipment (X30000-F9)
(2) 566-02-11420 RING 1 Unit shipment (X30000-F9)
(3) 562-13-16750 SPRING 3 Unit shipment (X30000-F9)
(4) 01580-11411 NUT 6 Unit shipment (X30000-F9)
(5) 566-02-8L412 TUBE 1 Installed to machine body
(6) 566-83-8L251 TUBE 1 Installed to machine body
Precautions Special tools Facility to be used
Name Q'ty Name Q'ty
Center deviation should be 3 mm or less. ATH-465-027 1 Welding machine 1
Others 4HCCC-A: When using dump body heating
36
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Field assembly instruction
Dump body welding procedure 2
No.C-0060
Dump body welding procedure 2
E-E
Precautions Tools to be used Facility to be used
Name Q'ty Name Q'ty
䚷
Others
54