Komatsu 325M Dump Truck (Haulpack) Service Repair Manual

Table of Contents

GENERAL INFORMATION ………………………………..A
STRUCTURES .. . . . .. .. . .. . . .. . . . . . .. . .. . . . . . . . . . . . . . . .. .. . B
ENGINE, FUEL, COOLING AND AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . C
ELECTRIC SYSTEM (24 VDC.N ON-PROPULSION) .. . . . . . .. .. . . . . . . . .. . .. . D
TRANSMISSION AND PTO …………… ; …………………. F
DRIVE AXLE, SPINDLES AND WHEELS . .. . . . . . .. . .. . . .. .. . . . . . . . . .. . . G
HYDRAIR ® II SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H
BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J
AIR SYSTEM . . .. . . .. . . . .. . . . . . .. .. . .. .. . .. . . . . . . . . . . . .. . . .K
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L
OPTIONS AND SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M
OPERATOR’S CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N
LUBRICATION AND SERVICE .. . . . .. . . . .. . . . .. . .. . . . . .. . . . . .. . .. . P
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q
SYSTEM SCHEMATICS ………………………………….R

This Service Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in
production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck. All safety notices, warnings and cautions should be understood and followed when accomplishing repairs on the truck.

The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example: The disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed repairs.

The illustrations used in this manual are, at times, typical of the component shown and do not necessarily refer to any one particular truck model.
This manual shows dimensionless of U.S. standard and metric (SI) units throughout and all location references “right” or “left” are made in respect to the operator’s normal seated position. Standard torque requirements are shown in torque charts in the general information section and individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque. All torque specifications have ± 10% tolerance unless otherwise specified.

The HAULPAK® model designation is based on maximum Gross Vehicle Weight (GVW). Model numbers consist of three numbers and one letter (i.e. 325M). The three numbers represent the
maximum gross vehicle weight (GVW) in thousands of pounds. This number reflects the maximum loaded weight of the vehicle rounded to the nearest 5,000 lbs. (2 268 kg). The letter ‘\M” or “E” stands for Mechanical or Electrical drive system.

This model designation is a job rating or range rating concept which establishes well defined maximum gross vehicle weights. The GVW is used for both design and application guidelines in
determining the load on the drive train, frame, tires, and other components. Maximum GVW means the total weight, which is: the Empty Vehicle Weight (EVW) + the fuel + the payload.
To determine allowable payload: Fill fuel tank of empty truck and weigh truck. Record this value and subtract from GVW rating. The result is the allowable payload. Exceeding the allowable payload will reduce expected life of truck components.