hd465.605-7 field assembly

1

CONTENTS

[1] Chart of separated units ........................................................................................................................... 3[2] Dimensions of separated units ................................................................................................................ 5[3] Order for assembly, facilities to use, schedule for assembly ................................................................. 6[4] Tools and equipment to use ................................................................................................................... 10[5] Procedure for local assembly ................................................................................................................. 12

A-1 Setting bare machine position .............................................................................................. 12A-2 Assembly of rear axle & suspension .................................................................................... 13A-3 Assembly of rear axle assembly (connection of suspension) ............................................ 14A-4 Assembly of rear axle assembly (connection of axle rod) .................................................. 15A-5 Assembly of rear axle assembly (connection of lubrication grease tube) ......................... 16A-6 Assembly of rear axle assembly (connection of drive shaft) .............................................. 17A-7 Assembly of right front axle .................................................................................................. 18A-8 Assembly of right front axle (connection of suspension) ................................................... 19A-9 Assembly of right front axle (connection of A arm) ............................................................ 20A-10 Assembly of right front axle (connection of steering cylinder & rod) ................................ 21A-11 Assembly of right front axle (connection of brake hose) .................................................... 22A-12 Assembly of tire & wheel assembly ..................................................................................... 23A-13 Assembly of front support .................................................................................................... 24A-14 Assembly of right fender lock bracket .................................................................................. 25A-15 Assembly of R.H. platform assembly ................................................................................... 26A-16 Assembly of L.H. catwalk assembly ..................................................................................... 27A-17 Assembly of L.H. handrail ..................................................................................................... 28A-18 Assembly of R.H. fender ........................................................................................................ 29A-19 Assembly of L.H. fender ........................................................................................................ 30A-20 Assembly of left and right mudguards ................................................................................. 31A-21 Assembly of left over fender ................................................................................................. 32A-22 Assembly of right over fender .............................................................................................. 33A-23 Mounting of dump body (lifting dump body) ...................................................................... 34A-24 Mounting of dump body (installation of hinge pin) ............................................................ 35A-25 Assembly of poke ejector ...................................................................................................... 36A-26 Assembly of dump body lock pin ......................................................................................... 37A-27 Assembly of dump body mudguard ..................................................................................... 38A-28 Mounting of dump body (shim adjustment procedure) ...................................................... 39A-29 Welding actual parts (installation of protective cover) ........................................................ 40A-30 Assembly of exhaust pipe tube............................................................................................. 41A-31 Connection of dump sensor .................................................................................................. 42A-32 Filling with grease, water 1 ................................................................................................... 43A-33 Filling with grease, water 2 ................................................................................................... 44A-34 Bleeding air from brake ......................................................................................................... 45A-35 Adjusting dump control ......................................................................................................... 46A-36 Painting ................................................................................................................................... 47A-37 Adjustment of suspension .................................................................................................... 48A-38 Settling floating seal .............................................................................................................. 49

Procedure for welding and assembling three separated body parts ......................................................... 51Field assembly inspection report

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HD465-7, HD605-7

[1] CHART OF SEPARATED UNITS

1. Bare machine

2. Dump body

3. Right front axle assembly

4. Rear axle & tire assembly

5. Rear suspension

6. Front tire & wheel assembly

7. R.H. platform & handrail assembly

8. L.H. catwalk & handrail assembly

9. L.H. handrail

10. R.H. front support

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HD465-7, HD605-7

[1] CHART OF SEPARATED UNITS

11. Right fender mounting bracket

12. Left and right fenders

13. Left and right mudguards

14. Left and right over fenders

15. Dump body mudguard

16. Poke ejector

16. Exhaust pipe & tube

17. Drive shaft

★ When the machine is shipped from the factory, it is shipped in the posture shown below.

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HD465-7, HD605-7

Specifications for completed

Related specificationsSpecifications

Weight (kg) Overall length (mm) Overall width (mm) Overall height (mm)

42,800 9,355 4,820 4,400HD465-7 (Weight of machine) (Front bumper to (When empty)

rear of body)

46,800 9,355 4,820 4,400HD605-7 (Weight of machine) (Front bumper to (When empty)

rear of body)

[2] DIMENSIONS OF SEPARATED UNITS

When machine is loaded on trailer

Weight Overall length Overall width Overall heightNo. Name of unit (kg) (mm) (mm) (mm)1 Bare machine 18,520 7,055 3,490 3,4602 Dump body / HD465-7 10,650 8,710 4,662 2,7003 Dump body / HD605-7 13,418 8,710 4,545 2,7004 Right front axle assembly (1 set) 1,100 1,300 1,300 1,6005 Rear axle & tire assembly 10,800 2,165 4,520 —6 Rear suspension (1 set) 172 270 — 9327 Front tire & wheel assembly (1 set) 1,200 2,165 645 —8 R.H. platform assembly 120 2,510 600 1,1009 L.H. catwalk assembly 95 2,500 735 1,10010 L.H. handrail 4.5 945 — 1,00011 R.H. front support 50 620 665 65212 Right fender lock bracket 11 470 550 29013 Left and right fenders (1 set) 24 396 900 57614 Left and right mudguards (1 set) 4 — 870 90015 Right over fenders 3 1,590 430 —16 Left over fenders 1.5 830 412 —17 Dump body mudguard 2 — 1,275 96018 Poke ejector (1 set) 25 — 100 69519 Exhaust pipe & tube 18 550 480 48020 Drive shaft 62 755 302 —

Whentravelingunderownpower

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Assembly unit

Assembly ProcedureSheet No.

Crane(hydraulic type,with operator)

Air compressor

Generator

No. of workers

Forklift truck

Remarks

HD465-7, HD605-7

[3-1] ORDER FOR ASSEMBLY, FACILITIES TO USE, SCHEDULE FOR ASSEMBLY

DayTime

(hrs) 1 2 3 4 5 6 7 8

1 Positioning base machine on sup-ports

A-1

2 cranes

30 ton 30 ton

3.7 m3/min(Komatsu EC35Z5 or equivalent)

For driving air compressor

3 workers

2 ton

Meeting before starting operationUnloading partsStart of assembly

1 Assembly of rear axle, suspensionass'y

2 Assembly of rear axle ass'y

A-2 — A-6

1 crane

30 ton

* Select a smooth flat surface whenpositioning the rear axle.

* Adjust the height of the woodenblock so that the rear axle is horizon-tal.

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1st day

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HD465-7, HD605-7


Assembly unit



Air compressor

Generator

No. of workers

Forklift truck

Remarks

DayTime

(hrs) 1 2 3 4 5 6 7 8

1 Assembly of front right axle

A-7 — A-11

1 crane

15 ton



2 workers

2 ton

1 Assembly of tire

A-12

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2nd day

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Assembly unit



Air compressor

Generator

No. of workers

Forklift truck

Remarks

HD465-7, HD605-7


DayTime

(hrs) 1 2 3 4 5 6 7 8

1 Assembly of R.H. platform ass'y2 Assembly of R.H. catwalk ass'y

A-13 — A-17

1 crane

5 ton



2 workers

2 ton

1 Assembly of body work2 Assembly of dump body

A-18 — A-29

30 ton

3 workers

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3rd day

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Assembly unit



Air compressor

Generator

No. of workers

Forklift truck

Remarks

HD465-7, HD605-7


DayTime

(hrs) 1 2 3 4 5 6 7 8



2 workers

2 ton

1 Adjustments

A-30 — A-47

2 workers

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4th day

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HD465-7, HD605-7

[4] TOOLS AND EQUIPMENT TO USE

1 Tools to use

No. Name Specification Q'ty Remarks1 Two-ended ring wrench 14/17/19/24/30/36 One each2 Impact wrench GT-S12M or equivalent 13 Impact wrench GT-S22M or equivalent 14 Impact wrench RSP220N x 22 or equivalent 15 Impact wrench RSP310N x 24 or equivalent 16 Impact wrench GTP-800P or equivalent 17 Socket 36 (Insertion angle: 25.4) /46mm 18 Socket 14/17/19/22/24/30 One each9 Wrench 14/17/19/24/30/36 One each10 Extension bar Insertion angle: 25.4 x L:160 mm 1 For assembling tire11 Torque wrench Able to measure 927 Nm 112 Torque wrench Able to measure 177 Nm 113 Torque wrench Able to measure 277 Nm 114 Torque wrench Able to measure 1568 Nm 115 Bar 1 For assembling tire16 Paint spray can Clear 2 For assembling tire17 Bucket 1 For "settling" work

2 Equipment to use

No. Name Specification Q'ty Remarks1 Truck crane Min. 30 ton 2 For lifting bare machine2 Truck crane Min. 15 ton 13 Truck crane Min. 5 ton 12 Forklift truck Min. 2 ton 1 For assembling tire3 Compressor Capacity: Min. 32 l 1 For impact wrench4 Stand (operating stand) 4 steps (approx. 1.5 m) 1 For use during operation5 Steel sheet t9 × 1219 × 2438 1 For positioning bare machine6 Wooden block 400 × 400 × 900 6 For positioning bare machine7 Wooden block 401 × 400 × 1200 1 For positioning rear axle

3 Lifting tools to use

No. Name Specification Q'ty Remarks1 Nylon sling For 15-ton x L4000 4 For lifting bare machine2 Tire lifting tool L4000, chain diameter d6.3 1 For lifting tire3 Chain block For 15 ton 1 For lifting axle

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HD465-7, HD605-7

[4] TOOLS AND EQUIPMENT TO USE

3 Lifting tools to use

1. Nylon sling 2. Tire lifting tool

3. Chain block

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PROCEDURE FOR LOCAL ASSEMBLY NO. A-1 1/1

SETTING BARE MACHINE IN POSITION

1 Lifting bare machine

1. When lifting the machine, fit a cloth at the contact point to prevent damage.2. Using two 30-ton cranes, raise the bare machine.

Lifting tool: Nylon sling (for 15 ton x L4000mm x 4)Lifting point at front: Lifting eye under bumperLifting point at rear: Body lock pin mount (using body lock pin)

2 Setting bare machine in position

3. Set the bare machine as shown in the diagram above.(Make sure that there is sufficient clearance from the ground as shown in the diagram above tomake it possible to assemble the tire & wheel assembly.)In addition, when setting on the ground surface, lay steel plates under the wooden blocks toprevent the machine from tilting if the wooden blocks sink into the ground. (1219 x 2438 x 9t x 1)

Precautions

Crane (30-ton) 2Nylon sling 4Steel plate 1

(1219 × 2438 × 9t)Wooden block 6

(400 × 400 × 900)

Tools to useName Q'ty

Equipment to useName Q'ty

Others

When lifting the chassis, fit a clothbetween the chassis and the nylonsling to prevent damage to the frontbumper or other parts.

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ASSEMBLY OF REAR AXLE AND SUSPENSION

1 Assembly of suspension

1. Using one 30-ton crane, raise the rear axle & tire assembly.Lifting tool : Nylon sling (for 15 ton x L4000mm x 2)Lifting point : Rod mount on top of differential

2 Positioning rear axle

2. Set the bare machine as shown in the diagram above.(Make sure that there is sufficient clearance from the ground as shown in the diagram above tomake it possible to assemble the tire & wheel assembly.)In addition, when setting on the ground surface, lay steel plates under the wooden blocks toprevent the machine from tilting if the wooden blocks sink into the ground.

3. Put blocks under the tires to prevent the rear axle from moving.

Precautions


(1219 × 2438 × 9t)Wooden block 1

(400 × 400 × 1200)Chocks to block tires 4



Others

Put blocks under the tires to preventthe tires from moving.

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ASSEMBLY OF REAR AXLE ASSEMBLY (CONNECTION OF SUSPENSION)

1 Connection of suspension

Part No. Part Name Q'ty Details of shipment1 569-40-61552 Pin 2 Already temporarily installed to chassis2 01010-81425 Bolt 2 Already temporarily installed to chassis3 569-40-61710 Washer 2 Already temporarily installed to chassis4 569-52-41950 Spacer 4 Already temporarily installed to chassis

1. Using two 30-ton cranes, raise the bare machine.Lifting tool: Nylon sling (for 15 ton x L4000mm x 4)Lifting point at front: Lifting eye under bumperLifting point at rear: Body lock pin mount (using body lock pin)

2. Set the rear axle as shown in the diagram above.3. Put blocks under the tires to prevent the rear axle from moving.4. Raise the bare machine and connect the rear axle assembly.

Precautions


(1219 × 2438 × 9t)Wooden block 1

(400 × 400 × 1200)Chocks to block tires 4Stand (operating stand) 1



Others

Put blocks under the tires to preventthe tires from moving.Do not use force when fitting thespacer. If the spacer is forced in, it willbe deformed.

·GTP-12 or equivalent Impact wrench 1 (22-mm socket)

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ASSEMBLY OF REAR AXLE ASSEMBLY (CONNECTION OF AXLE ROD)

1 Connection of axle rod

Precautions


(1219 × 2438 × 9t)Wooden block 1

(400 × 400 × 1200)Chocks to block tires 4



Others

Put blocks under the tires to preventthe tires from moving.Do not use force when fitting thespacer. If the spacer is forced in, it willbe deformed.

Part No. Part Name Q'ty Details of shipment1 569-40-81550 Pin 2 Already temporarily installed to rear axle2 569-52-81150 Pin 2 Already temporarily installed to chassis3 01010-81425 Bolt 4 Already temporarily installed to rear axle and chassis4 569-40-61710 Washer 4 Already temporarily installed to rear axle and chassis5 569-40-61160 Bushing 8 Already temporarily installed to rear axle and chassis6 569-52-41950 Spacer 8 Already temporarily installed to rear axle and chassis

1. Using two 30-ton cranes, raise the bare machine.Lifting tool: Nylon sling (for 15 ton x L4000mm x 4)Lifting point at front: Lifting eye under bumperLifting point at rear: Body lock pin mount (using body lock pin)

2. Set the rear axle in position.3. Put blocks under the tires to prevent the rear axle from moving.4. Raise the bare machine and connect the rear axle assembly.

·GTP-12 or equivalent Impact wrench 1 (22-mm socket)

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ASSEMBLY OF REAR AXLE ASSEMBLY(CONNECTION OF LUBRICATION GREASE TUBE)

1 Connection of lubrication grease tube

Part No. Part Name Q'ty Details of shipment1 569-52-62612 Tube 1 Sent as individual unit (separately packed)2 569-52-62622 Tube 1 Sent as individual unit (separately packed)3 421-09-12540 Elbow 2 Sent as individual unit (separately packed)4 423-09-12110 Connector 2 Sent as individual unit (separately packed)

Assemble the connector and elbow, then assemble the lubricator tube.

Precautions

Stand (operating stand) 1



Others

·Wrench (14 mm) 1

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ASSEMBLY OF REAR AXLE ASSEMBLY (ASSEMBLY OF DRIVE SHAFT)

1 Assembly of drive shaft

Fig. 1A) Tap the drive shaft spider portion with a hammer

to bring the spigot joint portion into close contact.B) Assemble the bolts and tighten in order on oppo-

site sides.C) Tighten again with a torque wrench to the torque

given in the drawing.D) Tighten in the order given in Fig.1.

Part No. Part Name Q'ty Details of shipment1 01050-61470 Bolt 8 Sent as individual unit (separately packed)2 569-89-82210 Guard 1 Sent as individual unit (separately packed)3 01010-82465 Bolt 4 Sent as individual unit (separately packed)4 01643-32460 Washer 4 Sent as individual unit (separately packed)

1. Remove guard 2 from the chassis.2. Raise the drive shaft with a crane and insert it between the rear axle and transmission.3. Align the drive shaft spigot joint portion securely, then tap with a hammer to insert into the spigot

joint portion. (See Fig.1)4. Tighten the bolts with a torque wrench.

Precautions

Stand (operating stand) 1Crane (5-ton) 1Nylon sling 1



Others

·Wrench (36 mm) 1·RSP220N x 22 1 (22 x 2200 RSP) or equivalent impact wrench

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ASSEMBLY OF RIGHT FRONT AXLE

1 Lifting right front axle

Precautions

Crane (15-ton) 1Nylon sling 2Chain block 1



Others

1. Using one 15-ton crane, raise the right front axle.Lifting tool : Nylon sling (for 15 ton x L4000mm x 1)

: Chain block (for 15 ton x 1)Lifting point : Front suspension, axle mount (nylon sling)

: Axle arm (chain block)

·GTP-12 or equivalent impact wrench (22-mm socket) 1

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ASSEMBLY OF FRONT AXLE (CONNECTION OF SUSPENSION)

1 Connection of suspension

Part No. Part Name Q'ty Details of shipment1 569-40-81540 Pin 1 Already temporarily installed to chassis2 01010-81425 Bolt 1 Already temporarily installed to chassis3 569-40-61710 Washer 1 Already temporarily installed to chassis4 566-52-11120 Spacer 2 Already temporarily installed to chassis

1. Using one 15-ton crane, raise the right axle assembly.Lifting tool : Nylon sling (for 15 ton x L4000mm x 1)Lifting point : Wind around suspension

2. Lift the front suspension with a nylon sling.3. Remove the pin and spacer temporarily installed to the chassis.4. Use the crane to move to the axle mount, then assemble.

5. Connect the suspension pressure sensor (CN SUFR) to the chassis wiring harness.

Precautions

Crane (15-ton) 1Nylon sling 1Stand (operating stand) 1



Others

Do not use force when fitting thespacer. If the spacer is forced in, it willbe deformed.


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ASSEMBLY OF RIGHT FRONT AXLE (CONNECTION OF AXLE ARM)

1 Connection of axle arm

Precautions

Crane (15-ton) 1Nylon sling 1Chain block 1Stand (operating stand) 1



Others

Do not use force when fitting thespacer. If the spacer is forced in, it willbe deformed.

Part No. Part Name Q'ty Details of shipment1 569-40-81230 Pin 1 Already temporarily installed to chassis2 569-52-81550 Pin 1 Already temporarily installed to chassis3 01010-81425 Bolt 2 Already temporarily installed to chassis4 569-40-61710 Washer 2 Already temporarily installed to chassis5 569-52-41950 Spacer 2 Already temporarily installed to chassis6 569-40-61130 Spacer 2 Already temporarily installed to chassis

1. Using one 15-ton crane, raise the right front axle.Lifting tool : Nylon sling (for 15 ton x L4000mm x 1)

: Chain block (for 15 ton x 1)Lifting point : Front suspension, axle mount (nylon sling)

: Axle arm (chain block)

2. Lift the axle with a nylon sling, then lift the axle arm with the chain block.3. Remove the pin and spacer temporarily installed to the chassis.4. Align that the mounting hole of the axle arm and chassis.5. Install the pin and spacer, then secure with the stopper bolt.


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ASSEMBLY OF RIGHT FRONT AXLE (CONNECTION OF STEERING CYLINDER & ROD)

1 Connection of steering cylinder & rod

Part No. Part Name Q'ty Details of shipment1 569-40-81240 Pin 1 Already temporarily installed to front axle2 569-40-81530 Pin 1 Already temporarily installed to front axle3 01010-81425 Bolt 2 Already temporarily installed to front axle4 569-40-61710 Washer 2 Already temporarily installed to front axle

1. Using one 15-ton crane, raise the right front axle.Lifting tool : Nylon sling (for 15 ton x L4000mm x 1)Lifting point : Axle mount

2. Lift the axle and adjust so that the steering cylinder and tie rod are parallel with the lever.3. Insert the rubber and boot, align the pin hole, then assemble the pin.4. Assemble the stopper bolt and tighten it.5. Connect the lubricant grease tubes (2 places).6. Grease the pin mount.

Precautions

Crane (15-ton) 1Nylon sling 1Chain block 1Stand (operating stand) 1



Others

1) Check that there are O-rings at thesteering cylinder and tie rodmounts.

2) The length of each pin is different,so be careful when assembling.


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ASSEMBLY OF RIGHT FRONT AXLE (CONNECTION OF BRAKE HOSE)

1 Connection of brake hose

1. Remove the blind plug from the tip of the drain hose removed from the chassis.2. Check the hose number and the block number, then assemble.

Precautions




Others

Check that there is no mistake in thehose number and the block number,then assemble.

·Wrench (19 mm) 1

23


ASSEMBLY OF TIRE & WHEEL ASSEMBLY

1 Lifting tire & wheel assembly

<Method of lifting tire & wheel assembly> <Image of transporting tire>

1. Fit the lifting tool to the tire & wheel assembly.Lifting tool: Chain lifting tool (L4000, chain diameter ø6.3)

2. Using a 15-ton crane, raise and set on a forklift truck.

2 Assembly of tire & wheel assembly

Part No. Part Name Q'ty Details of shipment1 569-22-72870 Nut 14 Already temporarily installed to front axle2 426-09-11520 Washer 14 Already temporarily installed to front axle

1. Remove the nuts and washers temporarily assembled to the axle.2. Use a forklift truck to install the tire to the axle, then assemble the nuts and washers.

Note: Be careful not to let the tire fall off the forklift truck.Be careful not to damage the tire inflation tube when positioning the tire & wheel assembly.

3. Tighten the tire bolts temporarily with an impact wrench.4. Using a 30-ton crane, raise the front of the bare machine and remove the wooden blocks.

Lifting tool: Nylon sling (for 15 ton x L4000mm x 2)5. Using a torque wrench, tighten the tire bolts to the specified tightening torque.6. Touch up the head of the bolts with a paint spray (clear). (To prevent rust)

Precautions

Crane (30-ton) 1Forklift truck 1

(min. 2 ton)Tire lifting tool 1



Others

1) Be careful not to let the tire &wheel assembly fall off the forklifttruck when transporting it.

2) Be careful not to damage the tireinflation tube when positioningthe tire & wheel assembly.

46-mm socket 1Impact wrench 1

(GT-S22M)Torque wrench 1

(1568 Nm)Extension bar 1Bar 1Paint spray can 2

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ASSEMBLY OF FRONT SUPPORT

1 Assembly of front support

Part No. Part Name Q'ty Details of shipment1 01010-82040 Bolt 4 Already temporarily installed to chassis2 01643-32060 Washer 4 Already temporarily installed to chassis3 04434-51010 Clip 1 Already temporarily installed to chassis4 01435-01016 Bolt 1 Already temporarily installed to chassis

1. Using a 5-ton crane, raise the front support.Lifting tool: Nylon sling (for 15 ton x L4000mm x 1)

2. Lift the front support with a nylon sling.3. Remove the bolts and washers temporarily installed to the chassis.4. Assemble the front support.

5. Connect the right platform intermediate connector (CN RP) to the chassis wiring harness.

Precautions




Others

·Wrench (30 mm) 1·GTP-800 or equivalent 1 impact wrench (14-mm socket)

25


ASSEMBLY OF RIGHT FENDER LOCK BRACKET

1 Assembly of right fender lock bracket

Part No. Part Name Q'ty Details of shipment1 01010-81230 Bolt 2 Already temporarily installed to chassis2 01643-31232 Washer 2 Already temporarily installed to chassis

1. Remove the bolts and washers temporarily assembled to the chassis.2. Assemble the right fender lock bracket.

Precautions




Others

·Two-ended ring wrench (19 mm) 1

26


ASSEMBLY OF R.H. PLATFORM ASSEMBLY

1 Assembly of R.H. platform assembly

Precautions




Others

Part No. Part Name Q'ty Details of shipment1 01010-81230 Bolt 8 Already temporarily installed to chassis2 01643-31232 Washer 8 Already temporarily installed to chassis3 01010-82045 Bolt 2 Already temporarily installed to chassis4 01643-32060 Washer 2 Already temporarily installed to chassis5 09415-05016 Cap 2 Already temporarily installed to chassis

1. Using a 5-ton crane, raise the right platform assembly.Lifting tool: Nylon sling (for 15 ton x L4000mm x 2)

1. Remove the bolts and washers temporarily assembled to the chassis.2. Assemble the right platform assembly.3. Install the cap.4. Adjust the mirror angle.

·Two-ended ring wrench (19 mm) 1·Two-ended ring wrench (30 mm) 1

27


ASSEMBLY OF L.H. CATWALK ASSEMBLY

1 Assembly of L.H. catwalk assembly

Precautions




Others

Part No. Part Name Q'ty Details of shipment1 01010-81230 Bolt 4 Already temporarily installed to chassis2 01643-31232 Washer 4 Already temporarily installed to chassis3 01010-81225 Bolt 8 Already temporarily installed to chassis4 01643-31232 Washer 8 Already temporarily installed to chassis

1. Using a 5-ton crane, raise the left catwalk assembly.Lifting tool: Nylon sling (for 15 ton x L4000mm x 2)

1. Remove the bolts and washers temporarily assembled to the chassis.2. Assemble the left catwalk assembly.3. Adjust the mirror angle.


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ASSEMBLY OF L.H. HANDRAIL

1 Assembly of L.H. handrail

Precautions




Others

Part No. Part Name Q'ty Details of shipment1 561-54-61910 Clamp 2 Already temporarily installed to chassis2 01010-81635 Bolt 4 Already temporarily installed to chassis3 01643-31645 Washer 4 Already temporarily installed to chassis4 01010-81240 Bolt 1 Already temporarily installed to catwalk assembly5 01580-11210 Nut 1 Already temporarily installed to catwalk assembly6 01643-31232 Washer 2 Already temporarily installed to catwalk assembly

1. Remove the bolts and washers temporarily assembled to the chassis and catwalk assembly.2. Assemble the handrail.

Two-ended ringwrench (19 mm) 1


29


ASSEMBLY OF R.H. FENDER

1 Assembly of R.H. fender

Part No. Part Name Q'ty Details of shipment1 01435-01225 Bolt 4 Already temporarily installed to fender bracket2 08036-01214 Clip 3 Already temporarily installed to fender3 01435-01020 Bolt 2 Already temporarily installed to fender

1. Remove the bolts and washers temporarily assembled to the fender bracket.2. Assemble the right fender.3. Remove the clips and the bolts temporarily assembled to the fender.4. Secure the fuel breather tube as shown in the diagram.

Precautions




Others



30


ASSEMBLY OF L.H. FENDER

1 Assembly of L.H. fender

Part No. Part Name Q'ty Details of shipment1 01435-01220 Bolt 4 Already temporarily installed to chassis

1. Remove the bolts and washers temporarily assembled to the chassis.2. Assemble the left fender.

Precautions




Others


31


ASSEMBLY OF LEFT AND RIGHT MUDGUARDS

1 Assembly of left and right mudguards

Part No. Part Name Q'ty Details of shipment1 569-54-41551 Plate 2 Already temporarily installed to fender2 01435-01225 Bolt 10 Already temporarily installed to fender

1. Remove the plate and the bolts temporarily assembled to the fender.2. Assemble the left and right mudguards.

Precautions




Others: This work process shows the right side of the truckbody. The work process for the left side of the truckbody is the same as this.


32


ASSEMBLY OF LEFT OVER FENDER

1 Assembly of left over fender

Precautions




Others

Part No. Part Name Q'ty Details of shipment1 283-54-11470 Plate 2 Already temporarily installed to catwalk2 01435-01025 Bolt 1 Already temporarily installed to catwalk3 417-43-16210 Washer 1 Already temporarily installed to catwalk4 01435-01025 Bolt 4 Already temporarily installed to catwalk5 01435-01025 Bolt 1 Already temporarily installed to catwalk6 417-43-16210 Washer 1 Already temporarily installed to catwalk

1. Remove the plates and the bolts temporarily assembled to the chassis and catwalk.2. Assemble the left over fender.

Two-ended ringwrench (14mm) 1

33


ASSEMBLY OF RIGHT OVER FENDER

1 Assembly of right over fender

Precautions




Others

Part No. Part Name Q'ty Details of shipment1 283-54-11470 Plate 3 Already temporarily installed to platform2 569-54-81620 Plate 2 Already temporarily installed to platform3 01435-81025 Bolt 12 Already temporarily installed to platform4 01435-81025 Bolt 1 Already temporarily installed to platform5 417-43-16210 Washer 1 Already temporarily installed to platform

1. Remove the plates and the bolts temporarily assembled to the left platform.2. Assemble the left over fender.


34


MOUNTING OF DUMP BODY (LIFTING DUMP BODY)

1 Lifting dump body

Precautions

Crane (30-ton) 1Nylon sling 4



Others

1. Using one 30-ton crane, raise the dump body.Lifting tool : Nylon sling (for 15 ton x L4000mm x 4)Lifting point : Special lifting positions at side of dump body (4 places)

Install the special dump body lifting pins at 4 places in the holes from the outside of the body sideface as shown in the diagram above.Install the nylon slings at the 4 specified lifting points.Check the center of gravity, then lift the dump body.

Select a level ground surface whencarrying out this operation.

35


MOUNTING OF DUMP BODY (INSTALLATION OF HINGE PIN)

1 Installation of hinge pin

Precautions




Others

1. Using one 30-ton crane, raise the dump body.Lifting tool : Nylon sling (for 15 ton x L4000mm x 4)Lifting point : Special lifting positions at side of dump body (4 places)

Part No. Part Name Q'ty Details of shipment1 569-74-11530 Shim t=6.0 4 Already temporarily installed to chassis2 569-74-11540 Shim t=1.0 12 Already temporarily installed to chassis3 569-74-61740 Pin 2 Already temporarily installed to chassis4 01010-81635 Bolt 2 Already temporarily installed to chassis5 01643-31645 Washer 2 Already temporarily installed to chassis6 421-70-11280 Washer 2 Already temporarily installed to chassis

1. Give signals to the crane operator and align the pin holes at the dump body mount and frame mount.2. Insert an equal thickness of shims on the left and right.3. Secure with the stopper bolt.4. Carry out the above operation in the same way on the left and right sides.

· Two-ended ring wrench (24mm) 1· RSP310N x 24 (24 x 3100 RSP) or equivalent impact wrench 1

36


ASSEMBLY OF POKE EJECTOR

1 Assembly of poke ejector

Precautions




Others

Part No. Part Name Q'ty Details of shipment1 569-74-61690 Spacer 2 Sent as individual unit (separately packed)2 01643-22540 Washer 2 Sent as individual unit (separately packed)3 01011-82490 Bolt 2 Sent as individual unit (separately packed)4 01580-12419 Nut 4 Sent as individual unit (separately packed)

1. Adjust with spacers and install the poke injector so that it is in the center between the two tires.


37


ASSEMBLY OF DUMP BODY LOCK PIN

1 Assembly of dump body lock pin

Part No. Part Name Q'ty Details of shipment1 569-74-61670 Pin 2 Sent as individual unit (separately packed)2 569-74-61470 Linch pin 2 Sent as individual unit (separately packed)

1. Assemble the body lock pins.2. Assemble the linch pins.

Precautions




Others

·Two-ended ringwrench (36 mm) 1

38


ASSEMBLY OF DUMP BODY MUDGUARD

1 Assembly of dump body mudguard

Precautions




Others

Part No. Part Name Q'ty Details of shipment1 569-74-61640 Support 1 Sent as individual unit (separately packed)2 569-74-61630 Support 1 Sent as individual unit (separately packed)3 569-74-61660 Guard 2 Sent as individual unit (separately packed)4 569-74-61650 Plate 2 Sent as individual unit (separately packed)5 01010-81230 Bolt 14 Sent as individual unit (separately packed)6 01643-31232 Washer 14 Sent as individual unit (separately packed)7 01010-81225 Bolt 14 Sent as individual unit (separately packed)8 01643-31232 Washer 14 Sent as individual unit (separately packed)

1. Assemble the support to the body.2. Assemble the mat guard to the support so that it fits inside the plate. (Assemble with the shiny

surface facing the rear of the machine.)


Assemble the mat guard with theshiny surface facing the rear of themachine.

39


MOUNTING OF DUMP BODY (SHIM ADJUSTMENT PROCEDURE)

1 Shim adjustment procedure

1. Procedure for adjusting shim at dump body mountAdjust as follows.

(1) Bottom mount (rubber mount of dump body bottomplate)a. Insert a spacer of height 29 mm at the tip of the dump

body.b. Measure dimension d of the frame and center posi-

tion of the bottom mount. (Left and right: 6 places)c. Make the shims at d1, d2, and d3 (d1-26) mm, (d2-26) mm,

and (d3-26) mm respectively.d. Install the bottom mount and remove the spacer.e. Lower the dump body and check that the bottom mount

contacts the top surface of the frame at all 6 places.f. This completes the adjustment of the bottom mount.

(2) Front mount (rubber mount of dump body front surface plate)a. After completing adjustment of the bottom mount above, put the bracket (569-46-62831) on

top of the frame (rear support), put in position and temporarily install so that the clearancefrom the dump body bracket is 57 mm.

b. Raise the dump body and weld the bracket in position.c. Insert 7 shims (569-74-61580) to make a thickness of 7 mm, then install the rubber pad (569-74-

61520).d. Lower the dump body and check that the overall thickness of

the rubber pad is 50 mm. If it is not 50 mm, adjust with shims tomake it 50 mm.

e. This completes the adjustment of the front mount.2. After assembling the dump body, adjust the shims so that the mis-

alignment between the protector and the cab is within 58 mm.(See cross section A - A)

3. Check that there is no paint on the mounting seat of the pin lockseat, inside surface of the thread, or seat surface of the washer.If there is paint on any tightening surface, use thinner to com-pletely remove the paint. (4 places marked ✩ )

Precautions




Others

Part No. Part Name Q'ty Details of shipment1 569-74-61531 Shim t=1.0 18 Sent as individual unit (separately packed)2 569-74-61541 Shim t=3.2 6 Sent as individual unit (separately packed)3 569-70-61840 Shim t=1.0 3 Sent as individual unit (separately packed)4 569-70-61850 Shim t=1.0 7 Sent as individual unit (separately packed)5 569-70-61860 Shim t=1.0 9 Sent as individual unit (separately packed)6 569-70-61870 Shim t=1.0 2 Sent as individual unit (separately packed)7 01010-81665 Bolt 24 Sent as individual unit (separately packed)8 01643-31645 Washer 24 Sent as individual unit (separately packed)9 569-74-61511 Plate 6 Sent as individual unit (separately packed)

·Two-ended ring wrench (22 mm) 1·RSP310N x 24 (24 x 3100 RSP) or equivalent impact wrench 1

For details of the welding work at thefront body mount, see the separateProcedure for "On-the-spot Welding".

40


WELDING ACTUAL PARTS (INSTALLATION OF PROTECTIVE COVER)

1 Installation of protective cover

Precautions




Others

1. Install the protective cover as shown in the photograph above.

41


ASSEMBLY OF EXHAUST PIPE TUBE

1 Assembly of exhaust pipe tube

Precautions




Others

Part No. Part Name Q'ty Details of shipment1 569-02-81150 Gasket 1 Sent as individual unit (separately packed)2 01010-81230 Bolt 6 Sent as individual unit (separately packed)3 01643-31232 Washer 6 Sent as individual unit (separately packed)

1. Check that dimension A = 119 mm at the time of delivery.2. Assemble the gasket and tube to the exhaust tube assembled inside the rear support.3. With dimension B = 87 mm, insert the plate to the tube, and insert the exhaust port into the body.4. Center of the tube and flange at the flange mating surface, then weld the dump body, plate, and

tube.* Center runout: Less than 3 mm

5. After completing the welding, remove the jig.


For details of the welding work for theexhaust pipe tube and body portion,see the separate design drawing 569-02-81001.

42


CONNECTION OF DUMP SENSOR

1 Connection of dump sensor

Precautions




Others

Part No. Part Name Q'ty Details of shipment1 01010-81035 Bolt 1 Sent as individual unit (separately packed)

1. Adjust the length of the rod so that the lever hole and the angle sensor hole (part marked Î) arealigned. (Specified value: 433 mm)

2. Secure to the dump body with bolts.


43


FILLING WITH GREASE, WATER 1

1 Filling with grease, water

Method of using fuel, lubricant, and coolant according to ambient temperature! Fuel, oil

Use the correct type for the ambient temperature as shown in the table below.Î Specified capacity: Total amount of oil including oil for components and oil in piping

Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.Î When starting the engine in an ambient temperature of less than 0ºC, always use SAE10W-30, or

SAE15W-40, even though the temperature goes up to 10ºC during the daytime.! Coolant

Komatsu genuine super coolant (AF-ACL) is added to the cooling water, so there is no need tochange it for temperatures down to -10ºC.If the temperature goes below -10ºC, adjust the density. For details, see CLEANING INSIDE OFCOOLING SYSTEM in the WHEN REQUIRED Section of the Operation and Maintenance Manual.

Precautions Tools to useName Q'ty


Others

1. Check the oil and water levels before starting the engine.Engine oil level, steering cylinder, hoist cylinder oil level, rear brake cooling oil level, transmis-sion oil level, front brake oil level, sub-tank water level, fuel tank level

44


FILLING WITH GREASE, WATER 2

1 Filling with grease, water

Reservoir Kind of fluid Specified capacity (l) Refill capacity (l)

Engine oil pan 67 57

Transmission case 285 190

Steering, hoist, oil tank 180 122

Front suspension Engine oil Left and right: 17 each —

Rear suspension Left and right: 11.3 each —

Differential case 95 95

Final drive case Left and right: 32 each Left and right: 21 each

Fuel tank Diezel fuel 780 —

Cooling system Water 154 —



Others

45


BLEEDING AIR FROM BRAKE

1 Bleeding air from brake

Front brake Rear brake: Slack adjuster



Others

Procedure for bleeding air1. Fill the oil tank with brake fluid. (Brake fluid: EO-10CD)2. Remove the bleeder screw cap, insert the tip of a vinyl hose into the screw hole, and insert the

other end into a container of brake fluid.3. Depress the pedal, loosen the bleeder screw, release the air, tighten the screw, then release the

pedal.4. epeat this operation until no more bubbles come out with the brake fluid from the hose, then

depress the pedal fully and tighten the bleeder screw while the fluid is flowing out.5. Repeat the procedure to bleed all the air from each caliper, then check the oil level in the oil tank

and add oil if necessary.

46


ADJUSTING DUMP CONTROL

1 Adjusting dump control

Precautions




Others

1. Lower the dump body and seat it completely, then start the engine, set the control lever to theFLOAT position, and hold it there for at least 5 sec.* Hydraulic oil temperature: 80 - 90ºC* Check that the float caution lamp is out.

2. Raise the dump body to the cylinder stopper, run the engine at low idling, and keep the controllever at the RAISE position for at least 5 sec.

3. Run the engine at high idling, raise the dump body fully, then run the engine at low idling, set thecontrol lever to the FLOAT position, and lower the dump body to the seated position. Repeat thisoperation 5 - 10 times.

4. Run the engine at high idling, raise the dump body fully, keep the engine running at high idling,set the control lever to the LOWER position, and lower the dump body to the seated position.Repeat this operation 5 - 10 times.

47


PAINTING

1 Painting

Precautions




Others

Bottom coat Top coatRethane GP primer NAX Mightylac GIIKB Natural YellowRethane GP hardening agent NAX Mightylac GIIKB hardening agentRethane GP thinner NAX Mightylac GIIKB thinner

Exhaust pipe: Heat-resistant silver

1. Use the specified paint for the above places and paint the welded portions.2. Mix the paint in a proportion of 5:1 of base and hardening agent before using.3. Wash the paint gun in thinner before the paint hardens.

48


ADJUSTMENT OF SUSPENSION

1 Adjustment of suspension

Precautions




Others

Part No. Part Name Q'ty Details of shipment1 566-98-14401 Bolt 1 Sent as individual unit (separately packed)

1. Charge the suspension with nitrogen gas.2. Using a set of nitrogen gas charging tools, charge the left and right cylinders at the same time.3. Align the front with the decal, then charge with gas so that the dimension at the rear is the

dimension shown in the diagram.4. Move the machine to the front and rear to settle the cylinders, then adjust again. (See to next page)

1. Do not extend the cylinder fully.2. After moving the machine to the

front and rear, stop the machinewithout using the brake. (Usingthe brake will create a higher loadon one side.)

49


SETTLING FLOATING SEAL

1 Settling floating seal

Precautions




Others

Fig. 1: Travel conditionsShift Travel distance (guideline) m

F1 500F2 500F3 1000F4 1000F5 1000F6 1500F7 1500

1. Using Fig. 1 for reference, travel a total distance of at least 7000 m.2. Settle the floating seal inside the rear axle.3. After traveling, check visually that the amount of drained oil is very small.

(Max. 30 cc for every standard 7 km traveled)

Oil container 1

51

HD465-7 HD605-7

PROCEDURE FOR WELDING AND ASSEMBLING THREESEPARATED BODY PARTS

CONTENTS

Preparation work for local assembly of body divided into three parts ............................................... 52Assembly of divided body parts ............................................................................................................ 54Welding procedure for divided body parts ........................................................................................... 56Operation for assembly and welding of divided body protector ........................................................ 62Protector .................................................................................................................................................. 64Welding of the body assembly .............................................................................................................. 66

Process drawing

52

PREPARATION WORK FOR LOCAL ASSEMBLY OF BODYDIVIDED INTO THREE PARTS

Welding machine Generator Semi-automatic welding machine

Order of work Work procedure

53

1. Selection of place for welding operation

2. Arrange welding machine, generator, andtools.

3. Unload the body. (Lower the body in thespecified condition)

4. Remove the protector stored in the body.

5. Remove the paint from the places to be welded.

6. Turn the body part.

7. Place support stands on the ground surfaceas shown in the diagram on the right to sup-port the body part at the assembly point.

• The floor or ground surface area must be atleast 169 m2 (13 m x 13 m).

• The flatness of the floor or ground surfacemust be less than 0.05 m over a distance of10 m.

• Place the body part on top of suitable woodenblocks.

• If the protector is secured by a plate, removeit with a gas cutter.

• The range for the whole line of the matingportion shall be 15 mm.

• Heat with gas to burn off the paint or removeit with a grinder.

• This work can be performed easily, if 2 truckcranes are used.

Process drawing

54

ASSEMBLY OF DIVIDED BODY PARTS


55

1. Set one of the divided body parts on top ofthe support stands.

2. Set the divided body part on the opposite sideon top of the support stands so that the clear-ance is constant.

3. Using the plate (front and bottom portions)(566-83-6H190), tighten with the followingparts.

01011-82010 Bolt01643-32060 Washer01580-12016 Nut581-74-11630 Tube

4. Mark the position of the temporarily installedbracket (569-74-61210), then remove.

5. Pass the alignment pin through the bottomhinge brackets (569-74-61181, 61191 Bracket),check the height and position, then removethe pin.

6. The temporarily installed the body.

7. Position and temporarily install brackets (569-24-61460).

8. Temporarily install bracket (569-74-61210) atthe marked position.

• If the two parts do not match correctly, use ahydraulic cylinder to adjust.

• After temporarily installing, remove the bolt,washer, nut, and tube.

• If the divided body parts are positioned in-correctly, correct with a hydraulic cylinder.

• When correcting, check that the tighteningbolts are loose.

Process drawing

56

WELDING PROCEDURE FOR DIVIDED BODY PARTS


57

1. Weld the front portion (portion X).(Large plate joint and channel joint)

2. Position 2 plates (561-83-69450) and 1 plate(569-83-69490).

3. Set bottom portion (Y portion) horizontal andcarry out welding.(Large plate joint and channel joint, and 2brackets (569-74-61460) and 1 bracket (569-74-61210))

4. Set 4 plates (569-83-69470), 2 plates (569-83-89460), and 1 plate (569-83-69550) in positionon the channel, and weld them.

5. After completing the welding, remove thesputter with a grinder and finish the bead por-tion.

• Use arc welding and weld the front vertically.(The conditions for vertical welding shall con-form with Table 1.)

• Weld the inside of the channel also.

• Insert backup material into the joint betweenone channel and the other channel. (Only thejoint of the bottom plate)(For backup material, use SS400B 9 mm)

• Set the bottom rear portion on the stand andkeep it horizontal.

• Carry out reverse return welding at the beadjoint and beginning of the arc.

Process drawing

60


61

• Insert wooden blocks at the front and rear ofthe bottom.

• Connect the welding ground securely to thebody.

• Use CO2 gas shield welding as the standard.However, use arc welding in places where itis difficult.

• Drying time for arc welding rod(1) Temperature: 150 to 200°C(2) Time: 120 minutes

• Check that there are no welding defects.(1) Check for adhered metal(2) Check for undercuts, overlaps, adherence

of sputter(3) Insufficient welding leg length (a nega-

tive value is not allowed)

• TurningRaise the bottom hinge bracket (569-74-61181, 61191) and enter turning posture.

(Procedure for turning)

• Maintain the posture on the left (raised by acrane) and weld the front mating portion.

• Next, weld the bottom joint.

Table 1.

• FinishingRemove the sputter and finish the bead por-tion with a grinder.

(1) Do not useCO2 gasweldingwhen thewind speedexceeds 2 -3 m/sec.

(2) Remove allmoisture,dust, andpaint fromthe placesto bewelded.

Remarks

Weldingposture

Weldingrod

Weldingcurrent

Preheating, post-heating

Gasshieldamount

Flat (F)

JIS Z 3312YGW11 orequivalentd1.2, d1.6

320 – 350 A380 – 420 A

Not needed

CO2 25 – 35 l/min.

Flat, vertical (V)

JIS Z 3312D5016 orequivalentd4.0, d5.0

130 – 160 A220 – 260 A

Not needed

�

Arc weldingCO2 gasshield

welding

Process drawing

62

OPERATION FOR ASSEMBLY AND WELDING OF DIVIDEDBODY PROTECTOR


63

• Insert wooden blocks at the front, rear, left,and right of the bottom plate and set the bodyso that the top surface of the left and rightside plates is approximately horizontal.

• If there is a plate securing the protector, cut itwith a gas cutter.

• As shown above, raise the front face of theprotector approx. 1º (visual) after welding,and weld to the protector side plate.

1. Using a crane, set the protector on top of theside plate and front plate.Weight of protector: Approx. 1,150 kgCrane capacity: Min. 2 tons, lifting height:Min. 7 mWire rope, chain, chain block: Strength atleast two tons

2. Position so that the end face of the body sideplate and the plate at the side face of the pro-tector are parallel.

3. When positioning, use the gas cutter to cutthe plate at the side face and front face of theprotector so that the top of the body side plateand the top of the protector are parallel.Note : The protector and front face plate are

deformed by welding as shown in be-low, so it is necessary to use a gas cut-ter to cut the plate at the side face andfront face of the protector so that thegap is the minimum when welding.(The gap must be less than 3 mm.)

4. After positioning, temporarily install the pro-tector front face.

5. Weld the protector.Welding order: Weld the side face plates

(left and right) first.Welding symbol: As given on the right.Welding conditions: According to the table

Process drawing

64

PROTECTOR


65

• For the welding posture, basically use hori-zontal position or vertical position welding.(At high places only, when a safe foothold isensured, it is also possible to turn the bodyand carry out flat position welding.)

• Use back-step process for the welding.

• Use CO2 welding as the standard.However, use arc welding in places wherethere are restrictions.

• Drying time for arc welding rod(1) Temperature: 150 to 200°C(2) Time: 120 min

(6) After completion of welding, use agrinder to remove the sputter and finishthe bead joint.

(7) Check that there are no welding defects.1 Check for adhered metal.2 Check for undercuts, overlaps, adher-

ence of sputter.3 Insufficient welding leg length (a

negative value is not allowed).

6. Install the dump body to the machine again.

Table 1

Weldingmethod

(1) Do not useCO2 gasweldingwhen thewind speedexceeds 2 –3 m/sec.

(2) Remove allmoisture,dust, andpaint fromthe placesto bewelded.

Remarks

Weldingwire, rod

Wire, roddiameter

Weldingcurrent

Preheat-ing, post-heating

Gasshieldamount

JIS Z 3312YGW11 orequivalent

d1.2

320 – 350 A

Not needed

25 – 35 l/min.

JIS Z 3312D5016 orequivalent

d4.0

130 – 160 A

Not needed

�

Arc weldingCO2 gasshield

welding

Process drawing

66

WELDING OF THE BODY ASSEMBLY


67

1. Install the dump body to the frame, set tothe dump posture, then adjust.(For details of installation, see the assemblymanual.)

2. Use shims to adjust the dimension betweenthe dump body and frame before starting.

3. Welding dump body mountSet 2 brackets (569-46-62381) on top of theframe so that the dimension between thedump body and the bracket is 57mm, thenweld in position.(See View Z on left)

4. Welding anti-vibration bracketThis bracket has been discontinued on theDash 7 model, so this operation is notneeded.

5. Welding flange for dump body weldingWeld according to 569-02-81001.

• Move the body to the dump position whiledoing this.

FIELD ASSEMBLY INSPECTION REPORT

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

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

Printed in Japan

Model-Type Machine Serial No. User Unit No. Engine Model Engine Serial No.

Service Meter Reading Date of Inspection

Location of Machine at Inspection

Distributor’s Name

Customer’s Name Address: Signature: DeliveryReportNo. attached

Date:

Inspector’s Comments:

Inspector’s Name:

Title

Signature:

KOMATSU USE ONLY :

C. Sheet Receiving Date :

By :

Remark:

Attachment

Manufacture

Model

Serial No.

1 2

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.

SEAW003800

Report No.

!

HD465-7HD605-7

1/4

SAA6D170E-3

2/4

No.

1

2

Inspection item Judgment procedure and standards Check Mainte-nance

Remarks

Front axle Nos.

Rear axle Nos.

Record the serial Nos. of the component parts.

Check the oil and water levels.

Engine oil level (Check withengine stopped)

Hydraulic oil level

Transmission oil level

Coolant level

Battery fluid level

Windshield washer fluid level

Function of horn

Function of backup buzzer

The level must be between (H) and (H-10 mm).

The level must be inside the inspection window.

The level must be between (H) and (midpoint between H and L).* Check while the engine is running at low idling.

The level must be above the midpoint between Full and Lowof the sub-tank.

The fluid level must be 10 – 12 mm above the plates.

The fluid level must be above 2/3 of the tank.

The sound volume must be sufficient and free from beats.(Sensory evaluation)

The sound volume must be sufficient and free from beats.(Sensory evaluation)

Turn the key switch ON.

9

10

11

12

13

14

15

16

Start the engine. (Before starting the engine, check the safety around the truck.)

Exhaust gas color

Exhaust gas leakage

Safety function (1)

Safety function (2)

Function of clearance lamps

Check of head lamp

Check of high beam (Functionof dimmer switch)

Function of turn signal lamps

Function of hazard lamp

Function of backup lamp

Function of brake lamp

When the engine is accelerated sharply (Li → Hi), is ex-haust gas color good. (Sensory evaluation)

Exhaust gas must not leak through exhaust pipe joints, ex-haust gas shutter, etc.

When the transmission shift lever is not in N, the enginemust not start.

When the parking brake switch is ON and the transmissionshift lever is not in N, the centralized warning lamps andalarm buzzer must be turned ON.

When the lamp switch is turned ON (1st/2nd stage), both frontlamps and 3 rear lamps (right, center, and left) must light up.

When the lamp switch is turned ON (2nd stage), the headlamps (1 lamp on each side) must light up.

When the head lamp is turned ON and the dimmer switch isoperated, the number of the lamps must change between 2and 4. (The lighting direction must change.)

When the turn signal lever is operated, the front and rearturn signal lamps in the turning direction must flash.

When the hazard switch is turned ON, both turn signal lampsand pilot (arrow) lamp in the cab must flash.

When the transmission shift lever is in R, the backup lampmust light up.

When the brake pedal is pressed, the 3 red brake lamps(Right, center, and left) must light up.

When the retarder lever is pulled, the 2 red brake lamps(Right and left) must light up. The center brake lamp mustnot light up at this time.

When the lamp switch is turned ON and the brake is used,the brightness of the brake lamp must change (increase).

Check the lamps.

17

18

19

20

21

22

23

Enter the Nos. (Left: ) (Right: )*The Nos. must be clear. They are stamped on the front

suspension cylinders.

Enter the Nos. (Left: ) (Right: )*The Nos. must be clear. The nameplate is installed to the

differential case.

3

4

5

6

7

8

The engine must not generate abnormal noise. (Sensoryevaluation)

Engine speed at torque converter stall - Measured value:( rpm) Power mode standard: 1,910 ± 100 rpm

Engine speed at torque converter stall - Measured value:( rpm) Economy mode standard: 1,910 ± 100 rpm

Abnormal noise of engine

Engine speed* Engine coolant temperature: In

green range* Engine oil temperature: 70 – 80ºC* Torque converter oil temperature:

70 – 80ºC

3/4

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

Check the travel and brake. (Before checking the following items, check the safety around the truck.)

Drive inside the yard and touch the brake disc to check thatit is not overheating.

After the truck is driven for 7 km, the drainage on each sidemust not exceed 30 CC.Measured value: Left ( cc ), Right ( cc )

When the engine is stalled at F2 (above 1,670 rpm), the truckmust not start.Measured value (F : rpm)



When the emergency brake is turned ON, the service brakeand parking brake must operate. (Check that the pilot lamplight up.)

Enter the start limit.Measured value (F : rpm)

Overheating of front brake disc(Both sides)

Drainage from floating seal(Both sides)

Function of parking brake

Function of service brake

Function of retarder brake

Function of emergency brake

34

35

36

37

38

39

40

41

42

Check of function of body op-eration caution lamp

Operating effort of dump lever

Functions of dump lever

When the dump lever is not in FLOAT or when the body isnot seated, the body operation caution lamp must light up.

The operating effort must be proper and dump lever mustnot be hitched. Check by sensory evaluation.

(1) The functions of the dump lever must be arranged in theorder of RAISE → HOLD → FLAOT → LOWER from the top.

(2) The body must be stopped at any position when the dumplever is set in HOLD.

(3) When the dump lever is released in LOWER, it must re-turn to FLOAT.

(4) When the dump lever is in RAISE or LOWER, the pres-sure must be regulated.

(5) When the dump lever is in HOLD, the safety stopper (knob)must be applied without interference.

Shocks of body at lowering end

Function of boom positioner

Unevenness of body

Safety function (3)* When checking, start engine and

turn parking brake OFF.





Body rising speed (Oil tem-perature: 80°C)

Body lowering speed (Lever atFLOAT, Oil temperature: 50 –70°C)

Hydraulic drift of body

When the body is seated on the frame, unpleasant shocksmust not be made. (Sensory evaluation)

When the lever is released in RAISE, it must not return to HOLD.

When the lever is set in RAISE to raise the body, it must beset in HOLD automatically just before the H/T cylinderreaches the stroke end.

When the body rises to the end, it must not run out in eitherdirection. (Criterion - Difference between dimensions of bothhoist cylinders: Max. 7 mm)

When the body is lowered to the end, it must contact themount evenly. (The contact area must be at least 80%.)

When the dump lever is not in FLOAT and the transmissionshift lever is not in N, the centralized warning lamps andalarm buzzer must be turned ON.

When the body is not seated and the transmission shift le-ver is not in N, the centralized warning lamps and alarmbuzzer must be turned ON.

When the body is not seated, the truck must not travel inreverse, even if the transmission shift lever is set in R. Whenthe body is not seated and transmission lever is shifted to D- L, "only 2nd speed must be selected in D and only 1st speedmust be selected in 6 to L".

Engine speed: 2,100 rpm, Measured value: ( sec)Standard (Common to HD465 and 605): 11.5 ± 1.5 sec

Engine speed: Low idling speed, Measured value ( sec)Standard (Common to HD465 and 605): 10.5 ± 1.5 sec

The hydraulic drift in 5 minutes must be 85 mm or less. (Frompoint where cylinder No. 2 is extended by 100 mm) Mea-sured value: ( mm )

25

26

27

28

29

30

Check the functions of the work equipment. (Before checking the following items, perform ADJUSTING DUMP CONTROL,Field assembly procedure A-36.)

31

32

33

When the switch is turned ON, the room lamp must light up.24 Function of room lamp

4/4

No.

43

44

45

46

47

48

49

50

51

52

53

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Inspection item Judgment procedure and standards Check Mainte-nance

Remarks

Check of automatic suspensioncontrol function (Optional)Measure with dump bodyempty.

(1): When the dump lever is set to any position other thanFLOAT, display must change from [Soft] to [Hard].

(2): When the service brake or emergency brake is turnedON, the display must change from [Soft] to [Medium].

(3): The display must show [Soft] in all cases other than (1)and (2) above.

Tightness of tire hub nutsTightening torque: 1,519 - 1,617 Nm(Target: 1,568 Nm)* When nothing is applied to

the threads.

The safety pin must be inserted without obstruction in theright and left stopper holes.

The safety pin must be removed from, installed to, and lockedat the storage position securely.

All the mounting bolts must be free from looseness andabnormal play.

The mounting bolts must be free from looseness.

No oil and water leakage.

No oil and water leakage.

Inspect each part.

Tightness of large-capacity bat-tery (optional) terminals

Rubber cap of large-capacity bat-tery (optional) wiring (+) terminal

Flaw of tires

Tension of fan belt

Steering cylinders (Both sides)

Hoist cylinders (Both sides)

Suspension cylinders (Bothsides, front)

Suspension cylinders (Bothsides, rear)

Appearance of cab glass

The plated surfaces must be free from rust, harmful flaw,spatter, paint, etc.




Glass must be free from flaw, paint, etc.

(1) Front left: Retighten.

(2) Front right: Retighten.

(3) Rear left: Retighten.

(4) Rear right: Retighten.

Tire inflation pressure (Whendump body is empty)24.00-35-36PRE4: 0.47 ± 0.01MPa24.00-R35:0.69 ± 0.01 MPa

When the terminals are shaken by hand, they must not move.

The cap must be fitted securely. (The terminal must notproject from the cap.)

Standard: Shown at leftMeasured value: Front left ( MPa), Front right ( MPa)

Standard: Shown at leftMeasured value: Rear left inside ( MPa), Rear rightinside ( MPa)

Standard: Shown at leftMeasured value: Rear left outside ( MPa), Rear rightoutside ( MPa)

The tires must be free from flaw and tear. Check the all 6 tires.

When the belt is pushed with the thumb (approx. 6 kg), itsdeflection must be 10 - 15 mm. The belt must be free fromflaw and twist

No leakage.

No leakage.

No leakage.

Function of safety pin

Storage function of safety pin

Installation of drive shaft(Transmission → Differential)

Front support (Right)

Inspection around engine

Inspection around transmission

Fuel leakage from fuel system

Oil leakage from hydraulic oil sys-tem (tank, cylinder, pump, piping)

Oil leakage from brake system

Stop the truck on level ground and measure.

Length of suspension cylinder(Front)* Measure with dump body empty.

Length of suspension cylinder(Rear)* Measure with dump body empty.

The length must be shorter than dimension A. DimensionA: 249 (Position of label) ± 10 mmMeasured value: Left ( mm), Right ( mm)

Length must be shorter than dimension A. Dimension A:220 (Position of label) ± 10 mmMeasured value: Left ( mm), Right ( mm)

hd465.605-7 field assembly

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