HD465-7 Field Assembly GEN00046-01 PDF

CONTENTS
1. Major points changed from model 7 ............................................................................................................. 1

2. Outline of division ......................................................................................................................................... 1
3. Dimensions of main components ................................................................................................................. 2
4. Rough schedule of assembly and welding ................................................................................................... 3
5. List of equipments, tools, and consumables ................................................................................................ 6
6. Assembly process No. ................................................................................................................................. 8
List of jigs, tools, and consumables ....................................................................................................... 8
0010 Oil, grease, and coolant........................................................................................................... 9
0020 Levels of oil, grease, and coolant .......................................................................................... 10
0030 Positioning rear axle assembly .............................................................................................. 11
0040 Installing rear suspension ...................................................................................................... 12
0050 Installing of axle rod (upper) .................................................................................................. 13
0060 Slinging bare machine 14
0070 Installing rear axle assembly (Connecting axle rods) ............................................................ 15
0080 Connecting rear suspension .................................................................................................. 16
0090 Positioning bare machine ...................................................................................................... 17
0100 Installing right front axle (Connecting A-arm) ........................................................................ 18
0110 Installing right front axle (Connecting suspension) ................................................................ 19
0120 Installing right front axle (Connecting steering cylinder and tie rod) ...................................... 20
0130 Installing right front axle (Connecting brake hose) ................................................................ 21
0140 Installing right front axle (Connecting piping for automatic suspension)................................ 22
0145 Connection and fixing of right front axle wiring harness (ABS specification) ......................... 23
0146 Connection and fixing of right front centralized lubrication hoses
[4-point greasing specification] .............................................................................................. 24
0150 Installing tire and wheel assembly ......................................................................................... 25
0160 Installing body hinge grease tube .......................................................................................... 26
0165 Installation of rear monitor ..................................................................................................... 27
0170 Installing drive shaft ............................................................................................................... 28
0180 Connecting cooling hose ....................................................................................................... 29
0190 Connecting brake actuating hose .......................................................................................... 30
0195 Connection and fixing of rear centralized lubrication hoses [4-point greasing specification] .... 31
0200 Installing right front support ................................................................................................... 32
0210 Installing R.H platform assembly ........................................................................................... 33
0215 Fixing of ORBCOMM antenna cable ..................................................................................... 34
0216 Installation of ORBCOMM antennal pole ............................................................................... 35
0220 Installing of fire prevention cover ........................................................................................... 36
0221 Installation of fire prevention cover (Sand terrain specification) ............................................ 37
0230 Installing right fender ............................................................................................................. 38
0231 Installation of right fender (Side lamp specification) .............................................................. 39
0240 Installing L.H catwalk assembly ............................................................................................. 40
0250 Installing L.H handrail ............................................................................................................ 41
0260 Installing radio antenna and fixing its cable ........................................................................... 42
0270 Installing L.H fender ............................................................................................................... 43
0271 Installation of left fender (Side lamp specification) ................................................................ 44
0280 Installing left side mudguard.................................................................................................. 45
0290 Installing right side mudguard................................................................................................ 46
0295 Installation of R.H exhaust pipe cover (Muffler specification)................................................ 47
0296 Installation of R.H exhaust pipe cover (Exhaust selector box specification) ......................... 48
0300 Installing transmission underguard........................................................................................ 49
0305 Installation of radiator curtain (Radiator curtain specification and sand terrain specification)... 50
0310 Removing hoist cylinder bracket............................................................................................ 51
0320 Removing hoist piping blind plate.......................................................................................... 52
0330 Welding body......................................................................................................................... 53
0340 Slinging body ......................................................................................................................... 54
0350 Installing hinge pin................................................................................................................. 55
0360 Connecting hoist cylinder ...................................................................................................... 56
0370 Welding protective cover by actually positioning it on machine............................................. 57
0380 Installing body mount............................................................................................................. 58
0390 Procedure for adjusting body mount shim ............................................................................. 59
0395 Welding front body mount bracket......................................................................................... 60
0400 Welding exhaust tube by actually positioning it on machine ................................................. 61
0405 Installation of grease junction tube [4-point greasing specification] ...................................... 62
0410 Installing poke ejector............................................................................................................ 63
0420 Installing body lock pin .......................................................................................................... 64
0430 Installing body mudguard ...................................................................................................... 65
0440 Connecting dump sensor....................................................................................................... 66
0450 Procedure for adjusting dump sensor.................................................................................... 67
0460 Calibrating dump control........................................................................................................ 68
0470 Bleeding air from brake system (Preparation) ....................................................................... 69
0480 Bleeding air from brake system (Front) ................................................................................. 70
0490 Bleeding air from brake system (Rear).................................................................................. 71
0500 Adjusting suspension............................................................................................................. 72
0510 Greasing (Right front axle) .................................................................................................... 73
0520 Greasing (Hoist cylinder) ....................................................................................................... 74
0530 Greasing (Rear suspension and axle rod)............................................................................. 75
0540 Painting.................................................................................................................................. 76
0550 Sticking body decal................................................................................................................ 77
0560 Removing jig.......................................................................................................................... 78
0570 Adjusting angles of mirrors .................................................................................................... 79
0580 Checking/Adding lubricants ................................................................................................... 80
C-0010 Preparation of welding body .................................................................................................. 81
C-0020 Assembly of split body........................................................................................................... 82
C-0030 Tack welding body................................................................................................................. 83
C-0040 Welding body......................................................................................................................... 84
C-0050 Welding body instruction (1/2) ............................................................................................... 85
C-0060 Welding body instruction (2/2) ............................................................................................... 86
C-0070 Turn over the body ................................................................................................................ 87
C-0080 Welding body protector (1/2) ................................................................................................. 88
C-0090 Welding body protector (2/2) ................................................................................................. 89
C-0100 Finishing and painting welded parts of body ......................................................................... 90
C-0110 Reworking on body (Exhaust selector box specification) ...................................................... 91
C-0120 Welding of body exhaust pipe (Exhaust selector box specification)...................................... 92
Appendix
Field assembly inspection report
1. Major points changed from model 7
• Floor and cab are made as a unit (Those of present model are split type).
• Floating seal drain oil collecting reservoir is added.
• Number of oil filters is changed (from 2 to 3).
• Brake cooling valve is added.
• Limit switches are used for steering hoist hydraulic circuit.
• Circuit breakers are added to primary power supply system and engine controller power supply circuit.
• Engine heater relay is mounted on chassis.
2. Outline of division (Only main components)
1. Bare machine
2. Dump body (Divided into 3) 4. Rear axle and tire assembly
3. Right front axle assembly 5. Front tire and wheel assembly
1
3. Dimensions of main components
Weight Overall length Overall width Overall height

No. Unit name
(kg) (mm) (mm) (mm)
1 Bare machine 18,520 7,055 3,500 3,460
2 Dump body/HD465-7 10,650 6,500 2,600 3,300
Dump body/HD605-7 13,418 6,500 2,600 3,300
3 Right front axle assembly 1,100 1,300 1,300 1,600
4 Rear axle and tire assembly 12,000 2,500 4,520 2,500
5 Front and wheel assembly (1 set) 1,200 2,500 645 2,500
Drawing of bare machine on trailer
Reference
Specifications of completed truck

Related items
Specifications
Weight (kg) Overall length (mm) Overall width (mm) Overall height (mm)
44,090 9,355 4,820 4,400
HD465-7E0 (Mass of machine) (Front bumper – (When empty)
In self- End of body)
propelled
travel 47,190 9,355 4,820 4,400
HD605-7E0 (Mass of machine) (Front bumper – (When empty)
End of body)
2
4-1. Rough schedule of assembly and welding
Day 1st day
Hour 1 2 3 4 5 6 7 8
Condition of chassis
Rough contents of assem- Positioning rear axle Installing front axle

bly work Positioning chassis Installing tires
Crane
245 kN {25 ton} 245 kN {25 ton} 245 kN {25 ton} (98 kN {10 ton})
Number of workers 2
Day 1st day

Hour 1 2 3 4 5 6 7 8
Condition of body
Unloading Positioning and fixing split body

Contents of welding work
Removing stands, fixing material, etc. Welding back side
Crane
245 kN {25 ton} 245 kN {25 ton}
Number of workers 3
3
Day 2nd day
Hour 1 2 3 4 5 6 7 8
Installing platform Mounting body

Rough contents of assem-
Installing various exterior parts Adjusting shims
bly work
Welding by actually positioning parts on machine
Crane
490 kN {50 ton} (98 kN {10 ton}) 490 kN {50 ton}
Number of workers 2
Day 2nd day

Hour 1 2 3 4 5 6 7 8
Condition of body
Positioning and fixing split body Turning over

Welding back side
Crane
245 kN {25 ton}
Number of workers 3
4
Day 3rd day
Hour 1 2 3 4 5 6 7 8
Rough contents of assem- Installing exterior parts Maintenance, adjustment

bly work Painting Inspection
Crane
Number of workers 2
Day 3rd day

Hour 1 2 3 4 5 6 7 8
Condition of body
Welding inside of body Welding protector

Crane
Number of workers 3
5
5. List of equipments, tools, and consumables
No. Item Specification Q'ty Location
1 Truck crane 245 kN {25 ton} 1 See field assembly manual
2 Truck crane 490 kN {50 ton} 1 See field assembly manual
3 Forklift truck 24.5 kN {2.5 ton} 1
4 Gas cutting machine 1
5 Nozzle No. 1220N2 1
6 Acetylene gas 1 For gas cutting machine
7 Oxygen gas 14.7 MPa {150 kg/cm²} 1 For gas cutting machine
8 Grinder (Round) FG50L-1 1
9 Abrasive wheel SCW50 × 19 • 10 1
10 Grinder LISG-7S 1 For finishing
11 Abrasive wheel 180 ø × 6 × 22 3
12 Diamond ber CB7C105 1
13 Diamond ber edge 6GH 1
14 Semi-automatic welding machine 500A 3
15 Hand shield GP-1S 3
16 Wire for semi-automatic welding 1.2 mm 80 kg
machine
17 Chipper scaling hammer FCM-20F 2
18 Port-Power 300 mm for 98 kN {10 ton} 1 For correcting position of body
19 Hydraulic jack 98 kN {10 ton} 1 For body
20 Hydraulic jack 49 kN {5 ton} 1 For body
21 Body hinge through pin WJ-H46-74001-022 1
22 Flame-resistant cloth 1 m × 10 m 1 Protection from welding by actually
positioning parts on machine
23 Spacer ATH-465-027 3 For welding exhaust flange by actually
positioning it on machine
24 Nitrogen gas filler 7826-10-1000 1
25 Nitrogen gas cylinder 14.7 MPa {150 kg/cm²} 1 Filling suspension with nitrogen gas
26 Tire inflation pressure gauge No. 2252 1
27 Grease pump gun For 20kg can 1
28 Grease GL-2 5 kg
29 Stepladder 3-step 1
30 Stepladder 6-step 1
31 Vinyl sheet 5 m × 10 m 5 Protection of machinery and material
32 Wood block 300 mm square, 1 m long 12
33 Oil can 5l 1 For supplying oil
34 Oil See field assembly manual – See field assembly manual
35 Oil container, washing can 2
36 Waste oil can Drum 1
37 Cloth 5 kg
38 Fuel oil ASTM D975 No.1 or No.2 For machine
39 Antifreeze 5l For filling sub-tank (Change concentra-
tion, depending on district.)
40 Air hose 6ø×1m 1 For bleeding air
41 Sanding machine for painting 914B 1
42 Sandpaper for painting #80 100
43 Sandpaper for painting #180 10
44 Cup gun set W87-20R2S 1 For painting
45 Brush 1 For touching up painted surface
46 Air compressor 3.5 m³/min, 1
Min. 686 kPa {7 kg/cm²}
47 Air hose With 12 ø adapter 5 For impact grinder
6
No. Item Specification Q'ty Location
48 Impact wrench UW-13SK 2
49 Impact wrench KW-3800P 1
50 Impact wrench UW-9SK 2
51 For extension impact 38S 150 mm long 1
52 Socket 1 inch × 46 mm 1 For tightening tire
53 Socket 1 inch × 30 mm 1 For tightening support
54 Torque wrench 2800QL 1 For drive shaft and body pin
55 Torque wrench 21000QLE 1 For tightening tire
56 Steel measure tape 5m 1
57 Loctite LT-2 1
58 Vinyl tape 1 For binding wiring harness
59 Standard tools (For ISO) 700SX 2
60 Bar 1m 1
61 Pointed steel bar 1 For matching holes
62 Sledgehammer 10 lb 1
63 Shackle BD10 for 4.9 kN {500 kg} 4
64 Shackle BC40 for 98 kN {10 ton} 4 For installing body
65 Chain ATH-465-042 1 Multi-purpose type
66 Nylon sling Width of 250 mm * 5 m 1 For installing right platform
67 Nylon sling Width of 60 mm * 3 m 2 For installing support and small parts
68 Nylon sling Width of 100 mm * 12 m 1 For installing front tire
69 Nylon sling Width of 30 mm * 2 m 3 For installing front axle
70 Nylon sling Width of 100 mm * 3 m 1 For installing front axle
71 Pin 60 ø * 250 mm 2 For slinging chassis on rear side (Safety
pin can substitute)
72 Jig for slinging body AHT-785-006 4 For installing body
73 Lever block 3/4 ton LB008 3 For installing front axle
74 Lever block 19.6 kN {2 ton} LB020 1 For installing front axle
75 Wire 7 m 28 ø 2 For slinging chassis
76 Wire 4 m 28 ø 2 For installing body
77 Wire 5 m 28 ø 2 For installing body
The following 4 items can substitute for Nos. 75 – 77.
ATH-465-039 1 For installing body
ATH-465-040 2 For slinging chassis
ATH-465-041 1 For sling split body
List of touch-up paints for export machine with body (Delivered from factory for Japanese market)
No. Part name Unit Q'ty
1 RETAN GP Primer 4 kg 1
2 RETAN GP Hardener 0.8 kg 1
3 RETAN GP Thinner 4l 1
4 SR3000 Natural yellow 16 kg 2
5 SR3000 Hardener 15 kg 2
6 Urethane thinner 205 17 l 1
7 Black gray Spray can 1
8 Heat-resistant silver Spray can 1
7
Assembly process No. List of jigs, tools, and consumables
Exhaust pipe welding jig No.0400

When welding by actually positioning exhaust flange on machine
Precautions Necessary tools Necessary equipment

Name Q'ty Name Q'ty
Other remarks
8
Assembly process No. Oil, grease, and coolant
0010
Method of using fuel, lubricant, and coolant according to ambient temperature

t Fuel, oil
Use the correct type for the ambient temperature as shown in the table below.
a 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.
a When starting the engine in an ambient temperature of less than 0°C, always use EOS0W30, or
EOS5W40, even though the temperature goes up to 10°C during the daytime.
t Coolant
Komatsu genuine super coolant (AF-NAC) is added to the cooling water, so there is no need to
change it for temperatures down to -10°C.
If the temperature goes below -10°C, adjust the density. For details, see CLEANING INSIDE OF
COOLING SYSTEM in the WHEN REQUIRED Section of the Operation and Maintenance Manual.

a For details of the notes (e.g., Note. 1, Note. 2 ...) in Name Q'ty Name Q'ty
the table, see the Operation and Maintenance Man-
ual.
Other remarks
9
Assembly process No. Levels of oil, grease, and coolant
0020
Volume of refilled oil

Lubrication point Type of oil Specified q'ty (l) Refill capacity (l)
(l)
Engine oil pan Engine oil 86 80 —
Transmission case 318 215 60

Power train oil
Steering and hoist oil tank 180 122 100
16.5 each on right

Front suspension — —
and left sides
Hydraulic oil
11.3 each on right
Rear suspension — —
and left sides
Differential case 95 95 —
Power train oil
32 each on right and 21 each on right and
Final drive case —
left sides left sides
Fuel tank Diesel fuel 780 — —
Cooling system Coolant 157 — —
Caution) Before starting the engine, be sure to check each oil/coolant level.
Do not steer the machine largely before adjusting the suspension

(If it is steered largely, the piping may be damaged).

Name Q'ty Name Q'ty
Other remarks
10
Assembly process No. Positioning rear axle assembly
0030
1. Sling the rear axle and tire assembly with 1,245 kN {25 ton} crane.
Hanging points: Rod mounting parts on differential.
2. Position the rear axle as shown above.

(Secure the clearance between the ground and coupling as shown above so that the rear axle
assembly will be horizontal.)
When positioning the assembly on the ground, take proper measures so that the assembly will not
sink and lean.
3. Secure the rear axle with chocks.
Secure the rear axle with chocks. Name Q'ty Name Q'ty
Other remarks
11
Assembly process No. Installing rear suspension
0040
Part No. Part name Q'ty State of parts

(1) 569-40-81550 Pin 2 Temporarily installed to frame
(2) 01010-81425 Bolt 2 Temporarily installed to frame
(3) 569-40-61710 Washer 2 Temporarily installed to frame
(4) 569-52-41950 Spacer 4 Temporarily installed to frame
1. Sling the rear suspension and lower it to the fixing position of the rear axle.
2. Align the fixing hole of the rear suspension with those of the rear axle, insert the pin, and secure it
with the bolt.

1. Do not install the spacer forcibly. If it is installed so, Name Q'ty Name Q'ty
it will be deformed.
2. When holding the spacer, take care not to catch your
fingers in it.
Other remarks
12
Assembly process No. Installing of axle rod (upper)
0050

(1) 569-40-81550 Pin 2 Temporarily installed to chassis
(2) 01010-81425 Bolt 2 Temporarily installed to chassis
(3) 569-40-61710 Washer 2 Temporarily installed to chassis
(4) 569-52-41950 Spacer 4 Temporarily installed to chassis
1. Remove the pins from the upper rod joint on the frame side ((1) – (4) in the figure).
2. When connecting, guide the crane and align the holes.

1. If the spacers are installed forcibly, they are deformed. Name Q'ty Name Q'ty
Take care.
2. When holding a spacer, take care not pinch your fin-
gers.
3. Do not break the bellows by installing it forcibly.
Other remarks
13
Assembly process No. Slinging bare machine
0060
1. When slinging the chassis, apply cloths to protect it.

2. Sling the bare machine with 2 245 kN {25 ton} cranes.
Sling : Chain sling (ATH-465-040) or wires 28 mm in diameter
Front hanging point: Hanging bracket of bumper
Rear hanging point: Mounting part of body lock pin (Use pin 60 mm in diameter × 250 or body
lock pin) Part No.: 569-74-61670 (Red)

Name Q'ty Name Q'ty
ATH-465-040 2
Other remarks
14
Assembly process No. Installing rear axle assembly (Connecting axle rods)
0070
1. Install the upper axle rod.

2. Install the lower axle rod.

(1) 569-40-81550 Pin 2 Temporarily installed to rear axle
(3) 01010-81425 Bolt 4 Temporarily installed to rear axle and chassis
(4) 569-40-61710 Washer 4 Temporarily installed to rear axle and chassis
(5) 561-52-41950 Spacer 8 Temporarily installed to rear axle and chassis
1. Remove the pins from the upper rod connecting part on the axle side and the pins from the lower rod
connecting part on the chassis side. ((1) – (5) in the figure)
2. Move the crane to match the pin holes and connect the axle rods.

1. If the spacers are installed forcibly, they are deformed. Name Q'ty Name Q'ty
Take care.
2. When holding a spacer, take care not pinch your fin-
gers.
3. Do not break the bellows by installing it forcibly.
Other remarks
15
Assembly process No. Connecting rear suspension
0080

(1) 569-40-81550 Pin 2 Temporarily installed to rear axle
(2) 01010-81425 Bolt 2 Temporarily installed to rear axle
(3) 569-40-61710 Washer 2 Temporarily installed to rear axle
(4) 569-52-41950 Spacer 4 Temporarily installed to rear axle
1. Guide the slung bare machine to above the rear axle.
2. Remove the pins ((1) – (4) in the figure) on the rear axle side.
3. While matching the rear suspension fixing hole, insert the pin and fix it with the bolt.

Fix the wheels with chocks to prevent the rear axle from Name Q'ty Name Q'ty
moving.
Other remarks
16
Assembly process No. Positioning bare machine
0090
Lay 2 lines of 4 wood blocks.

Position bare machine so that
front of chassis will be a little
higher than level line.
(For installation of front tires) 1,200 Wood blocks
Steel plate
1. Position the frame vertical of the bare machine on wood blocks as shown above.
(Secure the clearance above the ground as shown above so that you can install the front tires.)
When positioning the bare machine on the ground, place a steel plate under the wood blocks so that
the bare machine will not sink and lean.
2. Remove the sling.

Take care that the chassis will not move. Name Q'ty Name Q'ty
Set the bare machine to proper height so that you can

install the front tires.
Other remarks
17
Assembly process No. Installing right front axle
0100 (Connecting A-arm)

1. Remove the pins and spacers installed to the chassis temporarily.
2. Before installing, clean the pin holes.
3. Match the mounting holes of the chassis and A-arm.
(Adjust them with lever blocks, etc.)
4. Install the spacers and pins and secure them with set bolts.
(You can work easily by bending a thin sheet and using it to hold each spacer.) A-arm
it will be deformed. Lever block (For 2 ton) 1
2. When holding the spacer, take care not to catch your Lever block (For 3/4 ton) 1
fingers in it. Nylon sling 1
(100 mm x L3,000)
Other remarks
18
0110 (Connecting suspension)

1. This figure shows the pins installed to the chassis.
2. When connecting each part, match the pin holes.
3. Install the spacers and pins and secure them with set bolts.
4. Connect the suspension pressure sensor (CN-SUFR) to the wiring harness on the chassis side (only
when the attachment needs it).
it will be deformed.
2. When holding the spacer, take care not to catch your
fingers in it.
Other remarks
19
0120 (Connecting steering cylinder and tie rod)

(1) 569-40-81240 Pin 1 Temporarily installed to front axle
(2) 569-40-81530 Pin 1 Temporarily installed to front axle
(3) 01010-81425 Bolt 2 Temporarily installed to front axle
(4) 569-40-61710 Washer 2 Temporarily installed to front axle
(5) 569-40-61660 Boot 4 Temporarily installed to front axle
1. Remove the pin side of the remote grease tube, and then remove the pins.
2. Adjust the axle so that the steering cylinder and tie rod will be in parallel with the axle lever.
3. Put boot (5), adjust the pin holes, and install the pin.
4. Fix the pin with the set bolt.
5. Connect the remote grease tube again.
6. After connecting, supply grease. (See No.0510.)

1. Check that the O-rings are fitted to the steering cyl- Name Q'ty Name Q'ty
inder and tie rod spherical bushing.
2. Note that the lengths of the pins are different from
one another.
Other remarks
20
0130 (Connecting 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.

Check that there is no mistake in the hose number Name Q'ty Name Q'ty
and the block number, then assemble.
Other remarks
21
0140 (Connecting piping for automatic suspension)
Note: Perform the following work for only the attachment of automatic suspension model.
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.

Check that there is no mistake in the hose number Name Q'ty Name Q'ty
and the block number, then assemble.
Other remarks
22
Assembly process No. Connection and fixing of right front axle wiring harness
0145 (ABS specification)
Right front axle seen from FWD

right
Connection
Wheel speed sensor (FR)
To be fixed together with

junction block
Plate attached to axle
1. Remove the clips installed temporarily and fix the wheel speed sensor wiring harness as shown in
the above figure.
2. Connect the wiring harness.
Part No. Part name Q'ty State of part (Parts list No.)
(1) 04434-51510 Clip 3 Separately packed (H4E-06-150)
(2) 01024-81030 Bolt 2 Separately packed (H4E-06-150)
(5) 01580-11008 Nut 1 Separately packed (H4E-06-150)
(6) 01643-31032 Washer 1 Separately packed (H4E-06-150)
Name Q'ty Name Q'ty
Other remarks
23
Assembly process No. Connection and fixing of right front centralized
0146 lubrication hoses [4-point greasing specification]
Chassis seen from front
Upper front
suspension
R.H17
View Z
To be fixed with brake
hose fixing bolts.
Detail of part A
King pin
R.H15
Tie rod end

R.H14
Rear frame
1. Connect the hoses coming out of the right front centralized grease block. R.H13
2. Fix the lubrication hoses with clips (1).

Name Q'ty Name Q'ty
Other remarks
24
Assembly process No. Installing tire and wheel assembly
0150
Installing 2 front tires to right and left
<How to sling tire and wheel assembly> <Image of mounting tire>
Nylon sling
Wight of tire
1,200 kg
Hitch sling to tire tread.
Installed to front axle temporarily
Tightening torque:
1,519 -- 1,852 Nm {154.9 -- 188.8 kgm}

(1) 569-22-72870 Nut 28 Temporarily installed to front axle
(2) 426-09-11520 Washer 28 Temporarily installed to front axle
1. Remove the nuts and washers installed to the front axle temporarily.
2. Install the tire with the forklift and then install the nuts and washers.
Note) Take care that the tire will not fall from the forklift.
When positioning the tire, take care not to damage the valve for inflating the tire.
3. Tighten the nuts with the impact wrench temporarily.
4. Lift up the front part of the chassis with the crane and remove the wood blocks.
5. Tighten the tire mounting nuts with the torque wrench.
(Tightening torque: 1,519 – 1,852 Nm {154.9 – 188.8 kgm})
6. Touch up the tightened parts (to prevent rusting).
(Use the yellow paint used for the body.)
1. When carrying the tire, take care that it will not fall. Name Q'ty Name Q'ty
2 When positioning the tire, take care not to damage Torque wrench 1
the air valve. QLE21000
Other remarks
25
Assembly process No. Installing body hinge grease tube
0160
Install the connectors and elbows, and then install the lubrication tubes.

(1) 569-52-62612 Tube 1 Loose-supply item (Packed separately)
(2) 569-52-62622 Tube 1 Loose-supply item (Packed separately)
(3) 421-09-12540 Elbow 2 Loose-supply item (Packed separately)
(4) 423-09-12110 Connector 2 Loose-supply item (Packed separately)
1. After installing the grease tube, supply grease around the rear axle. (See No.0530.)

Name Q'ty Name Q'ty
Other remarks
26
Assembly process No. Installation of rear monitor
0165
1. Remove bolts (2), clips (3) and bolts (4)

installed to the rear lamp assembly.
2. Install rear monitor assembly (1) and fix it

with bolts (2).
3. Connect the rear monitor cable.
4. Fix the rear monitor cable as shown in view

Z.
Connection
View Z
Fix together
(1) 561-86-8310A Rear monitor assembly 1 Separately packed (H4E-06-140)
(2) 01024-81020 Bolt 4 Temporarily installed to rear lamp assembly.
(3) 04434-50610 Clip 3 Temporarily installed to rear lamp assembly.
(4) 01024-81016 Bolt 2 Temporarily installed to rear lamp assembly.

Name Q'ty Name Q'ty
Other remarks
27
Assembly process No. Installing drive shaft
0170

(1) 569-20-72000 Drive shaft 1 Loose-supply item (Packed separately)
(2) 569-89-82211 Guard 1 Loose-supply item (Packed separately)
(3) 01050-61470 Bolt 4 Loose-supply item (Packed separately)
1. Remove guard (2) from the chassis (only when the attachment of rear drive shaft guard is installed).
2. Sling the drive shaft with the crane and put it between the rear axle and
transmission.
3. Hit the drive shaft spider lightly with a hammer to fit the socket and spigot.
4. Check that the socket and spigot are fixed together, and then tighten the
bolts. (For the tightening order, see Fig. 1) Fig. 1
5. Tighten the bolts again with the torque wrench.
(Tightening torque: 157 – 196 Nm {16.0 – 19.9 kgm})
6. Install the guard again.

Tighten the bolts in the order shown in the figure. Name Q'ty Name Q'ty
Torque wrench 1800QL 1
Other remarks
28
Assembly process No. Connecting cooling hose
0180
Hose stopper on chassis

side, 2 pieces
Rear axle
Rear axle
Axle tube stopper, 4 pieces

(1) 07371-21465 Flange 8 Installed parts
(2) 07375-21240 Bolt 16 Installed parts
(3) 07000-F3048 O-ring 4 Installed parts
1. Remove hose stoppers on the chassis side (2 pieces) and tube stoppers on the rear axle (4 pieces).
2. Loosen the straight end of the hose and reverse its direction.
3. Using the above parts, connect the cooling hose.
(Use parts (1) – (3) attached on either axle side or chassis side. Discard the rest.)
4. Tighten the loosened straight end of the hose.

1. When connecting, prevent foreign matter from enter- Name Q'ty Name Q'ty
ing. Oil receiver 2
2. Check that the O-ring is fitted securely.
Other remarks
29
Assembly process No. Connecting brake actuating hose
0190
1. Remove the stopper from each opening.

2. Connect the 3 hoses.

1. Do not mistake the positions of hoses A and B for Name Q'ty Name Q'ty
each other.
2. When remove a stopper from each opening, do not
lose the O-ring.
Other remarks
30
Assembly process No. Connection and fixing of rear centralized lubrication
0195 hoses [4-point greasing specification]
Upper rear suspension Upper rear suspension

L.H33 R.H26
Upper rod axle Upper rod axle

L.H32 R.H27
Lower rod axle Lower rod axle

L.H30 R.H29
Lower rear suspension Lower rear suspension
L.H34 R.H25
1. Connect the hoses coming out of the rear centralized grease block.
2. Fix the lubrication hoses with clips (1) and bolts (2).

Name Q'ty Name Q'ty
Other remarks
31
Assembly process No. Installing right front support
0200

(1) 569-54-81681 Front support assembly 1 Loose-supply item (Separately packed)
1. Remove the bolts and washers temporarily installed to the chassis.

2. Install front support assembly (1).
3. Fix the wiring harness to the clip and connect the connector (CN-RP).
4. Connect the ground wire (CN-PR07 and CN-T10) (Grounding part must not be coated with paint).

If the grounding part is coated with paint, remove the Name Q'ty Name Q'ty
paint.
Other remarks
32
Assembly process No. Installing R.H platform assembly
0210

(2) 01010-82045 Bolt 2 Temporarily installed to front support and right platform
(3) 01643-32060 Washer 2 Temporarily installed to front support and right platform
(4) 09415-05016 Cap 2 Temporarily installed to right platform
1. Remove (1) – (4) temporarily installed.
2. Install the right platform assembly and fix it with (1) – (3).
3. Install cap (4).
4. Adjust the angle of the mirror.

Name Q'ty Name Q'ty
Other remarks
33
Assembly process No. Fixing of ORBCOMM antenna cable
0215
FWD
( 8 places)
Installed angle
Right platform seen from above
1. Remove clips (1) temporarily installed to the right handrail and toe guard and fix the antenna cable to
its original position.
(1) 04434-51812 Clip 8 Temporarily installed to right handrail and toe guard

Name Q'ty Name Q'ty
Other remarks
34
Assembly process No. Installation of ORBCOMM antennal pole
0216
( 7 places)
Connection
Antenna cable
Plates installed
(Fixed with bolt for pole (2)) to handrail
A A
Section A-A
Right platform seen from front

1. Remove clips (4) and bolts (5) temporarily installed to pole (1).
2. Install pole (1) with bolts (2).
3. Fix pole (1) with clips (7), washers (8) and nuts (9) temporarily installed to the plates installed to the
right handrail.
4. Fix the antenna cable with clips (3) and (4) and bolts (5).
5. Install the antenna to the pole end and connect it to analysis (6).
(1) 566-97-81111 Pole 1 Separately packed (H4E-09-030)
(4) 04434-51810 Clip 7 Temporarily installed to pole
(5) 01435-01016 Bolt 7 Temporarily installed to pole
(6) 8A13-10-2100 Antenna 1 Separately packed (H4E-09-030)
(7) 07283-36155 Clip 3 Temporarily installed to plate
(8) 01643-31032 Washer 6 Temporarily installed to plate
(9) 01597-01009 Nut 6 Temporarily installed to plate

Name Q'ty Name Q'ty
Other remarks
35
Assembly process No. Installing of fire prevention cover
0220
1. Install the fire prevention cover.
(1) 569-54-89341 Guard 1 Separately packed (H4E-06-060)
(5) 425-46-12H80 Plate 2 Separately packed (H4E-06-060)
(9) 01024-81020 Bolt, sems 3 Temporarily installed to chassis
Name Q'ty Name Q'ty
Other remarks
36
Assembly process No. Installation of fire prevention cover
0221 (Sand terrain specification)
1. Install the fire prevention cover. Part A seen from rear
CAB
Fix wiring
harness with clips.
Front of
chassis
Battery
box
A
(5) 425-46-12H80 Plate 2 Separately packed (H4E-06-061)
Name Q'ty Name Q'ty
Other remarks
37
Assembly process No. Installing right fender
0230
Weight of right
fender: 30.7 kg
Parts for fixing

right platform
(For part No.,
see No. 0210)
Tightening torque
29.4 -- 49.0 Nm
{3 -- 5 kgm}
Set glossy side toward

front of chassis.
(2) 569-54-8852A Fender assembly 1 Separately packed (H4E-06-080)
(4) 569-54-41551 Plate 1 Temporarily installed to right fender
(5) 01435-01225 Bolt 5 Temporarily installed to right fender
1. Remove (1) temporarily installed to the chassis.
2. Install the right fender.
3. When installing right fender (2), fix the right fender together with the right platform fixing bolts.
4. Remove (4) and (5) temporarily installed to right fender (2).
5. Install mudguard (3).
Install guard (3) with the glossy side toward the front of Name Q'ty Name Q'ty
the chassis.
Other remarks
38
Assembly process No. Installation of right fender (Side lamp specification)
0231
Detail of part Z
Connection: CN SLR
Fix wiring harness with
welded clip in right fender.
View Z (Right fender seen from above)

Weight of right fender: 31.1 kg
Parts for fixing right platform
(For part No., see No. 0210)
Tightening torque
29.4 -- 49.0 Nm
{3 -- 5 kgm}
Set glossy
side toward front of chassis.
(2) 569-85-8813A Fendey assembly 1 Separately packed (H4E-06-090)
(4) 569-54-41551 Plate 1 Temporarily installed to right fender
(5) 01435-01225 Bolt 5 Temporarily installed to right fender
(6) 04434-50812 Clip 3 Temporarily installed to chassis
1. Remove (1) temporarily installed to the chassis.
2. Install right fender (2).
3. When installing right fender (2), fix the right fender together with the right platform fixing bolts.
4. Remove (4) and (5) temporarily installed to right fender (2).
5. Install mudguard (3).
6. Remove (6) and (7) temporarily installed and fix the installed wiring harness.
7. Fix the wiring harness installed to the right platform with the clip welded in the right fender.
8. Pass the wiring harness through the cap installed to the right fender and connect it.
the chassis.
Other remarks
39
Assembly process No. Installing L.H catwalk assembly
0240
Detail of installation * Take care of positions of bolts.

1. Remove (1), (2), (3) and (4) temporarily installed to the chassis.
2. Install the L.H catwalk assembly.

If the radio is installed, remove the rust-preventive Name Q'ty Name Q'ty
sheets.
Other remarks
40
Assembly process No. Installing L.H handrail
0250

(1) 561-54-61910 Clamp 2 Temporarily installed to chassis
(3) 01643-31645 Washer 4 Temporarily installed to chassis
(4) 01024-81240 Bolt 1 Temporarily installed to catwalk assembly
(5) 01580-11210 Nut 1 Temporarily installed to catwalk assembly
(6) 01643-31232 Washer 1 Temporarily installed to catwalk assembly
(7) 569-54-81770 Guard 1 Loose-supply item (Packed separately)
1. Remove (1) – (6) temporarily installed to the chassis and catwalk assembly.
2. Install (7).

Name Q'ty Name Q'ty
Other remarks
41
Assembly process No. Installing radio antenna and fixing its cable
0260
Perform this work only when the radio is installed.

View Z
Bind connector and cable.
L.H platform
Connect. assembly

(1) 175-911-6140 Antenna assembly 1 Loose-supply item (Separately packed)
(2) 01225-40416 Screw 1 Loose-supply item (Separately packed)
(3) 01023-10420 Screw 1 Loose-supply item (Separately packed)
(4) 07270-51513 Tube 1 Loose-supply item (Separately packed)
(5) 04434-51910 Clip 7 Loose-supply item (Separately packed)
(6) 01024-81020 Bolt, sems 7 Loose-supply item (Separately packed)
(7) 08037-11825 Grommet 1 Loose-supply item (Separately packed)
(8) 561-54-86940 Cover 1 Loose-supply item (Separately packed)
(10) 08037-01008 Grommet 1 Loose-supply item (Separately packed)
(11) 08210-00610 Spairal tube 1 Loose-supply item (Separately packed)
1. Install antenna (1) to the handrail installed to the L.H platform assembly as shown in the above figure.
2. Connect the antenna cable coming from the cab to the cable coming from the antenna.
3. Fix the cable with the other parts as shown in the above figure.
If the antenna cable at the lower outlet of the cab is Name Q'ty Name Q'ty
pulled, it will be broken. Take care.
Other remarks
42
Assembly process No. Installing L.H fender
0270
(3) 569-54-41551 Plate 1 Temporarily installed to fender (Separately packed)
(4) 01435-01225 Bolt 5 Temporarily installed to fender (Separately packed)
1. Remove bolts (2) temporarily installed to the chassis.

2. Install L.H fender (1).
3. Install mudguards (3) – (5).

Install the guard (5) with the glossy side toward the front Name Q'ty Name Q'ty
of the chassis.
Other remarks
43
Assembly process No. Installation of left fender (Side lamp specification)
0271
Fix wiring harness with welded clip.
Connection: CN SLL
Cab bottom seen from front
Tightening torque
29.4 -- 49.0 Nm
{3 -- 5 kgm}
Weight: 24.4 kg
Set glossy side toward

front of chassis.
(3) 569-54-41551 Plate 1 Temporarily installed to fender (Separately packed)
(4) 01435-01225 Bolt 5 Temporarily installed to fender (Separately packed)
1. Remove bolts (2) temporarily installed to the chassis.
2. Install left fender (1).
3. Install mudguards (3) - (5).
4. Fix the wiring harness installed to the cab with the welded clip.
5. Pass the wiring harness through the cap installed to left fender (1) and connect it.
the chassis.
Other remarks
44
Assembly process No. Installing left side mudguard
0280

(1) 283-54-11470 Plate 2 Temporarily installed to under cab
(2) 01024-81025 Bolt 4 Temporarily installed to under cab
(3) 01024-81025 Bolt 2 Temporarily installed to fender and catwalk
(4) 417-43-16210 Washer 2 Temporarily installed to fender and catwalk
(5) 569-54-81571 Guard 1 Loose-supply item (Separately packed)
1. Remove parts (1) – (4) temporarily installed.
2. Install guard (5).

Name Q'ty Name Q'ty
Other remarks
45
Assembly process No. Installing right side mudguard
0290

(1) 283-54-11470 Plate 3 Temporarily installed to right platform and fender
(2) 569-54-81620 Plate 2 Temporarily installed to right platform
(3) 01024-81030 Bolt 13 Temporarily installed to right platform and fender
(4) 417-43-16210 Washer 1 Temporarily installed to right platform and fender
1. Remove parts (1) – (4) temporarily installed to the right platform and fender.
2. Install guard (5).
Name Q'ty Name Q'ty
Other remarks
46
Assembly process No. Installation of R.H exhaust pipe cover
0295 (Muffler specification)
Left fender
L.H exhaust pipe cover
Right fender
Outside of right platform
FWD
Inside of right
platform
Rear support seen from above

(1) 569-54-89370 Cover 1 Loose-supply item (Separately packed)
(2) 01024-81225 Bolt 6 Temporarily installed to rear support
1. Remove parts (2) temporarily installed to the rear support.

2. Install cover (1).

Name Q'ty Name Q'ty
Other remarks
47
Assembly process No. Installation of R.H exhaust pipe cover
0296 (Exhaust selector box specification)
Exhaust Muffler
selector box
Chassis seen from rear
1. Remove bolts (2) temporarily installed to the rear support and install cover (1).
2. When installing cover (1), reduce the clearance between the rear support and cover to 0.5 mm or
less with shim (3).
(1) 569-54-89370 Cover 1 Separately packed (H4E-06-070)
(2) 01024-81225 Bolt 6 Temporarily installed to rear support
(3) 431-40-11330 Shim – Separately packed (H4E-06-070)

Name Q'ty Name Q'ty
Other remarks
48
Assembly process No. Installing transmission underguard
0300

(3) 01580-12016 Nut 2 Temporarily installed to chassis
(5) 561-54-66250 Collar 2 Temporarily installed to chassis
1. Bring the transmission underguard with the forklift to the mounting position under the chassis.
2. Remove parts (1) – (7) temporarily installed to the chassis.
3. Sling the underguard with the crane and install it.
Name Q'ty Name Q'ty
Other remarks
49
Assembly process No. Installation of radiator curtain (Radiator curtain
0305 specification and sand terrain specification)
Radiator
1. Remove (2) and (3) temporarily installed to the radiator guard.

2. Install radiator curtain (1) with (2) and (3).

(1) 569-84-88811 Sheet 1 Separately packed (H4E-06-160)
(2) 409-03-19130 Hineri 15 Temporarily installed to radiator guard
(3) 01602-20720 Washer 15 Temporarily installed to radiator guard

Name Q'ty Name Q'ty
Other remarks
50
Assembly process No. Removing hoist cylinder bracket
0310
1. Fix the cylinders with a chain block and nylon sling, etc. so that they will not lean backward after
starting this work until the cylinder tops are connected to the body.
2. Remove the parts marked with A in the figure. Discard those parts since they are not used any
more.

Name Q'ty Name Q'ty
Other remarks
51
Assembly process No. Removing hoist piping blind plate
0320

(3) 01643-50823 Washer 8 Loose-supply item (Separately packed)
(4) 07000-F3022 O-ring 2 Loose-supply item (Separately packed)
(5) 07000-F3032 O-ring 2 Loose-supply item (Separately packed)
1. Remove bolts A and B and parts marked with A.
Discard the parts marked with A since they are not used any more.
2. Using bolt (1) instead of bolt A and bolt (2) instead of bolt B, connect the hoses again.
When connecting the hoses again, use the O-rings supplied loosely.
Precautions
When starting the engine or moving the machine before mounting the body, set the dump lever in the
HOLD position (to prevent extension of the hoist cylinder).
When moving the machine in reverse before mounting the body, see Adjustment procedure for dump
sensor No. 0450.
Take care that the O-rings will not be caught in the Name Q'ty Name Q'ty
hoses.
Other remarks
52
Assembly process No. Welding body
0330
* For details of welding of body, see separate welding manual (C-0010 - 0100).

Name Q'ty Name Q'ty
Other remarks
53
Assembly process No. Slinging body
0340
Body sling pins (ATH-785-006)

Shackles BC40 for 98 kN {10 ton}
Chain sling (ATH-465-039)
or ø 28 wires
1. Install the body sling pins to the 4 holes from outside of the body.
2. Set the shackles and sling as shown in the above figure.
3. Check the center of gravity and sling the body.
Note: When slinging the body, raise its front side a little.

Name Q'ty Name Q'ty
ATH-465-039 1
ATH-785-006 4
BC40
Other remarks
54
Assembly process No. Installing hinge pin
0350

(1) 569-74-11530 Shim t = 6.0 4 Loose-supply item (Separately packed)
(3) 569-74-61740 Pin 2 Loose-supply item (Separately packed)
(4) 01010-81635 Bolt 2 Loose-supply item (Separately packed)
(6) 421-70-11280 Washer 2 Loose-supply item (Separately packed)
1. Move the crane to match the pin holes of the frame mounting part and body mounting part.
2. Insert the shim so that the clearance will be even and below 1 mm, and then insert pin (3).
(Do not drive in the shim with a hammer to prevent its deformation.)
3. Secure the pin with the set bolt.

1. Do not put your finger in the pin hole. Name Q'ty Name Q'ty
2. Before installing, clean the pin hole.
Other remarks
55
Assembly process No. Connecting hoist cylinder
0360

(3) 569-40-61710 Washer 2 Loose-supply item (Separately packed)
1. Match the hoist cylinder rod hole to the pin hole of the body mounting part.
2. Insert pin (1) and fix it.
3. Tighten set bolts (2) and (3).
4. After connecting the hoist cylinder, supply grease (See No.0520).

1. Before installing, clean the pin hole. Name Q'ty Name Q'ty
Other remarks
56
Assembly process No. Welding protective cover by actually positioning it
0370 on machine
1. Cab 2. Hoist cylinder
3. Mirror 4. Steering cylinder
5. Each hose and tire
1. Install protection covers to the circled parts in above photos 1 – 5.

Name Q'ty Name Q'ty
Other remarks
57
Assembly process No. Installing body mount
0380
For the adjustment procedure, see the next page.

(7) 569-74-61511 Pad 6 Loose-supply item (Separately packed)
(10) 569-74-61520 Pad 2 Loose-supply item (Separately packed)
(11) 569-74-61580 Shim 20 Loose-supply item (Separately packed)
(14) 569-46-62831 Bracket, blank 2 Loose-supply item (Separately packed)
Name Q'ty Name Q'ty
Other remarks
58
Assembly process No. Procedure for adjusting body mount shim
0390
Front mount
d2 d3
d1
Bottom mount
Spacer
1. Procedure for adjusting shim at dump body mount

Adjust as follows.
(1) Bottom mount (rubber mount of dump body bottom plate)
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)
(See Fig. (1))
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 clearance from the dump body
bracket is 57 mm. (See Fig. (2))
b. Raise the dump body and weld the bracket in posi-
tion. See No. 0395
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 to make it 50 mm.
e. This completes the adjustment of the front mount.
2. After assembling the dump body, adjust the shims so that
the misalignment between the protector and the cab is
within 58±12 mm. (See cross section A - A)

Name Q'ty Name Q'ty
Other remarks
59
Assembly process No. Welding front body mount bracket
0395
Weld the front body mount bracket.

1. Install the body to the frame and adjust its dumping posture. (For the method of installation, see
Assembly manual No. 0340 – 0390.)
2. Adjust the distance between the body and frame with shims in advance. (See Assembly manual No.
0390.)
3. Position the front body and mount bracket properly and weld them. For the welding condition, see
Table 1.
Place 2 brackets (569-46-62831) on the frame (rear support) and measure the clearance between
the body and bracket at 4 places.
If the clearance is 57 mm or less, cut the lower part of the bracket (hatched part).
(See the following figure.)
4. Position the front body mount bracket properly and weld it.
Table 1
CO2 gas arc welding Arc welding Remarks
Welding position Flat (F) Flat, vertical (V) (1) Do not apply CO2 gas welding
Welding rod JIS Z3312YGW11 JIS Z3212D5816 when wind velocity is higher than 2
or equivalent or equivalent – 3 (m/sec).
AWS ER70S-G and AWS E8016-G and (2) Remove moisture, dust, and paint
equivalent equivalent from surfaces to be welded.
ø 1.2, 1.6 ø 4.0, 5.0 (3) Drying time of arc welding rod
Welding current (A) 320 – 350, 380 – 420 130 – 160, 220 – 260 1] Temperature: 150 – 200°C
2] Time: 120 minutes
Preheating/Postheating Unnecessary Unnecessary
Gas shielding rate (l/min) 25 – 35 —

Name Q'ty Name Q'ty
Other remarks
60
Assembly process No. Welding exhaust tube by actually positioning it
0400 on machine
Restrict to 20 mm with jig.

Set between exhaust tube
of R support and (2).
Fix with ATH-465-027 so that

ø1
dimension B will be obtained.
81
±
0.
2
ø1
78
ø1
±
0.
54
1
.7
20
Mating face
of flange
62
87
Check that dimension

9
11
A A is 119 mm.
B If it is not, adjust it.
(1) 569-02-81150 Gasket 1 Loose-supply item (Separately packed)
(3) 569-02-81140 Tube assembly 1 Loose-supply item (Separately packed)
(4) 569-02-41140 Tube assembly 1 Loose-supply item (Separately packed)
(5) 569-02-41160 Plate 1 Loose-supply item (Separately packed)
1. When delivered, check that dimension A = 119 mm.
2. Install gaskets (1) – (3) and tube assembly.
3. Set restricting jig ATH-465-027 to part A of tube assembly (4) shown in the figure to secure 20 mm.
4. Insert plate (5) in tube assembly (4), and then insert them in body exhaust gas inlet.
5. Align the tube and flange on the mating face of the flange, and then weld the plate and tube by actually position-
ing them on the body.
Welding --- Apply fillet welding of 6 mm all around the plate and tube.
Caution) Runout of center: Max. 3 mm
6. After finishing welding, remove the jig.
Runout of the center must be 3 mm or less. Name Q'ty Name Q'ty
ATH-465-027 1
Other remarks
61
Assembly process No. Installation of grease junction tube
0405 [4-point greasing specification]
Work on right and left sides similarly. Detail of part A
Lubrication hose (R.H)

installed to hoist (L.H)
cylinder
Lubrication hose
installed to rear
FWD Rear of chassis seen from left centralized
grease block
1. The lubrication hoses are installed to the top of the right and left hoist cylinders. Install the side hav-
ing no hose to the body.
2. Install connector (3), elbow (4) and plug (7) to the block of the body.
3. Install right tube (1) and left tube (2).
4. Fix the tubes installed in "3" above with clips (1) and bolts (2).
5. Connect the lubrication hose installed to the rear centralized grease block.
(1) 569-95-84650 Tube 1 Separately packed (H4E-05-400)
(2) 569-95-84660 Tube 1 Separately packed (H4E-05-400)
(3) 423-09-12110 Connector 4 Separately packed (H4E-05-400)
(4) 426-70-13270 Elbow 2 Separately packed (H4E-05-400)
(7) 07043-70108 Plug 2 Separately packed (H4E-05-400)
Name Q'ty Name Q'ty
Other remarks
62
Assembly process No. Installing poke ejector
0410
Weight: 32.8 kg

(1) 569-74-81622 Bar 2 Loose-supply item (Separately packed)
(3) 04050-18055 Pin 2 Loose-supply item (Separately packed)

Name Q'ty Name Q'ty
Other remarks
63
Assembly process No. Installing body lock pin
0420

(2) 569-74-61470 Linch pin 2 Loose-supply item (Separately packed)

Name Q'ty Name Q'ty
Other remarks
64
Assembly process No. Installing body mudguard
0430

(1) 569-74-61640 Support 1 Loose-supply item (Separately packed)
(2) 569-74-61630 Support 1 Loose-supply item (Separately packed)
(6) 569-74-61650 Plate 2 Loose-supply item (Separately packed)

Install mudguard with the glossy side toward the front Name Q'ty Name Q'ty
of the chassis.
Other remarks
65
Assembly process No. Connecting dump sensor
0440

(1) 01010-81060 Bolt 1 Attached to rod end
(2) 566-40-11560 Spacer 2 Attached to rod end
(3) 6132-21-4630 Spacer 1 Attached to rod end
1. Check that the distance between the centers of the rod ends is 440 mm. (If it is not, adjust it.)
2. Fix the rod to the body side with bolt (1).
3. Referring to Procedure for adjusting dump sensor linkage on the next page, adjust the dump sensor.

Name Q'ty Name Q'ty
Other remarks
66
Assembly process No. Procedure for adjusting dump sensor
0450
Note) Be sure to perform the following adjustment after adjusting the shim of the body mount.
1. Seat the dump body.
2. Check that the difference between the centers of the lever hole and potentiometer hole (Positioning
hole marked with a: ø 5) is below 1 mm.
Caution) If the difference exceeds 1 mm, reduce it to below 1 mm by adjusting the rod length. At
this time, never reduce the adjustment dimension below 436 mm.
3. Check the value of the "Body position" on the real-time monitor in the cab.
Standard value of "Body position" when dump body is seated: 0.46 – 0.54 V
Procedure for using real-time monitor
(1). Press the "t" and "<" switches simultaneously to set the machine monitor in the service mode
and input the ID. ID No.: 6491
(2). Select the real-time monitor. (Change the item with the ">" and "<" switches and select it with
the "U" switch.)
(3). Select BRAKE (Retarder controller). (Select the item with the ">" and "<" switches.)
(4). Check the value of Item No. 34400: "Body position".
If the value of the "Body position" is out of the standard range, adjust the rod length to set the value
in the standard range. To increase the value, increase the rod length. To decrease the value,
decrease the rod length.
Caution) At this time, never reduce the adjustment dimension below 436 mm.
4. Check that the value of the "Body position" is in the standard range and tighten the rod permanently.
5. Raise the dump body to the stroke end and check the value of the "Body position".
Standard value of "Body position" when dump body is at rising end: 4.0 – 4.7 V
At this time, keep pulling the lever to the RAISE position until the hoist cylinders move to the stroke
end, even if the dump lever kicks out.

Never reduce the rod length below 436 mm. If it is Name Q'ty Name Q'ty
reduced below 436 mm, the potentiometer may be bro-
ken.
Other remarks
67
Assembly process No. Calibrating dump control
0460
a Perform the calibration while the hydraulic oil temperature is 80 – 90 °C.

1. While the body is seated perfectly, start the engine and keep the control lever in the FLOAT position
for 5 seconds.
a Check that the float caution lamp is turned OFF.
2. Run the engine at high idle and raise the body to the cylinder stopper, then run the engine at low idle
(850 rpm or lower) and keep the control lever in the RAISE position for at least 5 seconds.
3. Run the engine at high idling and raise the body to the stroke end, and then run the engine at low
idling (below 850 rpm) and set the lever in the FLOAT position to lower the body to the seat. Repeat
this operation 5 – 10 times.
4. Run the engine at high idling and raise the body to the stroke end, and then keep running the engine
at high idling and set the lever in the LOWER position to lower the body to the seat. Repeat this
operation 5 – 10 times.

Name Q'ty Name Q'ty
Other remarks
68
Assembly process No. Bleeding air from brake system (Preparation)
0470
Before bleeding air from the brake circuit, perform the following work.
Check of oil level in brake sub tank
1. Before starting the engine, check that the transmission oil level is proper.
2. After starting the engine, the oil level lowers. While running the engine at low idle, add oil so that the
oil level will be between H and L of the level gauge of the oil feed pipe.
3. At this time, check that the oil level in the brake sub tank is in the sight gauge. If the oil level is low,
add oil through the transmission oil filler.
Check after bleeding air

4. After bleeding air, run the engine at low idle again and check that the oil is at the specified level.

Name Q'ty Name Q'ty
Other remarks
69
Assembly process No. Bleeding air from brake system (Front)
0480
Air bleeders of brake circuit (12 places)

1. 2 places each on right and left sides of joint on back side of brake calipers (4 places in total)
The following figure shows the right side.
2. 4 places each on right and left sides of front brake calipers (8 places in total)
Bleed air through all of the 12 air bleeders.

For details, see Shop manual, "Bleeding air from brake circuit".

1. Before and after bleeding air, check the oil level in Name Q'ty Name Q'ty
the oil tank.
2. Bleed air from the above air bleeders with the foot
brake.
3. Before and after bleeding air, check that the sur-
faces of the disc and pad are free from oil and for-
eign matter.
Other remarks
70
Assembly process No. Bleeding air from brake system (Rear)
0490
Air bleeders of brake circuit (7 places)

1. 2 places each on right and left sides on back side of brake (4 places in total)
The following figure shows the right side.
2. 2 places on slack adjuster and 1 place on junction block above slack adjuster (3 places in total)
Q Bleed air through all of the 7 air

bleeders.
Q For details, see Shop manual,
"Bleeding air from brake circuit".

1. Before and after bleeding air, check the oil level in Name Q'ty Name Q'ty
the oil tank.
2. Carryout the above air bleeding work for all of the
service brake, parking brake, and retarder brake.
3. Before and after bleeding air, check that the sur-
faces of the disc and pad are free from oil and for-
eign matter.
Other remarks
71
Assembly process No. Adjusting suspension
0500
1. Loosen the air bleeder valves of the right and left front suspensions to bleed all air.
(Check that air does not come out any more (only oil flows out), and then tighten the valves again. (Tightening
torque: 39.2 – 48 Nm {4 – 4.9 kgm}))
2. Check that the valves are closed and install the suspension gas filler unit to the suspension cylinders.
3. Connect the hoses of the suspension gas filler unit to the nitrogen gas filler valves. (Since there are 2 hoses,
connect them to the right and left suspension cylinders so that pressure will be applied to both cylinders evenly.)
4. Open the valve of the suspension gas filler unit gradually.
5. When the suspension cylinders rise to the specified level shown above, close the valve.
(Supply the gas to the front side according to the decal and to the rear side so that the dimensions in the figure
will be obtained.)
6. Remove the hoses from the nitrogen gas filler valves and move the chassis forward and in reverse to fit the sus-
pension cylinders, and then stop without applying the brake. (Finally, stop the truck without applying the brake
to prevent an uneven load caused by braking.)
7. Apply the parking brake and check the length of the suspension cylinders.
8. If the length of the suspension cylinders is out of the standard range, repeat steps 3 – 7. (Usually, adjustment is
completed by repeating those steps 3 – 4 times.)
Precaution
When pouring nitrogen gas, do not apply pressure higher than 3.9 MPa {40 kg/cm2} or extend the cylinder to the
stroke end.
1. Bleed air from the cylinders. Name Q'ty Name Q'ty
Quantity of oil to be supplied = 16.5 l (Reference) Suspension gas filler unit 1
2. Fill both suspension cylinders simultaneously. (7926-10-1000)
3. Do not extract the suspension cylinders to the stroke
end.
4. After moving the truck forward and in reverse, stop it
without applying the brake.
5. Do not steer the truck before finishing this adjust-
ment. (If it is steered, the piping may be broken.)
Other remarks
72
Assembly process No. Greasing (Right front axle)
0510
1. 1 place on right front suspension and 4 places on A-arm (5 places in total)

See No.0120.

Name Q'ty Name Q'ty
Other remarks
73
Assembly process No. Greasing (Hoist cylinder)
0520
1. 1 place on upper hoist cylinder (2 places in total)

Name Q'ty Name Q'ty
Other remarks
74
Assembly process No. Greasing (Rear suspension and axle rod)
0530
1. 1 place each on right and left sides of grease tube at rear of frame (2 places in total)
2 places on right and left sides of rear suspension (4 places in total)
3 places on right and left sides of axle rod (6 places in total)
See No.0160.

Name Q'ty Name Q'ty
Other remarks
75
Assembly process No. Painting
0540
Paint (Sent from factory for trucks in Japan)
Undercoat paint Topcoat paint

RETAN GP primer : 4 kg SR3000 natural yellow: 16 kg
RETAN GP hardener : 0.8 kg SR3000 hardener : 15 kg
RETAN GP thinner : 4 l Urethane thinner 205 : 17 l
Heat-resistant silver paint : Spray can

Black gray paint : Spray can
1. Paint each welded part and scratch with the specified paint.
2. Mix the base and hardener of the paint well at the ratio of "5:1, thinning rate: 10 – 30%" before using.
3. If there is a scratch on the chassis, touch up it with the above paint.

1. Before painting, mask the parts other than the parts Name Q'ty Name Q'ty
to be painted.
Other remarks
76
Assembly process No. Sticking body decal
0550
HD605
Right side

(1) 569-93-81320 Mark 2 Loose-supply item (Separately packed)
Stick decals to right and left of body.

1. Fit each decal perfectly and leave no bubbles. Name Q'ty Name Q'ty
2. Remove all oil and dust from the surfaces to which
the decals will be stuck.
Other remarks
77
Assembly process No. Removing jig
0560
1. Remove the slings from the frame.
2. Remove the frame supporters.

Name Q'ty Name Q'ty
Other remarks
78
Assembly process No. Adjusting angles of mirrors
0570
Adjusting mirrors
1. Make marks at A, B, C, D, E, and F on the ground.
2. Adjust each mirror so that you can see the above marks.
(1) o A – C and a part of machine
(2) o A – B and a part of machine
(3) o B – D and a part of machine
(4) o C – E and a part of machine
(5) o Part after D, part around bottom of tire, and top edge of body
(6) Upper o Part after F, part around bottom of tire, and top edge of body
(6) Lower o Part after E, part around bottom of tire, and top edge of body

Name Q'ty Name Q'ty
Other remarks
79
Assembly process No. Checking/Adding lubricants
0580
1. Check the levels of the oil, coolant, and fuel and add them if necessary.
Q Coolant level
Q Oil levels in engine oil pan and brake oil tank
Q Oil level in hydraulic tank
Q Fuel level in fuel tank

Name Q'ty Name Q'ty
Other remarks
80
Assembly process No. Preparation of welding body
C-0010
1. Select a place for work.

Select a place for work, secure an area of 169 m2 (13 m x 13 m) on the floor or ground. The grdient
of the floor or groung must not exeed 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 right half body and protector stored in the split body.
Cut off the angle bar and plate used to fix the right half body and
protector with gas.
At this time, sling the right half body and protector with a crane to
prevent them from falling after the angle bar and plate are cut.
Remove the protector first, and then remove the right half body.
After lowering the right half body, cut the 2 brackets (569-74-61460)
tack-welded to its inside with gas.
5. Remove the paint from the parts to be welded.
Remove the paint from the range of 15 mm through along the fitting
line of the body.
Burn the paint with a gas burner or scrape it with a grinder.
6. Reverse the split body.

It can be reversed easily with the following.
(1) Hanging shaft (ATH-785-006)
(2) Eagle clamp: For 5 ton, 2 pieces

Name Q'ty Name Q'ty
Other remarks
81
Assembly process No. Assembly of split body
C-0020
1. Install the stand on ground, as shown in right

figure.
2. Set the right side of the split body on the
stand.
3. Set the left side of the split body on the stand so that the clearance will be even.
4. Mark off the position of bracket (569-74-81212/81221) tack-welded

to the bottom of the body, and then remove the bracket.
5. Fix the set body with the bolts.
(1) Tighten the set right and left half bodies temporarily with the
bolts. (For the necessary parts, see the following table.)
(2) Pass the alignment pin (ø79.3) through the hinge bracket at the
bottom (See the photo at right) and check the heights and posi-
tions of the right and left half bodies.
(3) Tighten the bolts.
(4) Check that you can move the alignment pin with your fingers.
If the positions of the parting parts of the half bodies are very differ-
ent from each other, adjust them with a hydraulic cylinder or a
wedge.
When adjusting, check that the clamping bolts are loosened.

(1) 01011-82010 Bolt 6
(2) 01643-32060 Washer 6
(3) 01580-12016 Nut 6
(4) 581-74-11630 Tube 6
Name Q'ty Name Q'ty
Other remarks
82
Assembly process No. Tack welding body
C-0030
1. Tack-weld the body (outside and inside).

(1) Tack-weld to a degree of 6 100 – 500 . Tack-weld the corners and ends of weld lines.
Note) Limit the root gap at the joint of the front and bottom large plates to 3 mm (Direction on
drawing: 2 mm).
(2) After tack-welding, check that you can move the alignment pint with your fingers.
(3) Remove the bolts, washers, nuts, and tube.
2. Position and tack-weld 2 brackets (569-74-61460) removed in C-0010 above to the following dimen-
sions.
3. Position and tack-weld 2 brackets (569-74-81212/81221) removed in C-0020 above to the following
dimensions.

Name Q'ty Name Q'ty
Other remarks
83
Assembly process No. Welding body
C-0040
1. Weld the front plate. (Refer the C-0050 and C-0060 for welding instruction.)
Apply arc welding to the front plate in vertical position. Observe the welding condition shown in
Table 1.
2. Weld the bottom plate on the level. (Refer the C-0050 and C-0060 for welding instruction.)
Put a stand under the rear part of the bottom plate to keep the bottom plate on the level.
Note) Perform back step welding at each joint of beads and at each start of welding.
Note) Weld the inside of the channels of the large plates, too.
3. Position and weld 4 plates (569-83-69470), 2 plates (569-83-69460), 1 plate (569-83-89470), and 1
plate (569-83-69550) to the channels.
(For the installed positions and welding instructions, see C-0050.)
4. Check the welded parts for a defect.

(1) Check the deposited metal.
(2) Check for an undercut, overlap, and spatter.
(3) Check the leg length of weld for shortage
(Insufficient leg length is not permitted.)
5. After finishing the welding work, remove the spatters and finish the beads with a grinder.
Table 1
Name Q'ty Name Q'ty
Other remarks
84
Assembly process No. Welding body instruction (1/2)
C-0050

Name Q'ty Name Q'ty
Other remarks
85
Assembly process No. Welding body instruction (2/2)
C-0060

Name Q'ty Name Q'ty
Other remarks
86
Assembly process No. Turn over the body
C-0070
1. Remove the stands (8 pieces) for transportation installed to the bottom plate.
2. Reverse the body.

Install the sling to the body hinge hole of the bottom plate and prepare for reversing the body.
Keep the posture (2) shown below (Keep lifting the body) and weld the inside of the front plate.
For the welding condition, see Table 1.
Lower the body in posture (4) and weld the inside of the bottom plate.
Put wood blocks under the front and rear parts of
the bottom plate.
Connect the ground cable for welding to the body
securely.
Apply CO2 gas shielded arc welding as standard.
If it is difficult to apply, however, apply arc welding.
Table 1

Name Q'ty Name Q'ty
Other remarks
87
Assembly process No. Welding body protector (1/2)
C-0080
1. Weld the protector.

(1) Place the protector on the tops of the side plate and front plate with a crane.
Capacity of crane: Min. 2 tons
Lift of crane: Min. 7 m
Breaking strength of wire rope, chain, chain block: Min. 2 tons
(2) When positioning the protector, set the protector plate parallel to body side plate.
(3) Cut the front and side plates of the protector 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 clearance will be minimized at the
time of welding. (Reduce the clearance to below 3 mm.)
(4) After positioning, tack-weld the front panel of the protector.
If any plate is used to secure the protector, remove it with a gas cutting device or a grinder.

Preheating/Postheating Unnecessary Unnecessary 2] Time: 120 minutes

Name Q'ty Name Q'ty
Other remarks
88
Assembly process No. Welding body protector (2/2)
C-0090
1. Weld the protector.

Welding order: Weld the side plate first.
Welding symbol:
Follow welding instruction drawing below.
Welding condition:
Follow welding condition table below.
Perform welding according to KES04.343,
General, 2nd Grade.
2. Tack-weld the right and left triangular plates
(Section C-C shown below) and then weld
them permanently.
Apply CO2 gas shielded arc welding as standard. If it is difficult to apply, however, apply arc welding.

Name Q'ty Name Q'ty
Other remarks
89
Assembly process No. Finishing and painting welded parts of body
C-0100
1. 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.
2. 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 (Insufficient leg length is not permitted.)
3. After cooling, paint the welded parts.

(1) Mix the base and hardener of the paint well at the ratio of 5:1 as specified.
(2) After painting, clean the paint spray gun with paint thinner before the paint is hardened.
Put on mask, goggles, gloves, etc. to protect yourself from paint mist.
[Undercoat paint]
RETAN GP primer
RETAN GP hardener
RETAN GP thinner
[Top coat paint]

NAX MIGHTYLAC G II KB natural yellow
NAX MIGHTYLAC G II KB hardener
NAX MIGHTYLAC G II KB thinner

Name Q'ty Name Q'ty
Other remarks
90
Assembly process No. Reworking on body (Exhaust selector box specification)
C-0110
View Z
(1) 569-84-62221 Plate 1 Separately packed (H4E-06-120)
When welding (2), you may add hole 100 x 100
(part A) if necessary. Restore as shown at right in
this case, however.

Name Q'ty Name Q'ty
Other remarks
91
Assembly process No. Welding of body exhaust pipe
C-0120 (Exhaust selector box specification)
Section A-A
(Section of exhaust box mounting part)
Detail of welding method
(1) 569-84-84230 Box 1 Separately packed (H4E-06-120)
Assembly procedure for exhaust opening
(1) Fix dimension A of the exhaust box to 65 mm.
(2) Install box (1) to the body.
(3) Align the exhaust box with flange face and weld it as shown above.
(Runout in the forward, backward, right and left directions must not exceed 2 mm.)
(4) After welding, raise the body and check that dimension A is 120 mm.

Perform this work after adjusting the body shim. Name Q'ty Name Q'ty
Other remarks
92
1/5
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.
HD465-7E0
SAA6D170E-5
HD605-7E0
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
T..... Normal T ..... Correction made on abnormal point

T..... Abnormal T..... 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 KOMATSU 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.
Printed in Japan
2/5
Mainte-
No. Inspection item Judgment procedure and standards Check nance Remarks
Record the serial Nos. of the component parts.
Enter the Nos. (Left: ) (Right: )
1 Front axle Nos. * The Nos. must be clear. They are stamped on the front
suspension cylinders.
Enter the Nos. (Left: ) (Right: )
2 Rear axle Nos. * The Nos. must be clear. The nameplate is installed to the
differential case.
Check the oil and water levels.
Engine oil level (Check with The level must be between (H) and (H-10 mm).
3
engine stopped) (Check with oil level gauge.)
4 Hydraulic oil level The level must be inside the inspection window.
Level must be above (L) of gauge (engine stop position).
5 Transmission oil level (1) * Check the level finally while engine is running at low idle after
warm-up operation.
6 Coolant level The level must be above the midpoint between Full and Low
of the sub-tank.
7 Battery fluid level The fluid level must be 10 – 12 mm above the plates.
8 Windshield washer fluid level The fluid level must be above 2/3 of the tank.
Turn the key switch ON.

Sound volume must be sufficient and beat sound must not be
9 Function of horn made. (Sensory evaluation)
* Horn sounds even if key switch is turned OFF.
10 Function of backup buzzer The sound volume must be sufficient and free from beats.
(Sensory evaluation)
Start the engine. (Before starting the engine, check the safety around the truck. Measure each item after warm-up operation.)
11 Abnormal noise of engine The engine must not generate abnormal noise. (Sensory
evaluation)
Measure with parking brake ON, accelerator pedal OFF, and
AISS switch ON.
Standard: 700 – 800 rpm
Engine speed Low idle speed, Measured value: ( ) rpm
* Engine coolant temperature: In
green range Measure with parking brake ON and body seated (float caution
* Engine oil temperature: 70 – 80°C lamp OFF) in power mode.
* Torque converter oil temperature: Standard: 2,050 – 2,100 rpm
12
70 – 80°C High idle speed, Measured value: ( ) rpm
* If method of measuring engine
speed is unknown, see Shop Engine speed at torque converter stall - Measured value:
manual, Testing and adjusting, ( rpm) Power mode standard: 1,910 ± 100 rpm
Measuring engine speed.
Engine speed at torque converter stall - Measured value:
( rpm) Economy mode standard: 1,760 ± 100 rpm
When the engine is accelerated sharply (Li o Hi), is exhaust

13 Exhaust gas color
gas color good. (Sensory evaluation)
Exhaust gas must not leak through exhaust pipe joints, exhaust
14 Exhaust gas leakage gas shutter, etc.
When key switch is turned to START position while transmission
15 Safety function (1)
shift lever is not in N, engine must not start.
When the parking brake switch is ON and the transmission shift
16 Safety function (2) lever is not in N, the centralized warning lamps and alarm buzzer
must be turned ON.
Check the lamps.
When the lamp switch is turned ON (1st/2nd stage), both front
17 Function of clearance lamps
lamps and 3 rear lamps (right, center, and left) must light up.
3/5
No. Inspection item Judgment procedure and standards Check Mainte- Remarks
nance
When the lamp switch is turned ON (2nd stage), the head lamps
18 Check of head lamp
(1 lamp on each side) must light up.
When the head lamp is turned ON and the dimmer switch is
Check of high beam (Function
19 operated, the number of the lamps must change between 2 and
of dimmer switch) 4. (The lighting direction must change.)
When the turn signal lever is operated, the front and rear turn
20 Function of turn signal lamps signal lamps in the turning direction must flash.
21 Function of hazard lamp When the hazard switch is turned ON, both turn signal lamps
and pilot (arrow) lamp in the cab must flash.
When the transmission shift lever is in R, the backup lamp must
22 Function of backup lamp 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
23 Function of brake lamp and left) must light up. The center brake lamp must not 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).
When the switch is turned ON. Must light up when cab door is
24 Function of room lamp
open.
Check the travel and brake. (Before checking the following items, check the safety around the truck.)
25 Overheating of front brake disc Drive inside the yard and touch the brake disc to check that it is
(Both sides) not overheating.
After machine travels in yard, oil of abnormal quantity must not
26 Drainage from floating seal (Both
be drained through seal. * Check with drain plug removed.
sides) (Reference: After 60-minute travel, oil must not be drained more
than 100 cc from each side.)
*** Method of checking No. 27 – 30 (start limit value) ***
(1) Operate the brakes to be checked (Release other brakes).
(2) Set the transmission shift lever in the D range.
(3) Press the accelerator pedal gradually and read the engine speed when the machine starts.
(4) If the machine does not start when the engine speed reaches the torque converter stall speed in the D range (F2), return to (2) and
set the transmission shift lever in the 6 range (F1), and then check.
[Precautions]
1. When operating the transmission shift lever, set the engine speed to low idle.
2. Check the oil temperature gauge frequently and take care that the torque converter oil will not be overheated.
When the engine is stalled at F2 (above 1,670 rpm), the truck
27 Function of parking brake must not start. Enter start limit value.
Measured value (F : rpm)
28 Function of service brake must not start. Enter start limit value.
29 Function of retarder brake must not start. Enter start limit value.
When the emergency brake is turned ON, the service brake and
parking brake must operate. (Check that the pilot lamp light up.)
30 Function of emergency brake
Enter the start limit.
Check the functions of the work equipment.
[Note] Before checking, correctly carryout Assembling and adjusting dump sensor, "Field assembly manual". If the work equipment is
operated without carrying out correctly, the original performance is not obtained. In the worst case, the dump sensor potentiometer and
linkage (rod) may be broken.
Potentiometer voltage at lowering end (when body is seated)
Measured value: ( )V
Standard value: 0.46 – 0.54 V (Target: 0.50 V)
31 Check
of potentiometer voltage
* Check with real-time monitor. Potentiometer voltage at raising end (stroke end)
Measured value: ( )V
Standard value: 4.00 – 4.70 V
Check of function of body opera- When the dump lever is not in FLOAT or when the body is not
32 tion caution lamp seated, the body operation caution lamp must light up.
The operating effort must be proper and dump lever must not be
33 Operating effort of dump lever
hitched. Check by sensory evaluation.
4/5
nance
(1) The functions of the dump lever must be arranged in the
order of RAISE o HOLD o FLAOT o LOWER from the top.
(2) The body must be stopped at any position when the dump
lever is set in HOLD.
(3) When the dump lever is released in LOWER, it must return to
34 Functions of dump lever
FLOAT.
(4) When the dump lever is in RAISE or LOWER, the pressure
must be regulated.
(5) When the dump lever is in HOLD, the safety stopper (knob)
must be applied without interference.
When the body is seated on the frame, unpleasant shocks must
35 Shocks of body at lowering end not be made. (Sensory evaluation)
When the lever is released in RAISE, it must not return to HOLD.
36 Function of boom positioner When the lever is set in RAISE to raise the body, it must be set in
HOLD automatically just before the H/T cylinder reaches the
stroke end.
When the body rises to the end, it must not run out in either
direction. (Criterion - Difference between dimensions of both
37 Unevenness of body hoist cylinders: Max. 7 mm)
When the body is lowered to the end, it must contact the mount
evenly. (The contact area must be at least 80%.)
Safety function (3) When the dump lever is not in FLOAT and the transmission shift
38 * When checking, start engine lever is not in N, the centralized warning lamps and alarm buzzer
and turn parking brake OFF. must be turned ON.
Safety function (4) When the body is not seated and the transmission shift lever is
39 * When checking, start engine not in N, the centralized warning lamps and alarm buzzer must
and turn parking brake OFF. be turned ON.
When the body is not seated, the truck must not travel in
Safety function (5) reverse, even if the transmission shift lever is set in R. In D – L
40 * When checking, start engine
ranges, transmission shift lever must be settable in only 1st
and turn parking brake OFF. range.
Body rising speed (Oil tempera- Engine speed: 2,000 rpm, Measured value: ( sec)
41
ture: 80°C) Standard (Common to HD465 and 605): 11.5 ± 1.5 sec
Body lowering speed (Lever at Engine speed: Low idling speed, Measured value ( sec)
42
FLOAT, Oil temperature: 50 – 70°C) Standard (Common to HD465 and 605): 11.5 ± 1.5 sec
The hydraulic drift in 5 minutes must be 85 mm or less. (From
43 Hydraulic drift of body point where cylinder No. 2 is extended by 100 mm) Measured
value: ( mm )
Stop the truck on level ground and measure.
Level must be between (H) – (intermediate point between H – L)
44 Transmission
level (2) (Low idle
level) of gauge (on low idle side).
* Warm up machine sufficiently before checking.
The length must be in dimension A.
Dimension A:
249 (Center of label) ± 10 mm
Length of suspension cylinder
Measured value:
45 (Front) Left ( mm),
* Measure with dump body empty. Right ( mm)
The length must be in dimension A.

Dimension A: 204 ± 10 mm
Length of suspension cylinder Measured value: Left ( mm),
Right ( mm)
46 (Rear)
* Measure with dump body empty. Dimension A: From rod head
shoulder of suspension cylinder
to top of flange
(1): When the dump lever is set to any position other than
FLOAT, display must change from [Soft] to [Hard].
Check of automatic suspension
47 control function (Optional) (2): When the service brake or emergency brake is turned ON,
the display must change from [Soft] to [Medium].
Measure with dump body empty.
(3): The display must show [Soft] in all cases other than (1) and
(2) above.
5/5
nance
Inspect each part.
The safety pin must be inserted without obstruction in the right
48 Function of safety pin
and left stopper holes.
The safety pin must be removed from, installed to, and locked at
49 Storage function of safety pin
the storage position securely.
Installation of drive shaft All the mounting bolts must be free from looseness and abnor-
50
(Transmission o Differential) mal play.
51 Front support (Right) The mounting bolts must be free from looseness.
52 Inspection around engine No oil and water leakage.
53 Inspection around transmission No oil and water leakage.
54 Fuel leakage from fuel system No leakage.

Oil leakage from hydraulic oil sys-
55 No leakage.
tem (tank, cylinder, pump, piping)
56 Oil leakage from brake system No leakage.
Tightness of large-capacity bat-
57 When the terminals are shaken by hand, they must not move.
tery (optional) terminals
58 Rubber cap of large-capacity bat- The cap must be fitted securely. (The terminal must not project
tery (optional) wiring (+) terminal from the cap.)
Tightness of tire hub nuts (1) Front left: Retighten.

Tightening torque: 1,519 - 1,617
Nm {154.8 - 164.8 kgm} (2) Front right: Retighten.
59 (Target: 1,568 Nm {159.8 kgm})
(3) Rear left: Retighten.
* When nothing is applied to the
threads. (4) Rear right: Retighten.
Standard: Shown at left
Measured value:Front left ( MPa { kg/cm²}),
Tire inflation pressure Front right ( MPa { kg/cm²})
(When dump body is empty)
24.00-35-36PRE4: Standard: Shown at left
60 0.47 ± 0.01 MPa Measured value:Rear left inside ( MPa { kg/cm²}),
{4.8 ± 0.1 kg/cm²} Rear right inside ( MPa { kg/cm²})
24.00-R35: 0.69 ± 0.01 MPa
{7.0 ± 0.1 kg/cm²} Standard: Shown at left
Measured value:Rear left outside ( MPa { kg/cm²}),
Rear right outside ( MPa { kg/cm²})
61 Flaw of tires 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), its
62 Tension of fan belt deflection must be 10 - 15 mm. The belt must be free from flaw
and twist
The plated surfaces must be free from rust, harmful flaw, spatter,
63 Steering cylinders (Both sides)
paint, etc.
The plated surfaces must be free from rust, harmful flaw, spatter,
64 Hoist cylinders (Both sides)
paint, etc.
65 Suspension
cylinders (Both sides, The plated surfaces must be free from rust, harmful flaw, spatter,
front) paint, etc.
Suspension cylinders (Both sides, The plated surfaces must be free from rust, harmful flaw, spatter,
66 rear)
paint, etc.
67 Appearance of cab glass Glass must be free from flaw, paint, etc.
HD465-7E0, HD605-7E0 GALEO DUMP TRUCK
Form No. GEN00046-01
©2007 KOMATSU
All Rights Reserved
Printed In Japan 05-07

HD465-7 Field Assembly GEN00046-01 PDF

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

HD465-7 Field Assembly GEN00046-01 PDF

Загружено:

Авторское право:

Доступные форматы

CONTENTS

1. Major points changed from model 7 ............................................................................................................. 1

2. Outline of division (Only main components)

2. Dump body (Divided into 3) 4. Rear axle and tire assembly

3. Right front axle assembly 5. Front tire and wheel assembly

Weight Overall length Overall width Overall height

Drawing of bare machine on trailer

Specifications of completed truck

Rough contents of assem- Positioning rear axle Installing front axle

Day 1st day

Unloading Positioning and fixing split body

245 kN {25 ton} 245 kN {25 ton}

Installing platform Mounting body

490 kN {50 ton} (98 kN {10 ton}) 490 kN {50 ton}

Day 2nd day

Positioning and fixing split body Turning over

245 kN {25 ton}

Rough contents of assem- Installing exterior parts Maintenance, adjustment

Day 3rd day

Welding inside of body Welding protector

Exhaust pipe welding jig No.0400

Precautions Necessary tools Necessary equipment

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

Precautions Necessary tools Necessary equipment

Volume of refilled oil

Engine oil pan Engine oil 86 80 —

Transmission case 318 215 60

16.5 each on right

Fuel tank Diesel fuel 780 — —

Cooling system Coolant 157 — —

Do not steer the machine largely before adjusting the suspension

Precautions Necessary tools Necessary equipment

2. Position the rear axle as shown above.

Part No. Part name Q'ty State of parts

Precautions Necessary tools Necessary equipment

Part No. Part name Q'ty State of parts

Precautions Necessary tools Necessary equipment

1. When slinging the chassis, apply cloths to protect it.

Precautions Necessary tools Necessary equipment

1. Install the upper axle rod.

Part No. Part name Q'ty State of parts

Precautions Necessary tools Necessary equipment

Part No. Part name Q'ty State of parts

Precautions Necessary tools Necessary equipment

Lay 2 lines of 4 wood blocks.

2. Remove the sling.

Precautions Necessary tools Necessary equipment

Set the bare machine to proper height so that you can

Part No. Part name Q'ty State of parts

Part No. Part name Q'ty State of parts

Part No. Part name Q'ty State of parts

Precautions Necessary tools Necessary equipment

Precautions Necessary tools Necessary equipment

Precautions Necessary tools Necessary equipment

Right front axle seen from FWD

To be fixed together with

Plate attached to axle

Chassis seen from front

Tie rod end

Precautions Necessary tools Necessary equipment

Installing 2 front tires to right and left

<How to sling tire and wheel assembly> <Image of mounting tire>

Hitch sling to tire tread.