HD465.605-7 Field Assembly

CONTENTS
[1]
[2]
[3]
[4]
[5]
Chart of separated units ........................................................................................................................... 3

Dimensions of separated units ................................................................................................................ 5
Order for assembly, facilities to use, schedule for assembly ................................................................. 6
Tools and equipment to use ................................................................................................................... 10
Procedure for local assembly ................................................................................................................. 12
A-1 Setting bare machine position .............................................................................................. 12
A-2 Assembly of rear axle & suspension .................................................................................... 13
A-3 Assembly of rear axle assembly (connection of suspension) ............................................ 14
A-4 Assembly of rear axle assembly (connection of axle rod) .................................................. 15
A-5 Assembly of rear axle assembly (connection of lubrication grease tube) ......................... 16
A-6 Assembly of rear axle assembly (connection of drive shaft) .............................................. 17
A-7 Assembly of right front axle .................................................................................................. 18
A-8 Assembly of right front axle (connection of suspension) ................................................... 19
A-9 Assembly of right front axle (connection of A arm) ............................................................ 20
A-10 Assembly of right front axle (connection of steering cylinder & rod) ................................ 21
A-11 Assembly of right front axle (connection of brake hose) .................................................... 22
A-12 Assembly of tire & wheel assembly ..................................................................................... 23
A-13 Assembly of front support .................................................................................................... 24
A-14 Assembly of right fender lock bracket .................................................................................. 25
A-15 Assembly of R.H. platform assembly ................................................................................... 26
A-16 Assembly of L.H. catwalk assembly ..................................................................................... 27
A-17 Assembly of L.H. handrail ..................................................................................................... 28
A-18 Assembly of R.H. fender ........................................................................................................ 29
A-19 Assembly of L.H. fender ........................................................................................................ 30
A-20 Assembly of left and right mudguards ................................................................................. 31
A-21 Assembly of left over fender ................................................................................................. 32
A-22 Assembly of right over fender .............................................................................................. 33
A-23 Mounting of dump body (lifting dump body) ...................................................................... 34
A-24 Mounting of dump body (installation of hinge pin) ............................................................ 35
A-25 Assembly of poke ejector ...................................................................................................... 36
A-26 Assembly of dump body lock pin ......................................................................................... 37
A-27 Assembly of dump body mudguard ..................................................................................... 38
A-28 Mounting of dump body (shim adjustment procedure) ...................................................... 39
A-29 Welding actual parts (installation of protective cover) ........................................................ 40
A-30 Assembly of exhaust pipe tube ............................................................................................. 41
A-31 Connection of dump sensor .................................................................................................. 42
A-32 Filling with grease, water 1 ................................................................................................... 43
A-33 Filling with grease, water 2 ................................................................................................... 44
A-34 Bleeding air from brake ......................................................................................................... 45
A-35 Adjusting dump control ......................................................................................................... 46
A-36 Painting ................................................................................................................................... 47
A-37 Adjustment of suspension .................................................................................................... 48
A-38 Settling floating seal .............................................................................................................. 49
Procedure for welding and assembling three separated body parts ......................................................... 51
Field assembly inspection report
HD465-7, HD605-7
[1] CHART OF SEPARATED UNITS
6. Front tire & wheel assembly

1. Bare machine
2. Dump body
7. R.H. platform & handrail assembly
3. Right front axle assembly
8. L.H. catwalk & handrail assembly
9. L.H. handrail
4. Rear axle & tire assembly
10. R.H. front support

5. Rear suspension
HD465-7, HD605-7
[1] CHART OF SEPARATED UNITS
11. Right fender mounting bracket
15. Dump body mudguard
12. Left and right fenders

16. Poke ejector
13. Left and right mudguards
16. Exhaust pipe & tube
14. Left and right over fenders
17. Drive shaft
When the machine is shipped from the factory, it is shipped in the posture shown below.
HD465-7, HD605-7
Specifications for completed
Specifications
Weight (kg)
42,800
When
HD465-7 (Weight of machine)
traveling
under
46,800
own
HD605-7 (Weight of machine)
power
Related specifications
Overall length (mm) Overall width (mm) Overall height (mm)
9,355
(Front bumper to
rear of body)
9,355
(Front bumper to
rear of body)
4,820
4,400
(When empty)
4,820
4,400
(When empty)
[2] DIMENSIONS OF SEPARATED UNITS

No.
Name of unit
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Bare machine
Dump body / HD465-7
Dump body / HD605-7
Right front axle assembly (1 set)
Rear axle & tire assembly
Rear suspension (1 set)
Front tire & wheel assembly (1 set)
R.H. platform assembly
L.H. catwalk assembly
L.H. handrail
R.H. front support
Right fender lock bracket
Left and right fenders (1 set)
Left and right mudguards (1 set)
Right over fenders
Left over fenders
Dump body mudguard
Poke ejector (1 set)
Exhaust pipe & tube
Drive shaft
Weight
(kg)
18,520
10,650
13,418
1,100
10,800
172
1,200
120
95
4.5
50
11
24
4
3
1.5
2
25
18
62
Overall length Overall width Overall height

(mm)
(mm)
(mm)
7,055
3,490
3,460
8,710
4,662
2,700
8,710
4,545
2,700
1,300
1,300
1,600
2,165
4,520
270
932
2,165
645
2,510
600
1,100
2,500
735
1,100
945
1,000
620
665
652
470
550
290
396
900
576
870
900
1,590
430
830
412
1,275
960
100
695
550
480
480
755
302
When machine is loaded on trailer
HD465-7, HD605-7
[3-1] ORDER FOR ASSEMBLY, FACILITIES TO USE, SCHEDULE FOR ASSEMBLY
Day
-------
-------
-------
-------
-------
-------
1st day
-------
Time
(hrs)
Assembly unit
1 Positioning base machine on supports
1 Assembly of rear axle, suspension

ass'y
2 Assembly of rear axle ass'y
A-1
A-2 A-6
Assembly Procedure
Sheet No.
2 cranes
1 crane
Crane
(hydraulic type,
with operator)
30 ton
Air compressor
Generator
No. of workers
30 ton
30 ton
3.7 m3/min
(Komatsu EC35Z5 or equivalent)
For driving air compressor
3 workers
Forklift truck
2 ton
Remarks
Meeting before starting operation

Unloading parts
Start of assembly
* Select a smooth flat surface when

positioning the rear axle.
* Adjust the height of the wooden
block so that the rear axle is horizontal.
HD465-7, HD605-7
Day
-------
-------
-------
-------
-------
-------
2nd day
-------
Time
(hrs)
Assembly unit
1 Assembly of front right axle

Assembly Procedure
Sheet No.
1 Assembly of tire
A-7 A-11
A-12
1 crane
Crane
(hydraulic type,
with operator)
15 ton
Air compressor
Generator
No. of workers
3.7 m3/min
2 workers
Forklift truck
2 ton
Remarks
HD465-7, HD605-7
Day
Assembly unit
1 Assembly of R.H. platform ass'y

2 Assembly of R.H. catwalk ass'y
Assembly Procedure
Sheet No.
1 Assembly of body work

2 Assembly of dump body
A-13 A-17
A-18 A-29
5 ton
30 ton
1 crane
Crane
(hydraulic type,
with operator)
Air compressor
Generator
No. of workers
3.7 m3/min
2 workers
3 workers
Forklift truck
2 ton
Remarks
-------
-------
-------
-------
-------
-------
3rd day
-------
Time
(hrs)
HD465-7, HD605-7
Day
-------
-------
-------
-------
-------
-------
4th day
-------
Time
(hrs)
Assembly unit
1 Adjustments
Assembly Procedure
Sheet No.
A-30 A-47
Crane
(hydraulic type,
with operator)
Air compressor
Generator
No. of workers
3.7 m3/min
2 workers
2 workers
Forklift truck
2 ton
Remarks
HD465-7, HD605-7
[4] TOOLS AND EQUIPMENT TO USE
1 Tools to use
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Name
Two-ended ring wrench
Impact wrench
Impact wrench
Impact wrench
Impact wrench
Impact wrench
Socket
Socket
Wrench
Extension bar
Torque wrench
Torque wrench
Torque wrench
Torque wrench
Bar
Paint spray can
Bucket
Specification
14/17/19/24/30/36
GT-S12M or equivalent
GT-S22M or equivalent
RSP220N x 22 or equivalent
RSP310N x 24 or equivalent
GTP-800P or equivalent
36 (Insertion angle: 25.4) /46mm
14/17/19/22/24/30
14/17/19/24/30/36
Insertion angle: 25.4 x L:160 mm
Able to measure 927 Nm
Clear
Q'ty
One each
1
1
1
1
1
1
One each
One each
1
1
1
1
1
1
2
1
Remarks
For assembling tire
For assembling tire

For assembling tire
For "settling" work
2 Equipment to use
No.
1
2
3
2
3
4
5
6
7
Name
Truck crane
Truck crane
Truck crane
Forklift truck
Compressor
Stand (operating stand)
Steel sheet
Wooden block
Wooden block
Specification
Min. 30 ton
Min. 15 ton
Min. 5 ton
Min. 2 ton
Capacity: Min. 32 l
4 steps (approx. 1.5 m)
t9 1219 2438
400 400 900
401 400 1200
Q'ty
2
1
1
1
1
1
1
6
1
Remarks
For lifting bare machine
For assembling tire

For impact wrench
For use during operation
For positioning bare machine
For positioning bare machine
For positioning rear axle
Specification
For 15-ton x L4000
L4000, chain diameter d6.3
For 15 ton
Q'ty
4
1
1
Remarks
For lifting bare machine
For lifting tire
For lifting axle
3 Lifting tools to use

No.
Name
1
Nylon sling
2
Tire lifting tool
3
Chain block
10
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
11
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 bumper
Lifting 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 to
make it possible to assemble the tire & wheel assembly.)
In addition, when setting on the ground surface, lay steel plates under the wooden blocks to
prevent the machine from tilting if the wooden blocks sink into the ground. (1219 x 2438 x 9t x 1)
Precautions
Tools to use
Name
When lifting the chassis, fit a cloth

between the chassis and the nylon
sling to prevent damage to the front
bumper or other parts.
Others
12
Q'ty
Equipment to use
Name
Q'ty
Crane (30-ton)
2
Nylon sling
4
Steel plate
1
(1219 2438 9t)
Wooden block
6
(400 400 900)
NO. A-2 1/1
ASSEMBLY OF REAR AXLE AND SUSPENSION

1 Assembly of suspension
1. Using one 30-ton crane, raise the rear axle & tire assembly.
Lifting tool :
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 to
make it possible to assemble the tire & wheel assembly.)
In addition, when setting on the ground surface, lay steel plates under the wooden blocks to
prevent 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
Tools to use
Name
Put blocks under the tires to prevent

the tires from moving.
Q'ty
Equipment to use
Name
Q'ty
Crane (30-ton)
1
Nylon sling
2
Steel plate
1
(1219 2438 9t)
Wooden block
1
(400 400 1200)
Chocks to block tires
4
Others
13
NO. A-3 1/1
ASSEMBLY OF REAR AXLE ASSEMBLY (CONNECTION OF SUSPENSION)

1 Connection of suspension
1
2
3
4
Part No.
569-40-61552
01010-81425
569-40-61710
569-52-41950
Part Name
Pin
Bolt
Washer
Spacer
Q'ty
2
2
2
4
Details of shipment
Already temporarily installed to chassis

Lifting tool:
Lifting point at front:
Lifting eye under bumper
2. Set the rear axle as shown in the diagram above.
4. Raise the bare machine and connect the rear axle assembly.
Precautions
Do not use force when fitting the
spacer. If the spacer is forced in, it will
be deformed.
Tools to use
Name
GTP-12 or equivalent
Impact wrench
(22-mm socket)
Others
14
Q'ty
1
Equipment to use
Name
Q'ty
Crane (30-ton)
2
Nylon sling
4
Steel plate
1
(1219 2438 9t)
Wooden block
1
(400 400 1200)
4
1
NO. A-4 1/1
ASSEMBLY OF REAR AXLE ASSEMBLY (CONNECTION OF AXLE ROD)

1 Connection of axle rod
1
2
3
4
5
6
Part No.
569-40-81550
569-52-81150
01010-81425
569-40-61710
569-40-61160
569-52-41950
Part Name
Pin
Pin
Bolt
Washer
Bushing
Spacer
Q'ty
2
2
4
4
8
8
Details of shipment
Already temporarily installed to rear axle
Already temporarily installed to rear axle and chassis

Lifting tool:
Lifting point at front:
Lifting eye under bumper
2. Set the rear axle in position.
4. Raise the bare machine and connect the rear axle assembly.
Precautions
be deformed.
Tools to use
Name
Impact wrench
(22-mm socket)
Q'ty
1
Equipment to use
Name
Q'ty
Crane (30-ton)
2
Nylon sling
4
Steel plate
1
(1219 2438 9t)
Wooden block
1
(400 400 1200)
4
Others
15
NO. A-5 1/1
ASSEMBLY OF REAR AXLE ASSEMBLY

(CONNECTION OF LUBRICATION GREASE TUBE)
1 Connection of lubrication grease tube
1
2
3
4
Part No.
569-52-62612
569-52-62622
421-09-12540
423-09-12110
Part Name
Tube
Tube
Elbow
Connector
Q'ty
1
1
2
2
Details of shipment
Sent as individual unit (separately packed)
Assemble the connector and elbow, then assemble the lubricator tube.
Precautions
Tools to use
Name
Wrench (14 mm)
Others
16
Equipment to use
Q'ty
Name
Q'ty
1
1
NO. A-6 1/1
ASSEMBLY OF REAR AXLE ASSEMBLY (ASSEMBLY OF DRIVE SHAFT)

1 Assembly of drive shaft
Fig. 1
A) 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 opposite sides.
C) Tighten again with a torque wrench to the torque
given in the drawing.
D) Tighten in the order given in Fig.1.
1
2
3
4
Part No.
01050-61470
569-89-82210
01010-82465
01643-32460
Part Name
Bolt
Guard
Bolt
Washer
Q'ty
8
1
4
4
Details of shipment
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
Tools to use
Name
Wrench (36 mm)
RSP220N x 22
(22 x 2200 RSP) or
equivalent impact
wrench
Equipment to use
Q'ty
Name
Q'ty
1
1
Crane (5-ton)
1
1
Nylon sling
1
Others
17
NO. A-7 1/1
ASSEMBLY OF RIGHT FRONT AXLE

1 Lifting right front axle
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)
Precautions
Tools to use
Name
impact wrench
(22-mm socket)
Others
18
Q'ty
Equipment to use
Name
Q'ty
Crane (15-ton)
1
Nylon sling
2
Chain block
1
NO. A-8 1/1
ASSEMBLY OF FRONT AXLE (CONNECTION OF SUSPENSION)

1 Connection of suspension
1
2
3
4
Part No.
569-40-81540
01010-81425
569-40-61710
566-52-11120
Part Name
Pin
Bolt
Washer
Spacer
Q'ty
1
1
1
2
Details of shipment
1. Using one 15-ton crane, raise the right axle assembly.

Lifting tool :
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
be deformed.
Tools to use
Name
impact wrench
(22-mm socket)
Q'ty
Equipment to use
Name
Q'ty
Crane (15-ton)
1
Nylon sling
1
1
Others
19
NO. A-9 1/1
ASSEMBLY OF RIGHT FRONT AXLE (CONNECTION OF AXLE ARM)

1 Connection of axle arm
1
2
3
4
5
6
Part No.
569-40-81230
569-52-81550
01010-81425
569-40-61710
569-52-41950
569-40-61130
Part Name
Pin
Pin
Bolt
Washer
Spacer
Spacer
Q'ty
1
1
2
2
2
2
Details of shipment

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.
3.
4.
5.
Lift the axle with a nylon sling, then lift the axle arm with the chain block.
Remove the pin and spacer temporarily installed to the chassis.
Align that the mounting hole of the axle arm and chassis.
Install the pin and spacer, then secure with the stopper bolt.
Precautions
be deformed.
Tools to use
Name
impact wrench
(22-mm socket)
Others
20
Q'ty
Equipment to use
Name
Q'ty
Crane (15-ton)
1
Nylon sling
1
Chain block
1
1
NO. A-10 1/1
ASSEMBLY OF RIGHT FRONT AXLE (CONNECTION OF STEERING CYLINDER & ROD)

1 Connection of steering cylinder & rod
1
2
3
4
Part No.
569-40-81240
569-40-81530
01010-81425
569-40-61710
Part Name
Pin
Pin
Bolt
Washer
Q'ty
1
1
2
2
Details of shipment
Already temporarily installed to front axle

Lifting tool :
Lifting point : Axle mount
2.
3.
4.
5.
6.
Lift the axle and adjust so that the steering cylinder and tie rod are parallel with the lever.
Insert the rubber and boot, align the pin hole, then assemble the pin.
Assemble the stopper bolt and tighten it.
Connect the lubricant grease tubes (2 places).
Grease the pin mount.
Precautions
1) Check that there are O-rings at the
steering cylinder and tie rod
mounts.
2) The length of each pin is different,
so be careful when assembling.
Tools to use
Name
impact wrench
(22-mm socket)
Q'ty
Equipment to use
Name
Q'ty
Crane (15-ton)
1
Nylon sling
1
Chain block
1
1
Others
21
NO. A-11 1/1
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
Check that there is no mistake in the
hose number and the block number,
then assemble.
Tools to use
Name
Wrench (19 mm)
Others
22
Equipment to use
Q'ty
Name
Q'ty
1
1
NO. A-12 1/1
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 6.3)
2. Using a 15-ton crane, raise and set on a forklift truck.
2 Assembly of tire & wheel assembly
1
2
Part No.
569-22-72870
426-09-11520
Part Name
Nut
Washer
Q'ty
14
14
Details of shipment
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
1) Be careful not to let the tire &
wheel assembly fall off the forklift
truck when transporting it.
2) Be careful not to damage the tire
inflation tube when positioning
the tire & wheel assembly.
Tools to use
Name
46-mm socket
Impact wrench
(GT-S22M)
Torque wrench
(1568 Nm)
Extension bar
Bar
Paint spray can
Others
Equipment to use
Q'ty
Name
Q'ty
1
Crane (30-ton)
1
1
Forklift truck
1
(min. 2 ton)
1
Tire lifting tool
1
1
1
2
23
NO. A-13 1/1
ASSEMBLY OF FRONT SUPPORT

1 Assembly of front support
1
2
3
4
Part No.
01010-82040
01643-32060
04434-51010
01435-01016
Part Name
Bolt
Washer
Clip
Bolt
Q'ty
4
4
1
1
Details of shipment
1. Using a 5-ton crane, raise the front support.

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
Tools to use
Equipment to use
Name
Q'ty
Name
Q'ty
Wrench (30 mm)
Crane (5-ton)
1
1
Nylon sling
1
1
1
impact wrench
(14-mm socket)
Others
24
NO. A-14 1/1
ASSEMBLY OF RIGHT FENDER LOCK BRACKET

1 Assembly of right fender lock bracket
1
2
Part No.
01010-81230
01643-31232
Part Name
Bolt
Washer
Q'ty
2
2
Details of shipment
1. Remove the bolts and washers temporarily assembled to the chassis.

2. Assemble the right fender lock bracket.
Precautions
Tools to use
Name
Two-ended ring
wrench (19 mm)
Q'ty
Equipment to use
Name
Q'ty
1
Others
25
NO. A-15 1/1
ASSEMBLY OF R.H. PLATFORM ASSEMBLY

1 Assembly of R.H. platform assembly
1
2
3
4
5
Part No.
01010-81230
01643-31232
01010-82045
01643-32060
09415-05016
Part Name
Bolt
Washer
Bolt
Washer
Cap
Q'ty
8
8
2
2
2
Details of shipment
1. Using a 5-ton crane, raise the right platform assembly.

1.
2.
3.
4.
Remove the bolts and washers temporarily assembled to the chassis.

Assemble the right platform assembly.
Install the cap.
Adjust the mirror angle.
Precautions
Tools to use
Name
Two-ended ring
wrench (19 mm)
Two-ended ring
wrench (30 mm)
Others
26
Q'ty
1
1
Equipment to use
Name
Q'ty
Crane (5-ton)
1
Nylon sling
2
1
NO. A-16 1/1
ASSEMBLY OF L.H. CATWALK ASSEMBLY

1 Assembly of L.H. catwalk assembly
1
2
3
4
Part No.
01010-81230
01643-31232
01010-81225
01643-31232
Part Name
Bolt
Washer
Bolt
Washer
Q'ty
4
4
8
8
Details of shipment
1. Using a 5-ton crane, raise the left catwalk assembly.

2. Assemble the left catwalk assembly.
3. Adjust the mirror angle.
Precautions
Tools to use
Name
Two-ended ring
wrench (19 mm)
Q'ty
1
Equipment to use
Name
Q'ty
Crane (5-ton)
1
Nylon sling
2
1
Others
27
NO. A-17 1/1
ASSEMBLY OF L.H. HANDRAIL

1 Assembly of L.H. handrail
1
2
3
4
5
6
Part No.
561-54-61910
01010-81635
01643-31645
01010-81240
01580-11210
01643-31232
Part Name
Clamp
Bolt
Washer
Bolt
Nut
Washer
Q'ty
2
4
4
1
1
2
Details of shipment
Already temporarily installed to catwalk assembly
1. Remove the bolts and washers temporarily assembled to the chassis and catwalk assembly.
2. Assemble the handrail.
Precautions
Tools to use
Name
Two-ended ring
wrench (19 mm)
Two-ended ring
wrench (24 mm)
Others
28
Q'ty
1
1
Equipment to use
Name
Q'ty
1
NO. A-18 1/1
ASSEMBLY OF R.H. FENDER

1 Assembly of R.H. fender
1
2
3
1.
2.
3.
4.
Part No.
01435-01225
08036-01214
01435-01020
Part Name
Bolt
Clip
Bolt
Q'ty
4
3
2
Details of shipment
Already temporarily installed to fender bracket
Already temporarily installed to fender
Remove the bolts and washers temporarily assembled to the fender bracket.
Assemble the right fender.
Remove the clips and the bolts temporarily assembled to the fender.
Secure the fuel breather tube as shown in the diagram.
Precautions
Tools to use
Name
Two-ended ring
wrench (14 mm)
Two-ended ring
wrench (17 mm)
Q'ty
Equipment to use
Name
Q'ty
1
1
1
Others
29
NO. A-19 1/1
ASSEMBLY OF L.H. FENDER

1 Assembly of L.H. fender
Part No.
01435-01220
Part Name
Bolt
Q'ty
4
Details of shipment

2. Assemble the left fender.
Precautions
Tools to use
Name
Two-ended ring
wrench (17 mm)
Others
30
Q'ty
1
Equipment to use
Name
Q'ty
1
NO. A-20 1/1
ASSEMBLY OF LEFT AND RIGHT MUDGUARDS

1 Assembly of left and right mudguards
1
2
Part No.
569-54-41551
01435-01225
Part Name
Plate
Bolt
Q'ty
2
10
Details of shipment
1. Remove the plate and the bolts temporarily assembled to the fender.
2. Assemble the left and right mudguards.
Precautions
Tools to use
Name
Two-ended ring
wrench (17 mm)
Q'ty
Equipment to use
Name
Q'ty
Stand (operating stand) 1
Others: This work process shows the right side of the truck
body. The work process for the left side of the truck
body is the same as this.
31
NO. A-21 1/1
ASSEMBLY OF LEFT OVER FENDER

1 Assembly of left over fender
1
2
3
4
5
6
Part No.
283-54-11470
01435-01025
417-43-16210
01435-01025
01435-01025
417-43-16210
Part Name
Plate
Bolt
Washer
Bolt
Bolt
Washer
Q'ty
2
1
1
4
1
1
Details of shipment
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.
Precautions
Tools to use
Name
Two-ended ring
wrench (14mm)
Others
32
Q'ty
1
Equipment to use
Name
Q'ty
1
NO. A-22 1/1
ASSEMBLY OF RIGHT OVER FENDER

1 Assembly of right over fender
1
2
3
4
5
Part No.
283-54-11470
569-54-81620
01435-81025
01435-81025
417-43-16210
Part Name
Plate
Plate
Bolt
Bolt
Washer
Q'ty
3
2
12
1
1
Details of shipment
Already temporarily installed to platform
1. Remove the plates and the bolts temporarily assembled to the left platform.
2. Assemble the left over fender.
Precautions
Tools to use
Name
Two-ended ring
wrench (14 mm)
Q'ty
Equipment to use
Name
Q'ty
1
Others
33
NO. A-23 1/1
MOUNTING OF DUMP BODY (LIFTING DUMP BODY)

1 Lifting dump body
1. Using one 30-ton crane, raise the dump body.

Lifting tool :
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 side
face 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.
Precautions
Tools to use
Name
Select a level ground surface when

carrying out this operation.
Others
34
Q'ty
Equipment to use
Name
Q'ty
Crane (30-ton)
1
Nylon sling
4
NO. A-24 1/1
MOUNTING OF DUMP BODY (INSTALLATION OF HINGE PIN)

1 Installation of hinge pin
1. Using one 30-ton crane, raise the dump body.

Lifting tool :
Lifting point : Special lifting positions at side of dump body (4 places)
1
2
3
4
5
6
1.
2.
3.
4.
Part No.
569-74-11530
569-74-11540
569-74-61740
01010-81635
01643-31645
421-70-11280
Part Name
Shim t=6.0
Shim t=1.0
Pin
Bolt
Washer
Washer
Q'ty
4
12
2
2
2
2
Details of shipment
Give signals to the crane operator and align the pin holes at the dump body mount and frame mount.
Insert an equal thickness of shims on the left and right.
Secure with the stopper bolt.
Carry out the above operation in the same way on the left and right sides.
Precautions
Tools to use
Name
Two-ended ring
wrench (24mm)
RSP310N x 24
(24 x 3100 RSP) or
equivalent impact
wrench
Q'ty
1
Equipment to use
Name
Q'ty
Crane (30-ton)
1
Nylon sling
4
Others
35
NO. A-25 1/1
ASSEMBLY OF POKE EJECTOR

1 Assembly of poke ejector
1
2
3
4
Part No.
569-74-61690
01643-22540
01011-82490
01580-12419
Part Name
Spacer
Washer
Bolt
Nut
Q'ty
2
2
2
4
Details of shipment
1. Adjust with spacers and install the poke injector so that it is in the center between the two tires.
Precautions
Tools to use
Name
Two-ended ring
wrench (36 mm)
Others
36
Q'ty
1
Equipment to use
Name
Q'ty
1
NO. A-26 1/1
ASSEMBLY OF DUMP BODY LOCK PIN

1 Assembly of dump body lock pin
1
2
Part No.
569-74-61670
569-74-61470
Part Name
Pin
Linch pin
Q'ty
2
2
Details of shipment
1. Assemble the body lock pins.

2. Assemble the linch pins.
Precautions
Tools to use
Name
Two-ended ring
wrench (36 mm)
Q'ty
Equipment to use
Name
Q'ty
1
Others
37
NO. A-27 1/1
ASSEMBLY OF DUMP BODY MUDGUARD

1 Assembly of dump body mudguard
1
2
3
4
5
6
7
8
Part No.
569-74-61640
569-74-61630
569-74-61660
569-74-61650
01010-81230
01643-31232
01010-81225
01643-31232
Part Name
Support
Support
Guard
Plate
Bolt
Washer
Bolt
Washer
Q'ty
1
1
2
2
14
14
14
14
Details of shipment
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.)
Precautions
Assemble the mat guard with the
shiny surface facing the rear of the
machine.
Tools to use
Name
Two-ended ring
wrench (19 mm)
Others
38
Q'ty
1
Equipment to use
Name
Q'ty
1
NO. A-28 1/1
MOUNTING OF DUMP BODY (SHIM ADJUSTMENT PROCEDURE)

1 Shim adjustment procedure
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 position 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 clearance
from 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 (569-7461520).
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 mm.
(See cross section A - A)
3. Check that there is no paint on the mounting seat of the pin lock
seat, inside surface of the thread, or seat surface of the washer.
If there is paint on any tightening surface, use thinner to completely remove the paint. (4 places marked )
1
2
3
4
5
6
7
8
9
Part No.
569-74-61531
569-74-61541
569-70-61840
569-70-61850
569-70-61860
569-70-61870
01010-81665
01643-31645
569-74-61511
Part Name
Shim t=1.0
Shim t=3.2
Shim t=1.0
Shim t=1.0
Shim t=1.0
Shim t=1.0
Bolt
Washer
Plate
Precautions
For details of the welding work at the
front body mount, see the separate
Procedure for "On-the-spot Welding".
Q'ty
18
6
3
7
9
2
24
24
6
Details of shipment
Tools to use
Name
Two-ended ring
wrench (22 mm)
RSP310N x 24
(24 x 3100 RSP) or
equivalent impact
wrench
Q'ty
1
Equipment to use
Name
Q'ty
Crane (30-ton)
1
Nylon sling
4
Others
39
NO. A-29 1/1
WELDING ACTUAL PARTS (INSTALLATION OF PROTECTIVE COVER)

1 Installation of protective cover
1. Install the protective cover as shown in the photograph above.
Precautions
Tools to use
Name
Others
40
Q'ty
Equipment to use
Name
Q'ty
1
NO. A-30 1/1
ASSEMBLY OF EXHAUST PIPE TUBE

1 Assembly of exhaust pipe tube
1
2
3
Part No.
569-02-81150
01010-81230
01643-31232
Part Name
Gasket
Bolt
Washer
Q'ty
1
6
6
Details of shipment
1.
2.
3.
4.
Check that dimension A = 119 mm at the time of delivery.

Assemble the gasket and tube to the exhaust tube assembled inside the rear support.
With dimension B = 87 mm, insert the plate to the tube, and insert the exhaust port into the body.
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.
Precautions
For details of the welding work for the
exhaust pipe tube and body portion,
see the separate design drawing 56902-81001.
Tools to use
Name
Two-ended ring
wrench (19 mm)
Q'ty
Equipment to use
Name
Q'ty
1
Others
41
NO. A-31 1/1
CONNECTION OF DUMP SENSOR

1 Connection of dump sensor
Part No.
01010-81035
Part Name
Bolt
Q'ty
1
Details of shipment
1. Adjust the length of the rod so that the lever hole and the angle sensor hole (part marked ) are
aligned. (Specified value: 433 mm)
2. Secure to the dump body with bolts.
Precautions
Tools to use
Name
Two-ended ring
wrench (17 mm)
Others
42
Q'ty
1
Equipment to use
Name
Q'ty
NO. A-32 1/1
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.
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.
When starting the engine in an ambient temperature of less than 0C, always use SAE10W-30, or
SAE15W-40, even though the temperature goes up to 10C during the daytime.
! Coolant
Komatsu genuine super coolant (AF-ACL) is added to the cooling water, so there is no need to
change it for temperatures down to -10C.
If the temperature goes below -10C, adjust the density. For details, see CLEANING INSIDE OF
COOLING SYSTEM in the WHEN REQUIRED Section of the Operation and Maintenance Manual.
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, transmission oil level, front brake oil level, sub-tank water level, fuel tank level
Precautions
Tools to use
Name
Q'ty
Equipment to use
Name
Q'ty
Others
43
NO. A-33 1/1
FILLING WITH GREASE, WATER 2

1 Filling with grease, water
Reservoir
Specified capacity (l)
Refill capacity (l)
Engine oil pan
67
57
Transmission case
285
190
Steering, hoist, oil tank
180
122
Left and right: 17 each
Rear suspension
Left and right: 11.3 each
Differential case
95
95
Final drive case
Diezel fuel
780
Water
154
Front suspension
Fuel tank
Cooling system
Kind of fluid
Engine oil
Precautions
Tools to use
Name
Others
44
Q'ty
Equipment to use
Name
Q'ty
NO. A-34 1/1
BLEEDING AIR FROM BRAKE

1 Bleeding air from brake
Front brake
Rear brake: Slack adjuster
Procedure for bleeding air

1. 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.
Precautions
Tools to use
Name
Q'ty
Equipment to use
Name
Q'ty
Others
45
NO. A-35 1/1
ADJUSTING DUMP CONTROL

1 Adjusting dump control
1. Lower the dump body and seat it completely, then start the engine, set the control lever to the
FLOAT position, and hold it there for at least 5 sec.
* Hydraulic oil temperature: 80 - 90C
* 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 control
lever 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 the
control lever to the FLOAT position, and lower the dump body to the seated position. Repeat this
operation 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.
Precautions
Tools to use
Name
Others
46
Q'ty
Equipment to use
Name
Q'ty
NO. A-36 1/1
PAINTING
1 Painting
Bottom coat
Rethane GP primer
Rethane GP hardening agent
Rethane GP thinner
Top coat
NAX Mightylac GIIKB Natural Yellow
NAX Mightylac GIIKB hardening agent
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.
Precautions
Tools to use
Name
Q'ty
Equipment to use
Name
Q'ty
Others
47
NO. A-37 1/1
ADJUSTMENT OF SUSPENSION
1 Adjustment of suspension
Part No.
566-98-14401
Part Name
Bolt
Q'ty
1
Details of shipment
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)
Precautions
Tools to use
Name
1. Do not extend the cylinder fully.

2. After moving the machine to the
front and rear, stop the machine
without using the brake. (Using
the brake will create a higher load
on one side.)
Others
48
Q'ty
Equipment to use
Name
Q'ty
NO. A-38 1/1
SETTLING FLOATING SEAL

1 Settling floating seal
Fig. 1: Travel conditions

Shift
Travel distance (guideline) m
F1
500
F2
500
F3
1000
F4
1000
F5
1000
F6
1500
F7
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)
Precautions
Tools to use
Name
Oil container
Equipment to use
Q'ty
Name
Q'ty
1 Stand (operating stand) 1
Others
49
HD465-7
HD605-7
PROCEDURE FOR WELDING AND ASSEMBLING THREE
SEPARATED BODY PARTS
CONTENTS
Preparation work for local assembly of body divided into three parts ............................................... 52
Assembly of divided body parts ............................................................................................................ 54
Welding procedure for divided body parts ........................................................................................... 56
Operation for assembly and welding of divided body protector ........................................................ 62
Protector .................................................................................................................................................. 64
Welding of the body assembly .............................................................................................................. 66
51
PREPARATION WORK FOR LOCAL ASSEMBLY OF BODY

DIVIDED INTO THREE PARTS
Process drawing
Welding machine
52
Generator
Semi-automatic welding machine
Order of work
Work procedure
The floor or ground surface area must be at

least 169 m2 (13 m x 13 m).
The flatness of the floor or ground surface

must be less than 0.05 m over a distance of
10 m.
3. Unload the body. (Lower the body in the

specified condition)
Place the body part on top of suitable wooden

blocks.
4. Remove the protector stored in the body.
If the protector is secured by a plate, remove

it with a gas cutter.
5. Remove the paint from the places to be welded.
The range for the whole line of the mating

portion shall be 15 mm.
Heat with gas to burn off the paint or remove

it with a grinder.
This work can be performed easily, if 2 truck

cranes are used.
1. Selection of place for welding operation
2. Arrange welding machine, generator, and

tools.
6. Turn the body part.
7. Place support stands on the ground surface

as shown in the diagram on the right to support the body part at the assembly point.
53
ASSEMBLY OF DIVIDED BODY PARTS

Process drawing
54
Order of work
Work procedure
1. Set one of the divided body parts on top of

the support stands.
2. Set the divided body part on the opposite side
on top of the support stands so that the clearance is constant.
If the two parts do not match correctly, use a

hydraulic cylinder to adjust.
3. Using the plate (front and bottom portions)

(566-83-6H190), tighten with the following
parts.
After temporarily installing, remove the bolt,

washer, nut, and tube.
If the divided body parts are positioned incorrectly, correct with a hydraulic cylinder.
When correcting, check that the tightening

bolts are loose.
01011-82010
01643-32060
01580-12016
581-74-11630
Bolt
Washer
Nut
Tube
4. Mark the position of the temporarily installed

bracket (569-74-61210), then remove.
5. Pass the alignment pin through the bottom
hinge brackets (569-74-61181, 61191 Bracket),
check the height and position, then remove
the pin.
6. The temporarily installed the body.
7. Position and temporarily install brackets (56924-61460).
8. Temporarily install bracket (569-74-61210) at
the marked position.
55
WELDING PROCEDURE FOR DIVIDED BODY PARTS

Process drawing
56
Order of work
1. Weld the front portion (portion X).
(Large plate joint and channel joint)
Work procedure
Use arc welding and weld the front vertically.

(The conditions for vertical welding shall conform with Table 1.)
Weld the inside of the channel also.
Insert backup material into the joint between

one channel and the other channel. (Only the
joint of the bottom plate)
(For backup material, use SS400B 9 mm)
3. Set bottom portion (Y portion) horizontal and

carry out welding.
(Large plate joint and channel joint, and 2
brackets (569-74-61460) and 1 bracket (56974-61210))
Set the bottom rear portion on the stand and

keep it horizontal.
4. Set 4 plates (569-83-69470), 2 plates (569-8389460), and 1 plate (569-83-69550) in position

on the channel, and weld them.
Carry out reverse return welding at the bead

joint and beginning of the arc.
2. Position 2 plates (561-83-69450) and 1 plate

(569-83-69490).
5. After completing the welding, remove the

sputter with a grinder and finish the bead portion.
57
58
59
Process drawing
60
Order of work
Work procedure
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 negative value is not allowed)
Turning
Raise the bottom hinge bracket (569-7461181, 61191) and enter turning posture.
(Procedure for turning)
Maintain the posture on the left (raised by a

crane) and weld the front mating portion.
Next, weld the bottom joint.
Table 1.
CO2 gas
shield
welding
Arc welding
Remarks
Welding
posture
Flat (F)
Welding
rod
JIS Z 3312
YGW11 or
equivalent
d1.2, d1.6
Flat, vertical (V) (1) Do not use

CO2 gas
welding
JIS Z 3312
when the
D5016 or
wind speed
equivalent
exceeds 2 d4.0, d5.0
3 m/sec.
Welding
current
320 350 A
380 420 A
130 160 A
220 260 A
Preheat
Not needed
ing, postheating
Not needed
Gas
shield
amount
CO2 25 35 l/
min.
Insert wooden blocks at the front and rear of

the bottom.
Connect the welding ground securely to the
body.
Use CO2 gas shield welding as the standard.
However, use arc welding in places where it
is difficult.
Drying time for arc welding rod
(1) Temperature: 150 to 200C
(2) Time: 120 minutes
(2) Remove all

moisture,
dust, and
paint from
the places
to be
welded.
Finishing
Remove the sputter and finish the bead portion with a grinder.
61
OPERATION FOR ASSEMBLY AND WELDING OF DIVIDED

BODY PROTECTOR
Process drawing
62
Order of work
1. Using a crane, set the protector on top of the
side plate and front plate.
Weight of protector: Approx. 1,150 kg
Crane capacity: Min. 2 tons, lifting height:
Min. 7 m
Wire rope, chain, chain block: Strength at
least two tons
Work procedure
Insert wooden blocks at the front, rear, left,

and right of the bottom plate and set the body
so that the top surface of the left and right
side plates is approximately horizontal.
If there is a plate securing the protector, cut it

with a gas cutter.
As shown above, raise the front face of the

protector approx. 1 (visual) after welding,
and weld to the protector side plate.
2. Position so that the end face of the body side

plate and the plate at the side face of the protector are parallel.
3. When positioning, use the gas cutter to cut
the plate at the side face and front face of the
protector so that the top of the body side plate
and the top of the protector are parallel.
Note : The protector and front face plate are
deformed by welding as shown in below, so it is necessary to use a gas cutter to cut the plate at the side face and
front face of the protector so that the
gap is the minimum when welding.
(The gap must be less than 3 mm.)
4. After positioning, temporarily install the protector 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
63
PROTECTOR
Process drawing
64
Order of work
Work procedure
(6) After completion of welding, use a

grinder to remove the sputter and finish
the bead joint.
(7) 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
negative value is not allowed).
For the welding posture, basically use horizontal position or vertical position welding.
(At high places only, when a safe foothold is
ensured, it is also possible to turn the body
and carry out flat position welding.)
Use back-step process for the welding.
Use CO2 welding as the standard.

However, use arc welding in places where
there are restrictions.
Drying time for arc welding rod

(1) Temperature: 150 to 200C
(2) Time:
120 min
6. Install the dump body to the machine again.

Table 1
Welding
method
CO2 gas
shield
welding
Arc welding
Welding JIS Z 3312

wire, rod YGW11 or
equivalent
JIS Z 3312
D5016 or
equivalent
Wire, rod d1.2

diameter
d4.0
Welding
current
130 160 A
320 350 A
Preheat- Not needed

ing, postheating
Gas
shield
amount
25 35 l/min.
Not needed
Remarks
(1) Do not use
CO2 gas
welding
when the
wind speed
exceeds 2
3 m/sec.
(2) Remove all
moisture,
dust, and
paint from
the places
to be
welded.
65
WELDING OF THE BODY ASSEMBLY

Process drawing
66
Order of work
Work procedure
1. Install the dump body to the frame, set to

the dump posture, then adjust.
(For details of installation, see the assembly
manual.)
2. Use shims to adjust the dimension between
the dump body and frame before starting.
3. Welding dump body mount
Set 2 brackets (569-46-62381) on top of the
frame so that the dimension between the
dump body and the bracket is 57mm, then
weld in position.
(See View Z on left)
Move the body to the dump position while

doing this.
4. Welding anti-vibration bracket

This bracket has been discontinued on the
Dash 7 model, so this operation is not
needed.
5. Welding flange for dump body welding
Weld according to 569-02-81001.
67
1/4
Report No.
FIELD ASSEMBLY INSPECTION REPORT

After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance and quality.
Model-Type
Machine Serial No.
User Unit No.
Engine Model
HD465-7
HD605-7
Service Meter Reading
Engine Serial No.
SAA6D170E-3
Date of Inspection
Attachment
1
Location of Machine at Inspection
Manufacture
Model
Distributors Name
Serial No.
Customers Name
Address:
Signature:
Delivery
Report
No. attached
Date:
Inspectors Comments:
Inspectors Name:
KOMATSU USE ONLY :

C. Sheet Receiving Date :
Title
By
Signature:
Remark:
Check sheets filling instructions:
1. Use following indexes for entry of judgement
! ..... Normal
..... Correction made on abnormal point
..... Abnormal
2. Enter actually measured values in parenthese, [
..... Not applied
].
Notes:
(1) Criteria are based on the standards when the machine is shipped out of the factory.
SUBMITTANCE OF THIS REPORT (AND CHECK SHEETS) TO COMATSU IS ONE OF THE CONDITIONS OF WARRANTY VALIDATION, COPY
FOR KOMATSU SHALL BE FORWARDED TO THE KOMATSU REGIONAL OFFICE TOGETHER WITH THE COPY OF DELIVERY SERVICE REPORT.
SEAW003800
Printed in Japan
2/4
No.
Inspection item
Judgment procedure and standards
Record the serial Nos. of the component parts.

1
Front axle Nos.
Enter the Nos. (Left:

) (Right:
)
Nos. must be clear. They are stamped on the front
* The
suspension cylinders.
Rear axle Nos.
Nos. must be clear.

* The
differential case.
Enter the Nos. (Left:
) (Right:
)
The nameplate is installed to the
Check the oil and water levels.

3
Engine oil level (Check with

The level must be between (H) and (H-10 mm).
engine stopped)
Hydraulic oil level
The level must be inside the inspection window.
Transmission oil level
The level must be between (H) and (midpoint between H and L).
* Check while the engine is running at low idling.
Coolant level
The level must be above the midpoint between Full and Low
of the sub-tank.
Battery fluid level
The fluid level must be 10 12 mm above the plates.
Windshield washer fluid level The fluid level must be above 2/3 of the tank.
Turn the key switch ON.

9
Function of horn
10 Function of backup buzzer
The sound volume must be sufficient and free from beats.

(Sensory evaluation)
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.)
11 Abnormal noise of engine
Engine speed
The engine must not generate abnormal noise. (Sensory

evaluation)
Engine speed at torque converter stall - Measured value:
(
rpm)
Power mode standard: 1,910 100 rpm
12
coolant temperature: In
* Engine
green range
* Engine oil temperature: 70 80C
converter oil temperature:
* Torque
70 80C
13
Exhaust gas color
When the engine is accelerated sharply (Li Hi), is exhaust gas color good. (Sensory evaluation)
14
Exhaust gas leakage
Exhaust gas must not leak through exhaust pipe joints, exhaust gas shutter, etc.
15
Safety function (1)
When the transmission shift lever is not in N, the engine

must not start.
16
Safety function (2)
When the parking brake switch is ON and the transmission

shift lever is not in N, the centralized warning lamps and
alarm buzzer must be turned ON.
Engine speed at torque converter stall - Measured value:

(
rpm) Economy mode standard: 1,910 100 rpm
Check the lamps.

17 Function of clearance lamps
When the lamp switch is turned ON (1st/2nd stage), both front

lamps and 3 rear lamps (right, center, and left) must light up.
When the lamp switch is turned ON (2nd stage), the head
lamps (1 lamp on each side) must light up.
18
Check of head lamp
19
Check of high beam (Function When the head lamp is turned ON and the dimmer switch is
operated, the number of the lamps must change between 2
of dimmer switch)
and 4. (The lighting direction must change.)
20
Function of turn signal lamps
When the turn signal lever is operated, the front and rear
turn 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.
22
Function of backup lamp
When the transmission shift lever is in R, the backup lamp

must light up.
23 Function of brake lamp
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 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).
Check Mainte- Remarks

nance
3/4
No.
Inspection item
24 Function of room lamp

nance

When the switch is turned ON, the room lamp must light up.
Check the travel and brake. (Before checking the following items, check the safety around the truck.)
25
26
27
28
Overheating of front brake disc Drive inside the yard and touch the brake disc to check that
(Both sides)
it is not overheating.
Drainage from floating seal After the truck is driven for 7 km, the drainage on each side
must not exceed 30 CC.
(Both sides)
Measured value: Left (
cc ), Right (
cc )
When the engine is stalled at F2 (above 1,670 rpm), the truck
Function of parking brake
must not start.
Measured value (F :
rpm)
Function of service brake
must not start.
Measured value (F :
rpm)

must not start.
Measured value (F :
rpm)
When the emergency brake is turned ON, the service brake
and parking brake must operate. (Check that the pilot lamp
30 Function of emergency brake light up.)
Enter the start limit.
Measured value (F :
rpm)
Check the functions of the work equipment. (Before checking the following items, perform ADJUSTING DUMP CONTROL,
Field assembly procedure A-36.)
29
Function of retarder brake
31
Check of function of body op- When the dump lever is not in FLOAT or when the body is
eration caution lamp
not seated, the body operation caution lamp must light up.
32
Operating effort of dump lever The operating effort must be proper and dump lever must
not be hitched. Check by sensory evaluation.
33 Functions of dump lever
34
(1) The functions of the dump lever must be arranged in the

order of RAISE HOLD FLAOT 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 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.
Shocks of body at lowering end When the body is seated on the frame, unpleasant shocks
must not be made. (Sensory evaluation)
When the lever is released in RAISE, it must not return to HOLD.
35
Function of boom positioner
36 Unevenness of body
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
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
37 * When checking, start engine and shift lever is not in N, the centralized warning lamps and
turn parking brake OFF.
alarm buzzer must be turned ON.
Safety function (4)
When the body is not seated and the transmission shift le38 * When checking, start engine and ver is not in N, the centralized warning lamps and alarm
buzzer must be turned ON.
When the body is not seated, the truck must not travel in
reverse, even if the transmission shift lever is set in R. When
the body is not seated and transmission lever is shifted to D
- L, "only 2nd speed must be selected in D and only 1st speed
must be selected in 6 to L".
Engine speed: 2,100 rpm, Measured value: (
sec)
Body
rising
speed
(Oil
tem40
Standard (Common to HD465 and 605): 11.5 1.5 sec
perature: 80C)
Safety function (5)
39 * When checking, start engine and

Body lowering speed (Lever at Engine speed: Low idling speed, Measured value (
41 FLOAT, Oil temperature: 50 70C) Standard (Common to HD465 and 605): 10.5 1.5 sec
42 Hydraulic drift of body
sec)
The hydraulic drift in 5 minutes must be 85 mm or less. (From

point where cylinder No. 2 is extended by 100 mm) Measured value: (
mm )
4/4
No.
Inspection item
Stop the truck on level ground and measure.

Length of suspension cylinder
43 (Front)
* Measure with dump body empty.
The length must be shorter than dimension A. Dimension

A: 249 (Position of label) 10 mm
mm), Right (
mm)
Length of suspension cylinder

44 (Rear)
* Measure with dump body empty.
Length must be shorter than dimension A. Dimension A:

220 (Position of label) 10 mm
mm), Right (
mm)
(1): When the dump lever is set to any position other than
FLOAT, display must change from [Soft] to [Hard].
Check of automatic suspension
control function (Optional)
45 Measure with dump body (2): When the service brake or emergency brake is turned
ON, the display must change from [Soft] to [Medium].
empty.
(3): The display must show [Soft] in all cases other than (1)
and (2) above.
Inspect each part.
46
Function of safety pin
The safety pin must be inserted without obstruction in the

right and left stopper holes.
47
Storage function of safety pin
The safety pin must be removed from, installed to, and locked
at the storage position securely.
48
Installation of drive shaft All the mounting bolts must be free from looseness and
(Transmission Differential) abnormal play.
49
Front support (Right)
The mounting bolts must be free from looseness.
50
Inspection around engine
No oil and water leakage.
51
Inspection around transmission No oil and water leakage.
52
Fuel leakage from fuel system No leakage.
53
Oil leakage from hydraulic oil system (tank, cylinder, pump, piping) No leakage.
54
Oil leakage from brake system No leakage.
Tightness of large-capacity bat- When the terminals are shaken by hand, they must not move.
55 tery (optional) terminals
Rubber cap of large-capacity bat- The cap must be fitted securely. (The terminal must not
56 tery (optional) wiring (+) terminal project from the cap.)
Tightness of tire hub nuts
Tightening torque: 1,519 - 1,617 Nm
57 (Target: 1,568 Nm)
* When nothing is applied to
the threads.
(1) Front left: Retighten.

(2) Front right: Retighten.
(3) Rear left: Retighten.
(4) Rear right: Retighten.
Standard: Shown at left
Measured value: Front left (
58
MPa), Front right (

MPa)
Tire inflation pressure (When
dump body is empty)
MPa), Rear right
24.00-35-36PRE4: 0.47 0.01 Measured value: Rear left inside (
inside (
MPa)
MPa
24.00-R35:0.69 0.01 MPa
Measured value: Rear left outside (
MPa), Rear right
outside (
MPa)
59
Flaw of tires
The tires must be free from flaw and tear. Check the all 6 tires.
60
Tension of fan belt
When the belt is pushed with the thumb (approx. 6 kg), its
deflection must be 10 - 15 mm. The belt must be free from
flaw and twist
61
Steering cylinders (Both sides) The plated surfaces must be free from rust, harmful flaw,
spatter, paint, etc.
62
Hoist cylinders (Both sides)
63
Suspension cylinders (Both The plated surfaces must be free from rust, harmful flaw,
sides, front)
64
Suspension cylinders (Both The plated surfaces must be free from rust, harmful flaw,
sides, rear)
65
Appearance of cab glass
The plated surfaces must be free from rust, harmful flaw,

Glass must be free from flaw, paint, etc.

nance

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What are the main steps involved in assembling the rear axle?

What are the main steps involved in assembling the rear axle?

What are the procedures described for assembling the right front axle?

What are the procedures described for assembling the right front axle?

CONTENTS

Chart of separated units ........................................................................................................................... 3

6. Front tire & wheel assembly

7. R.H. platform & handrail assembly

3. Right front axle assembly

8. L.H. catwalk & handrail assembly

10. R.H. front support

11. Right fender mounting bracket

15. Dump body mudguard

12. Left and right fenders

13. Left and right mudguards

16. Exhaust pipe & tube

14. Left and right over fenders

17. Drive shaft

[2] DIMENSIONS OF SEPARATED UNITS

Overall length Overall width Overall height

When machine is loaded on trailer

1 Positioning base machine on supports

1 Assembly of rear axle, suspension

Meeting before starting operation

* Select a smooth flat surface when

1 Assembly of front right axle

1 Assembly of R.H. platform ass'y

1 Assembly of body work

For assembling tire

For assembling tire

For assembling tire

3 Lifting tools to use

2. Tire lifting tool

PROCEDURE FOR LOCAL ASSEMBLY

NO. A-1 1/1

SETTING BARE MACHINE IN POSITION

3. Set the bare machine as shown in the diagram above.

When lifting the chassis, fit a cloth

PROCEDURE FOR LOCAL ASSEMBLY

NO. A-2 1/1

ASSEMBLY OF REAR AXLE AND SUSPENSION

2. Set the bare machine as shown in the diagram above.

Put blocks under the tires to prevent

PROCEDURE FOR LOCAL ASSEMBLY

NO. A-3 1/1

ASSEMBLY OF REAR AXLE ASSEMBLY (CONNECTION OF SUSPENSION)

1. Using two 30-ton cranes, raise the bare machine.

PROCEDURE FOR LOCAL ASSEMBLY

NO. A-4 1/1

ASSEMBLY OF REAR AXLE ASSEMBLY (CONNECTION OF AXLE ROD)

1. Using two 30-ton cranes, raise the bare machine.

PROCEDURE FOR LOCAL ASSEMBLY

NO. A-5 1/1

ASSEMBLY OF REAR AXLE ASSEMBLY

PROCEDURE FOR LOCAL ASSEMBLY

NO. A-6 1/1

ASSEMBLY OF REAR AXLE ASSEMBLY (ASSEMBLY OF DRIVE SHAFT)

1. Remove guard 2 from the chassis.

PROCEDURE FOR LOCAL ASSEMBLY

NO. A-7 1/1