Assembly Process for Construction Machine

CONTENTS
1. Points changed from model 5....................................................................................................................... 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
0010 Oil, grease, and coolant .............................................................................................................. 8
0020 Levels of oil, grease, and coolant................................................................................................ 9
0030 Positioning rear axle assembly.................................................................................................. 10
0040 Installing rear suspension.......................................................................................................... 11
0050 Slinging bare machine............................................................................................................... 12
0060 Installing rear axle assembly (Connecting suspension) ............................................................ 13
0070 Installing rear axle assembly (Connecting axle rods)................................................................ 14
0080 Positioning bare machine .......................................................................................................... 15
0090 Installing right front axle (Connecting A-arm) ............................................................................ 16
0100 Installing right front axle (Connecting steering cylinder and tie rod).......................................... 17
0110 Installing right front axle (Connecting suspension).................................................................... 18
0120 Installing right front axle (Connecting brake hose) .................................................................... 19
0130 Installing right front axle (Connecting piping for automatic suspension) ................................... 20
0140 Installing tire and wheel assembly............................................................................................. 21
0150 Installing body hinge grease tube.............................................................................................. 22
0160 Installing drive shaft................................................................................................................... 23
0170 Connecting cooling hose ........................................................................................................... 24
0180 Connecting brake actuating hose.............................................................................................. 25
0190 Installing right front support ....................................................................................................... 26
0200 Installing right fender ................................................................................................................. 27
0201 Installing right fender [Muffler specification] .............................................................................. 28
0210 Installing R.H platform assembly............................................................................................... 29
0220 Installing L.H catwalk assembly ................................................................................................ 30
0230 Installing L.H handrail................................................................................................................ 31
0240 Installing radio antenna and fixing its cable............................................................................... 32
0250 Installing L.H fender .................................................................................................................. 33
0260 Installing left side mudguard...................................................................................................... 34
0270 Installing right side mudguard ................................................................................................... 35
0280 Installing transmission underguard............................................................................................ 36
0290 Removing hoist cylinder bracket ............................................................................................... 37
0300 Removing hoist piping blind plate.............................................................................................. 38
0310 Welding body............................................................................................................................. 39
0320 Slinging body............................................................................................................................. 40
0330 Installing hinge pin .................................................................................................................... 41
0340 Connecting hoist cylinder .......................................................................................................... 42
0350 Welding protective cover by actually positioning it on machine ................................................ 43
0360 Installing body mount ................................................................................................................ 44
0370 Procedure for adjusting body mount shim................................................................................. 45
0380 Welding exhaust tube by actually positioning it on machine ..................................................... 46
0390 Installing poke ejector ............................................................................................................... 47
0400 Installing body lock pin .............................................................................................................. 48
0410 Installing body mudguard .......................................................................................................... 49
0420 Connecting dump sensor .......................................................................................................... 50
0430 Procedure for adjusting dump sensor ....................................................................................... 51
0440 Calibrating dump control ........................................................................................................... 52
0450 Bleeding air from brake system................................................................................................. 53
0460 Adjusting suspension ................................................................................................................ 54
0470 Fitting floating seal .................................................................................................................... 55
0480 Painting ..................................................................................................................................... 56
0490 Sticking body decal ................................................................................................................... 57
ASR (Anti Sliped Regulation) (If equipped).................................................................................................59

Procedure for welding and assembling three separated body parts ...........................................................65
Additional manual for Korea (If equipped)...................................................................................................85
APPENDIX
Field assembly inspection report
1. Points changed from model 5
• The cab having the ROPS guard in it is employed and installation of it in the field is abolished.
• As the shape of the fuel tank is changed, installation of it and its piping in the field is abolished.
• As the position of the battery box is changed, wiring of the battery in the field is abolished.
• As the right platform is divided, piping of the air cleaner in the field is abolished.
• Connection of the rear suspension and rear axle in the field is added.
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 3,490 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 10,800 2,500 4,520 2,500
5 Front tire 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)
42,800 9,355 4,820 4,400
HD465-7 (Mass of machine) (Front bumper – (When empty)
In self- End of body)
propelled
travel 46,800 9,355 4,820 4,400
HD605-7 (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 (Made on May 10 2003)
No. Item Specification Q'ty Location
1 Track crane 245 kN {25 ton} 1 See field assembly manual
2 Track crane 490 kN {50 ton} 1 See field assembly manual
3 Forklift 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 ENGINE OIL SAE10W – See field assembly manual
35 Oil container, washing can 2
36 Waste oil can Drum 1
37 Cloth 5 kg
38 Fuel oil No. 2 for summer, Special For machine
No. 3 for winter
39 Antifreeze 51 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
54 Socket 1 inch × 30 mm 1 For tightening support
55 Torque wrench 2800QL 1 For drive shaft and body pin
56 Torque wrench 21000QLE 1 For tightening tire
59 Steel measure tape 5m 1
60 LOCTITE LT-2 1
61 Vinyl tape 1 For binding wiring harness
62 Standard tools (For ISO) 700SX 2
63 Bar 1m 1
64 Pointed steel bar 1 For matching holes
65 Sledgehammer 101b 1
66 Shackle BD10 for 4.9 kN {500 kg} 4
67 Shackle BC40 for 98 kN {10 ton} 4 For installing body
68 Chain ATH-465-042 1 Multi-purpose type
70 Nylon sling Width of 250 mm * 5 m 1 For installing right platform
71 Nylon sling Width of 60 mm * 3 m 2 For installing support and small parts
72 Nylon sling Width of 100 mm * 12 m 1 For installing front tire
73 Nylon sling Width of 30 mm * 2 m 3 For installing front axle
74 Nylon sling Width of 100 mm * 3 m 1 For installing front axle
75 Pin 60 ø * 250 mm 2 For slinging chassis on rear side (Safety
pin can substitute)
76 Jig for slinging body AHT-785-006 4 For installing body
77 Lever block 3/4 ton LB008 3 For installing front axle
78 Lever block 19.6 kN {2 ton} LB020 1 For installing front axle
79 Wire 7 m 28 ø 2 For slinging chassis
80 Wire 4 m 28 ø 2 For installing body
81 Wire 5 m 28 ø 2 For installing body
The following 4 items can substitute for Nos. 79 – 81.
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. 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 SAE10W-30,
or SAE15W-40, even though the temperature goes up to 10°C during the daytime.
t 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 -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.
8
Assembly process No. Levels of oil, grease, and coolant
0020
Lubrication point Type of oil Specified q'ty (l) Refill capacity (l)
Engine oil pan 67 57
Transmission case 285 190
Steering and hoist oil tank 180 122
Front suspension Engine oil 17 each on right and left sides —
Rear suspension 11.3 each on right and left sides —
Differential case 95 95
Final drive case 32 each on right and left sides 21 each on right and left sides
Fuel tank Diesel fuel 780 —
Cooling system Coolant 154 —
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).
9
Assembly process No. Positioning rear axle assembly
0030
Weight
10.8 ton
1. Sling the rear axle and tire assembly with 1 245 kN {25 ton} crane.
Hanging points: Rod mounting parts on differential.
Wood block
1200
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.
Precautions Necessary tools Necessary equipment
Secure the rear axle with chocks. Name Q'ty Name Q'ty
Other remarks
10
Assembly process No. Installing rear suspension
0040
a If the rear suspension is installed to the rear axle, the rear

suspension does not fall backward, even if it is not fixed
particularly. Accordingly, no fixing parts are required.
Install with the air port on inside.
Install rear suspension position.
Part No. Part name Q'ty State of parts

(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. 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
11
Assembly process No. Slinging bare machine
0050
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 6 mm in diameter × 250 or body
lock pin)

Name Q'ty Name Q'ty
ATH-465-040 2
Other remarks
12
Assembly process No. Installing rear axle assembly (Connecting suspension)
0060

(1) 569-40-61552 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. Guide the slung bare machine to above the rear axle.

2. Remove pins ((1) – (4) in the figure) on the chassis side.
3. Guide the bare machine to the pin holes at the top of the suspension and connect it by the pins.

fingers in it.
Other remarks
13
Assembly process No. Installing rear axle assembly (Connecting axle rods)
0070
Detail of
connecting parts

(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.

fingers in it.
Other remarks
14
Assembly process No. Positioning bare machine
0080
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
15
Assembly process No. Installing right front axle
0090 (Connecting A-arm)
F.A/X
Install front axle a little higher
than frame for ease of work.
Section of frame Lever block

For 19.6 kN {2 ton}
Nylon sling
100 mm × L3000 × 1 piece
Lever block for 3/4 ton

1. Remove the pins and spacers installed to the chassis temporarily.

2. Match the mounting holes of the chassis and A-arm. (Adjust them with lever blocks, etc.)
3. 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

fingers in it.
Other remarks
16
0100 (Connecting steering cylinder and tie rod)
Remote grease tube
L=179
L=207

(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.

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
17
0110 (Connecting suspension)
Connect CN SUFR
Suspension pressure
sensor
(May not be installed,
depending on
attachment.)
Connecting point of CN SUFR

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).
fingers in it.
Other remarks
18
0120 (Connecting brake hose)
Connect 2 hoses.
These 4 hoses are

installed to only for
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
19
0130 (Connecting piping for automatic suspension)
Perform the following work for only the attachment of automatic suspension model.
Connect 4 hoses.
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
20
Assembly process No. Installing tire and wheel assembly
0140
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 -- 1,617 Nm {154.9 -- 164.9 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 – 1,617 Nm {154.9 – 164.9 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 or equivalent
Other remarks
21
Assembly process No. Installing body hinge grease tube
0150
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)

Name Q'ty Name Q'ty
Other remarks
22
Assembly process No. Installing drive shaft
0160
Attached to rear axle side
Apply LT-2.
Tightening torque:
157 -- 196 Nm {16.0 -- 19.9 kgm}
Install female side to transmission.

(1) 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. Install the bolts and tighten them in the diagonal order
(For the tightening order, see Fig. 1).
5. Tighten the bolts again with the torque wrench.
(Tightening torque: 157 – 196 Nm {16.0 – 19.9 kgm})
Fig. 1
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
or equivalent
Other remarks
23
Assembly process No. Connecting cooling hose
0170
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. Using the above parts, connect the cooling hose.
(Use parts (1) – (3) attached on either axle side or chassis side. Discard the rest.)

When connecting the cooling hose, take care that dust Name Q'ty Name Q'ty
will not enter it.
Check that the O-rings are fitted securely.
Other remarks
24
Assembly process No. Connecting brake actuating hose
0180
Check O-ring.
Slack adjuster line
Parking brake line
Check O-ring.
Rear axle
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
25
Assembly process No. Installing right front support
0190
View Z
Fix wiring harness to clip.

Connect CN-RP.

(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).

Name Q'ty Name Q'ty
Other remarks
26
Assembly process No. Installing right fender
0200
Right platform
Right fender
Fix breather tube
coming from fuel
tank.

(2) 569-54-R0000 Fender A. 1 Loose-supply item (Separately packed)
(3) 08036-01214 Clip 3 Temporarily installed to fender
(4) 01435-01020 Bolt 2 Temporarily installed to fender
1. Remove (1) temporarily installed to the chassis.
2. Install the right fender.
Name Q'ty Name Q'ty
Other remarks
27
Assembly process No. Installing right fender [Muffler specification]
0201
Right platform
Right fender
Fix breather tube

coming from fuel
tank.

(2) 569-84-R0000 Fender A. 1 Loose-supply item (Separately packed)
(3) 08036-01214 Clip 3 Temporarily installed to fender
(4) 01435-01020 Bolt 2 Temporarily installed to fender
1. Remove (1) temporarily installed to the chassis.
2. Install the right fender.
Name Q'ty Name Q'ty
Other remarks
28
Assembly process No. Installing R.H platform assembly
0210

(2) 01010-82045 Bolt 2 Temporarily installed to F support and right platform
(3) 01643-32060 Washer 2 Temporarily installed to F 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.

Take care of the claw of cap (4) which breaks easily. Name Q'ty Name Q'ty
Other remarks
29
Assembly process No. Installing L.H catwalk assembly
0220
Only model with radio
Remove rust-preventive sheet of

ground for radio antenna. (Remove
one on catwalk side, too.)

1. Remove (1) and (2) 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
30
Assembly process No. Installing L.H handrail
0230

(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) 569-54-81772 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
31
Assembly process No. Installing radio antenna and fixing its cable
0240
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 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) 01435-01016 Bolt 7 Loose-supply item (Separately packed)
(7) 08037-11825 Grommet 1 Loose-supply item (Separately packed)
(8) 569-54-82580 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.
Name Q'ty Name Q'ty
Other remarks
32
Assembly process No. Installing L.H fender
0250
Weight: 23.5 kg
Set glossy side
toward rear of
chassis.

(1) 569-54-L0000 Fender A. 1 Loose-supply item (Separately packed)
(3) 569-54-41551 Plate 1 Loose-supply item (Separately packed)
(5) 569-54-41541 Guard 1 Loose-supply item (Separately packed)
1. Remove bolts (2) temporarily installed to the chassis.

2. Install L.H fender (1).
3. Install mudguards (3) – (5).
Install guard (5) with the glossy side toward the rear of the chassis.

Install the guard (5) with the glossy side toward the rear Name Q'ty Name Q'ty
of the chassis.
Other remarks
33
Assembly process No. Installing left side mudguard
0260

(1) 283-54-11470 Plate 2 Temporarily installed to under cab
(2) 01435-01025 Bolt 4 Temporarily installed to under cab
(3) 01435-01025 Bolt 2 Temporarily installed to fender and catwalk
(4) 417-43-16210 Washer 2 Temporarily installed to fender and catwalk
1. Remove parts (1) – (4) temporarily installed.
2. Install guard (5).

Name Q'ty Name Q'ty
Other remarks
34
Assembly process No. Installing right side mudguard
0270

(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) 01435-01025 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
35
Assembly process No. Installing transmission underguard
0280

(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
36
Assembly process No. Removing hoist cylinder bracket
0290
Fix cylinders to lower side of bracket

so that they will not lean backward.
Hoist cylinder
Hoist cylinder
Fuel tank
Hydraulic tank
1. Fix the cylinders with a chain block, 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
37
Assembly process No. Removing hoist piping blind plate
0300
Hoist cylinder
Use this part again.
Use this part again.

(3) 07000-F3022 O-ring 2 Loose-supply item (Separately packed)
(4) 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.

Take care that the O-rings will not be caught in the Name Q'ty Name Q'ty
hoses.
After finishing this work, if the engine started, the cylin-
ders are extracted automatically.
Other remarks
38
Assembly process No. Welding body
0310
a For detail of welding of the body, see the separate manual.

Name Q'ty Name Q'ty
Other remarks
39
Assembly process No. Slinging body
0320
Body sling pins (ATH-785-006)

Shackles BC40 for 98 kN {10 ton}
Chain sling (ATH-465-039)
or ø 28 wires
Install the body sling pins to the 4 holes from outside of the body and set the shackles and sling as
shown in the above figure.
Check the center of gravity and sling the body.

Name Q'ty Name Q'ty
ATH-465-039 1
ATH-785-006 4
BC40
Other remarks
40
Assembly process No. Installing hinge pin
0330
Tightening torque: 245 -- 309 Nm

{25 -- 31.5 kgm}
Clearance must
Clearance must be below 1 mm.
be below 1 mm.

(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)
(5) 01643-31645 Washer 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).
3. Secure the pin with the set bolt.
Name Q'ty Name Q'ty
Other remarks
41
Assembly process No. Connecting hoist cylinder
0340
Tightening torque:
157 -- 196 Nm
Hoist cylinder {16 -- 20 kgm}
Main frame

(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).

Name Q'ty Name Q'ty
Other remarks
42
Assembly process No. Welding protective cover by actually positioning it
0350 on machine
1. Install the protective cover as shown in the above photo.

Name Q'ty Name Q'ty
Other remarks
43
Assembly process No. Installing body mount
0360
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) 569-99-60010 Bracket, blank 2 Loose-supply item (Separately packed)
Name Q'ty Name Q'ty
Other remarks
44
Assembly process No. Procedure for adjusting body mount shim
0370
Front mount
d2 d3
d1
Bottom mount
Spacer
1. Procedure for adjusting shim at dump body mount

Top surface
Adjust as follows. of frame
(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) Measure
c. Make the shims at d1, d2, and d3 (d1-26) mm, (d2- at center
26) mm, and (d3-26) mm respectively.
Detail of measurement point
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-
74-61520).
d. Lower the dump body and check that the overall thick-
ness of the rubber pad is 50 mm. If it is not 50 mm, Misalignment
adjust with shims to make it 50 mm. within 58 ± 12 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)

Name Q'ty Name Q'ty
Other remarks
45
Assembly process No. Welding exhaust tube by actually positioning it
0380 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)
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
46
Assembly process No. Installing poke ejector
0390
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)

a Remaking with S5EC1753 Name Q'ty Name Q'ty
(Part No. (1) is changed.)
Other remarks
47
Assembly process No. Installing body lock pin
0400

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

Name Q'ty Name Q'ty
Other remarks
48
Assembly process No. Installing body mudguard
0410
Bolt between support and body
Guard fixing bolt
Set glossy side toward

rear of chassis. Set glossy side toward
rear of chassis.

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

Install mudguard (5) with the glossy side toward the rear Name Q'ty Name Q'ty
of the chassis.
Other remarks
49
Assembly process No. Connecting dump sensor
0420
Connect to body
Potentiometer
Lever
Rod
L = 440

(1) 01010-81035 Bolt 1 Attached to rod end
(2) 566-40-11560 Washer 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
50
Assembly process No. Procedure for adjusting dump sensor
0430
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: 0.38 – 0.44 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: 3.8 – 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
51
Assembly process No. Calibrating dump control
0440
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.
* Check that the float caution lamp is turned OFF.
2. While the body is raised to the cylinder stopper, run the engine at low idling (below 850 rpm) and
keep the control lever in the RAISE position for 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
52
Assembly process No. Bleeding air from brake system
0450
Air bleeding points (9 points)

1. 2 points at right and left of front brake calipers
2. 7 points of rear brake

2 points of rear brake slack adjuster, 2 points at right and left of wheel brake, 1 point of upper block
of parking brake, and 2 points at right and left of wheel balancer
Bleed air from all of the above 9 points.
Perform the above air bleeding work for all of the foot brake, retarder brake, and parking brake.
For details, see SHOP MANUAL, Bleeding air from brake circuit.

Name Q'ty Name Q'ty
Other remarks
53
Assembly process No. Adjusting suspension
0460
Nitrogen gas filler valve
Air bleeder valve
Air bleeder
Nitrogen gas cylinder Location of air bleeder valve

of front suspension
Suspension gas filler unit (7826-10-1000)
Adjustment value
220 ± 10 mm
Reference
When cylinder is fully
retracted: 102 ± 1 mm
When charged with
oil of specified quantity:
140 ± 3 mm
When truck is empty:
220 ± 10 mm
Front When cylinder is fully
Rear extracted: 280 ± 1 mm
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 – 49 Nm {4 – 5 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.)
1. Bleed air from the cylinders. Name Q'ty Name Q'ty
2. Fill both suspension cylinders simultaneously. Suspension gas filler unit 1
3. Do not extract the suspension cylinders to the stroke (7926-10-1000)
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
54
Assembly process No. Fitting floating seal
0470
Oil drain tube of

floating seal
Install container with wires

to receive drained oil.
Container
To fit the floating seals in the rear axle, install an oil container as shown in the above figure and drive the
truck for several kilometers.
After driving the truck, visually check that little oil is drained.

Name Q'ty Name Q'ty
Receive oil drain container 1
Other remarks
55
Assembly process No. Painting
0480
Welded parts
Welded part of exhaust pipe of body
(Heat-resistant silver paint)
Welded part of
body mount
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.

Name Q'ty Name Q'ty
Other remarks
56
Assembly process No. Sticking body decal
0490
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
57
ASR (Anti Sliped Regulation) (If equipped)
Contents
Connection of brake hoses..................................................................................................................... 61
Connection of speed sensor connector.................................................................................................. 62
Bleeding air from ASR circuit ................................................................................................................. 63
59
Assembly process Connection of brake hoses
[1] Removal of caps and connection of hoses
1. Remove the caps from the shuttle valve in front of the rear cross (2 places).
2. Connect the hoses installed to the slack adjuster.

1. When connecting the hoses, take care not to Name Q'ty Name Q'ty
mistake them for each other. • Spanner (27 mm) 1
Other remarks
61
Assembly process Connection of speed sensor connector
[1] Remove the dummy connector
1. Remove connector WSLR (Left rear wheel speed sensor) and WSRR (Right rear wheel speed
sensor) from the dummy connector, and then remove the dummy connector from the connector
fixing plate (Twist the dummy connector, and it will be removed from the plate).
[2] Connection of rear wheel speed sensor connector
1. Connect connectors WSLR and WSRR. At this time, take care not to mistake them for each other.
a Since labels are not stuck to the connectors on the speed sensor side, follow the sensor
cables from the brake housing.
2. Remove the clips installed to the bracket temporarily and clamp the speed sensor cables with
them. (Install the clips with the bracket mounting bolts.)
1. When connecting the connectors, take care not to Name Q'ty Name Q'ty
mistake them for each other.
Other remarks
62
Assembly process Bleeding air from ASR circuit
[1] Bleeding air
1. Turn the key switch ON.
If the accumulator is pressurized (the brake caution lamp is turned OFF), the air can be bled
under this condition. If the accumulator is not pressurized (the brake caution lamp is turned ON),
run the engine.
2. Turn the ASR switch ON
3. Remove the rear cover from the rear of the operator's seat in the cab and connect connector
TEST under the rear cover.
The shut-off valve and ASR valve open and oil pressure is applied to both brake circuits.
1. Connect connectors WSLR and WSRR. At this time, take care not to mistake them for each other.
a Since labels are not stuck to the connectors on the speed sensor side, follow the sensor
cables from the brake housing.
2. Remove the clips installed to the bracket temporarily and clamp the speed sensor cables with
them. (Install the clips with the bracket mounting bolts.)

1. When connecting the connectors, take care not to Name Q'ty Name Q'ty
mistake them for each other.
Other remarks
63
Procedure for welding and assembling three separated body parts
Contents
Preparation work for local assembly of body divided into three parts (welding)..................................... 66
Assembly of divided body parts.............................................................................................................. 68
Welding procedure for divided body parts .............................................................................................. 70
Operation for assembly and welding of divided body protector.............................................................. 78
Welding of the body assembly ............................................................................................................... 82
65
HD465-7/HD605-7
Preparation work for local assembly of body divided
into three parts (welding)
Process drawing
Welding machine Generator Semi-automatic welding machine
66
Order of work Work procedure
1. Selection of place for welding operation • The floor or ground surface area must be at
least 169 m² (13 m × 13 m).
• The flatness of the floor or ground surface must

be less than 0.05 m over a distance of 10 m.
2. Arrange welding machine, generator, and tools.
3. Unload the body. (Lower the body in the speci- • Place the body part on top of suitable wooden
fied condition) 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 por-
tion shall be 15 mm.
6. Turn the body part.

You can turn over the body easily by using the
following.
1) Sling shaft • Heat with gas to burn off the paint or remove it
(See assembly procedure.) with a grinder.
2) Eagle clamp: For 5 tonnes, 2 pieces
• This work can be performed easily, if 2 truck
cranes are used.
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.
67
HD465-7/HD605-7
Assembly of divided body parts
Process drawing
68
1. Set one of the divided body parts on top of the

support stands.
2. Set the divided body part on the opposite side • If the two parts do not match correctly, use a
on top of the support stands so that the clear- hydraulic cylinder to adjust.
ance is constant.
3. Mark off the position of bracket 569-74-61210

installed temporarily, and then remove it.
4. Utilizing the plates (at the front and bottom sec-
tions), secure the set body temporarily with the
following.
01011-82010 Bolt
01643-32060 Washer
01580-12016 Nut
581-74-11630 Tube
5. Pass the alignment pin (ø 79.3) in hinge brack-
ets 569-74-61181 and 569-74-61191 on the
bottom side and check its height and position.
6. Tighten the bolt.
7. Check that you can move the alignment pin
with the hand.
8. Tack welding (Outside and inside)
• If the divided body parts are positioned incor-
• Perform tack welding of 6 100-500 at cor-
rectly, correct with a hydraulic cylinder.
ners and ends of weld line.
9. Check that you can move the alignment pin
with the hand.
Remove the bolt, washer, nut, and tube.
Note) Limit the root gap at the joints of the front
and bottom large plates to 3 mm (Value on
drawing: 2 mm).
• When correcting, check that the tightening bolts

are loose.
69
HD465-7/HD605-7
Welding procedure for divided body parts
Process drawing
Table 1
CO2 gas shielded
Arc welding Remarks
arc welding
Welding position Flat Flat/Vertical (1) Do not apply CO2 gas
shielded arc welding
Welding rod
when wind velocity is
JIS (Z3312) YGW11 D5016
higher than 2 – 3 m/sec.
AWS ER70S-6 E7016
(2) Remove water, dust,
ø 1.2 ø4
and paint from part to be
Welding current 320 – 350A 130 – 160A welded.
Preheating/Postheating Unnecessary Unnecessary
Shield gas supply rate 25 – 35 l/min
70
10. Set 2 brackets 569-74-61460 in position and

secure them by tack welding.
11. Install bracket 569-74-61210 to the position

marked off by tack welding.
• Use arc welding and weld the front vertically.

12. Weld the front portion (portion X). (The conditions for vertical welding shall con-
(Large plate joint and channel joint) form with Table 1.)
13. Position 2 plates (561-83-69450) and 1 plate • Weld the inside of the channel also.
(569-83-69440).
Note) Make a V-groove at the front channel and do
not use a backup material.
• Set the bottom rear portion on the stand and

14. Set bottom portion (Y portion) horizontal and keep it horizontal.
carry out welding.
(Large plate joint and channel joint, and 2
brackets (569-74-61460) and 1 bracket (569-
74-61210))
• 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)
15. Set 4 plates 569-83-69470, 2 plates 569-83-
69460, 1 plate 569-83-89470, and 1 plate 569- • Carry out reverse return welding at the bead
83-69550 in position on the channel, and weld joint and beginning of the arc.
them.
16. After completing the welding, remove the sput-

ter with a grinder and finish the bead portion.
71
HD465-7
Process drawing
Weld inside of cross rib

(inside of channel), also.
Fron
t mo
unt b
racke
t
Weld inside of cross rib

(inside of channel), also.
72
Process drawing
There shall be no overlap or undercut Cut back plate (569-74-61D40)

at the t9 end face of the weld. to the specifiled length, and add
10 places reinforcement at the tip of

the t19 weld.
4 places
When body
heating
system
is installed
Optional muffler specification

When body heating system is installed
73
HD605-7
Process drawing
74
Process drawing
There shall be no overlap or undercut Cut back plate (569-74-61D40)

at the t9 end face of the weld. to the specifiled length, and add
reinforcement at the tip of the
10 places t19 weld.
4 places
75
HD465-7/HD605-7
Process drawing
76
17. 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)
18. Turning Table 1

Raise the bottom hinge bracket (569-74-61181,
61191) and enter turning posture. CO2 gas
shielded arc Arc welding Remarks
welding
(Procedure for turning)
Welding Flat Flat/Vertical (1) Do not apply
position CO2 gas
shielded arc
Welding rod
welding
JIS (Z3312) YGW11 D5016
when wind
AWS ER70S-6 E7016
velocity is
ø 1.2 ø4
higher than
Welding 320 – 350A 130 – 160A 2 – 3 m/sec.
current (2) Remove
water, dust,
Preheating/ Unneces- Unneces-
and paint
Postheating sary sary
from part to
Shield gas 25 – 35 l/min be welded.
supply rate
19. Keeping the dump body in above posture (2)

(Slinging the dump body with a crane), weld the • Insert wooden blocks at the front and rear of the
front joint (inside). bottom.
• Connect the welding ground securely to the
20. Turn the dump body completely and set it in body.
posture (4). • Use CO2 gas shield welding as the standard.
However, use arc welding in places where it is
21. Weld the inner bottom joint. difficult.
• Drying time for arc welding rod
22. Finishing (1) Temperature: 150 to 200°C
Remove the sputter and finish the bead portion (2) Time: 120 minutes
with a grinder.
77
HD465-7/HD605-7
Operation for assembly and welding of divided body protector
Process drawing
78
1. Using a crane, set the protector on top of the • Insert wooden blocks at the front, rear, left, and
side plate and front plate. right of the bottom plate and set the body so
Weight of protector: Approx. 1,150 kg that the top surface of the left and right side
Crane capacity: Min. 2 tons, lifting height: Min. plates is approximately horizontal.
7m
Wire rope, chain, chain block: Strength at least • If there is a plate securing the protector, cut it
two tons with a gas cutter.
2. Position so that the end face of the body side

plate and the plate at the side face of the pro-
tector are parallel.
3. When positioning, use the gas cutter to cut the

plate at the side face and front face of the pro-
tector 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.)
(2 places on both sides

of rear of protector)
4. After positioning, temporarily weld the protector
front face.
5. Weld the protector. • As shown above, raise the front face of the pro-
Welding order: Weld the side face plates tector approx. 1° (visual) after welding, and
(left and right) first. weld to the protector side plate.
Welding symbol: As given on the right.
Welding conditions: According to the table
79
Process drawing
80
Table 1 • For the welding posture, basically use horizon-

CO2 gas tal position or vertical position welding.
shielded arc Arc welding Remarks (At high places only, when a safe foothold is
welding ensured, it is also possible to turn the body and
Welding Flat Flat/Vertical (1) Do not apply carry out flat position welding.)
position CO2 gas
Welding rod
shielded arc • Use back-step process for the welding.
welding
JIS (Z3312) YGW11 D5016
when wind
AWS ER70S-6 E7016
velocity is
ø 1.2 ø4
higher than
Welding 320 – 350A 130 – 160A 2 – 3 m/sec.
current (2) Remove
water, dust,
Preheating/ Unneces- Unneces-
and paint
Postheating sary sary
from part to
Shield gas 25 – 35 l/min be welded.
supply rate
• Use CO2 welding as the standard.
However, use arc welding in places where there
6. Finished chek are restrictions.
(1) After completion of welding, use a grinder
to remove the sputter and finish the bead • Drying time for arc welding rod
joint. (1) Temperature:150 to 200°C
(2) Check that there are no welding defects. (2) Time: 120 min
[1] Check for adhered metal.
[2] Check for undercuts, overlaps, adher-
ence of sputter.
[3] Insufficient welding leg length (a nega-
tive value is not allowed).
7. Install the dump body to the machine again.
81
HD465-7/HD605-7
Welding of the body assembly
Process drawing
82
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 • Move the body to the dump position while doing
Set the brackets (569-46-62831, 2 pieces) on this.
the frame (rear support) and measure the clear-
ance between the body and bracket at 4
places.
If the clearance is less than 57 mm, cut the
lower part of the bracket (hatched part). (See
the figure at left and view Z.)
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.
83
HD605-7
Additional manual for Korea (If equipped)
Contents
0211 Connection of R.H. platform mirror heater wiring harness (Additional work) .............................. 87
0241 Fixing of L.H. catwalk mirror heater wiring harness (Additional work) ........................................ 88
0281 Installing transmission underguard 1 (for LHC) (Replaced with standard manual No. 0280) ..... 89
0282 Installation of transmission underguard 2 (for LHC) (Additional work) ........................................ 90
85
Assembly process No.
Connection of R.H. platform mirror heater wiring harness
0211

Name Q'ty Name Q'ty
Other remarks
87
Fixing and connection of L.H. catwalk mirror heater
0241 wiring harness

(1) 04434-53412 Clip 3 Installed to left-hand handrail temporarily.
(2) 01435-01016 Bolt 3 Installed to left-hand handrail temporarily.
(3) 01584-11008 Nut 3 Installed to left-hand handrail temporarily.
(4) 04434-50810 Clip 3 Installed to left-hand handrail temporarily.
(5) 08034-20536 Band 10 Loose-supply item
1. Untie the wiring harness under the left of the cab.

2. Lay the wiring harness along the handrail and fix it with (1) - (5).
3. Connect the mirror heater wiring harness.

Name Q'ty Name Q'ty
Other remarks
88
Installing transmission underguard 1 (for LHC)
0281

(1) 56B-54-12415A Guard assembly 1 Loose-supply item (Sub-assembly)
(2) 561-54-66250 Collar 2 Loose-supply item (Sub-assembly)
(3) 01010-82080 Bolt 2 Loose-supply item (Sub-assembly)
(4) 01580-12016 Nut 2 Loose-supply item (Sub-assembly)
(5) 01643-32060 Washer 2 Loose-supply item (Sub-assembly)
(6) 01010-81650 Bolt 1 Loose-supply item
(8) 01643-31645 Washer 2 Loose-supply item
(9) 569-54-86280 Bracket 1 Loose-supply item
(11) 01643-31645 Washer 4 Loose-supply item
1. Take the transmission underguard with the forklift to the installing position under the machine.
2. Remove parts (2) – (5) from (1).
3. While slinging the underguard with the crane, install it.
4. Install (9).

Name Q'ty Name Q'ty
Other remarks
89
Installing transmission underguard 2 (for LHC)
0282

(4) 01024-81230 Nut 3 Loose-supply item
1. Take (1) and (2) with the forklift to the installing position under the machine (under the hydraulic
tank).
2. When installing (1), remove the retarder filter mounting bolt and replace (5) with it.
3. While lifting up (2) with the forklift, install it.
Name Q'ty Name Q'ty
Other remarks
90
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 Engine Serial No.
HD465-7
SAA6D170E-3
HD605-7
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 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 RE-
PORT.
Printed in Japan
2/4
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
3 The level must be between (H) and (H-10 mm).
engine stopped)
4 Hydraulic oil level The level must be inside the inspection window.
The level must be between (H) and (midpoint between H and L).
5 Transmission oil level * Check while the engine is running at low idling.
The level must be above the midpoint between Full and Low
6 Coolant level
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.
9 Function of horn The sound volume must be sufficient and free from beats.
(Sensory evaluation)
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.)
The engine must not generate abnormal noise. (Sensory
11 Abnormal noise of engine evaluation)
Engine speed Engine speed at torque converter stall - Measured value:
* Engine coolant temperature: In ( rpm) Power mode standard: 1,910 ± 100 rpm
12 green range
* Engine oil temperature: 70 – 80°C
* Torque converter oil temperature: Engine speed at torque converter stall - Measured value:
70 – 80°C ( rpm) Economy mode standard: 1,910 ± 100 rpm
13 Exhaust gas color When the engine is accelerated sharply (Li o Hi), is exhaust
gas color good. (Sensory evaluation)
Exhaust gas must not leak through exhaust pipe joints, exhaust
14 Exhaust gas leakage gas shutter, etc.
When the transmission shift lever is not in N, the engine
15 Safety function (1)
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.
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
19 Check of high beam (Function 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.
When the hazard switch is turned ON, both turn signal lamps
21 Function of hazard lamp
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).
3/4
No. Inspection item Judgment procedure and standards Check Mainte- Remarks
nance
24 Function of room lamp 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.)
Overheating of front brake disc Drive inside the yard and touch the brake disc to check that it is
25
(Both sides) not overheating.
After the truck is driven for 7 km, the drainage on each side must
26 Drainage from floating seal (Both not exceed 30 CC.
sides) Measured value: Left ( cc ), Right ( cc )
When the engine is stalled at F2 (above 1,670 rpm), the truck
27 Function of parking brake must not start.
Measured value (F : rpm)
28 Function of service brake must not start.
29 Function of retarder brake must not start.
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. (Before checking the following items, perform ADJUSTING DUMP CONTROL,
Field assembly procedure A-36.)
Check of function of body opera- When the dump lever is not in FLOAT or when the body is not
31
tion caution lamp 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.
(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.
33 Functions of dump lever (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.
When the body is seated on the frame, unpleasant shocks must
34 Shocks of body at lowering end
not be made. (Sensory evaluation)
When the lever is released in RAISE, it must not return to HOLD.
35 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
36 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
37 * 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
38 * 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. When the
39 * When checking, start engine body is not seated and transmission lever is shifted to D - L,
and turn parking brake OFF. "only 2nd speed must be selected in D and only 1st speed must
be selected in 6 to L".
Body rising speed (Oil tempera- Engine speed: 2,100 rpm, Measured value: ( sec)
40 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)
41 FLOAT, Oil temperature: 50 – 70°C) Standard (Common to HD465 and 605): 10.5 ± 1.5 sec
The hydraulic drift in 5 minutes must be 85 mm or less. (From

42 Hydraulic drift of body point where cylinder No. 2 is extended by 100 mm) Measured
value: ( mm )
4/4
No. Inspection item Judgment procedure and standards Check Mainte- Remarks
nance
Stop the truck on level ground and measure.
Length of suspension cylinder The length must be in dimension A.
43 (Front) Dimension A: 249 (Indicated position on the label) ± 10 mm
* Measure with dump body empty. Measured value: Left ( mm), Right ( mm)
Length of suspension cylinder The length must be in dimension A.
44 (Rear) Dimension A: 220 (Indicated position on the label) ± 10 mm
* Measure with dump body empty. Measured value: Left ( 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
45 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.
Inspect each part.
The safety pin must be inserted without obstruction in the right
46 Function of safety pin
and left stopper holes.
The safety pin must be removed from, installed to, and locked at
47 Storage function of safety pin the storage position securely.
Installation of drive shaft All the mounting bolts must be free from looseness and abnor-
48
(Transmission o Differential) mal 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.

Oil leakage from hydraulic oil sys-
53 No leakage.
tem (tank, cylinder, pump, piping)
54 Oil leakage from brake system No leakage.
Tightness of large-capacity bat-
55 When the terminals are shaken by hand, they must not move.
tery (optional) terminals
56 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.
57 (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
58 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})
59 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
60 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,
61 Steering cylinders (Both sides) paint, etc.
62 Hoist cylinders (Both sides) The plated surfaces must be free from rust, harmful flaw, spatter,
paint, etc.
63 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,
64 rear)
paint, etc.
65 Appearance of cab glass Glass must be free from flaw, paint, etc.

Assembly Process for Construction Machine

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Assembly Process for Construction Machine

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CONTENTS

1. Points changed from model 5....................................................................................................................... 1

ASR (Anti Sliped Regulation) (If equipped).................................................................................................59

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

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

Engine oil pan 67 57

Transmission case 285 190

Steering and hoist oil tank 180 122

Front suspension Engine oil 17 each on right and left sides —

Rear suspension 11.3 each on right and left sides —

Fuel tank Diesel fuel 780 —

Cooling system Coolant 154 —

Do not steer the machine largely before adjusting the suspension

2. Position the rear axle as shown above.

a If the rear suspension is installed to the rear axle, the rear

Install with the air port on inside.

Install rear suspension position.

Part No. Part name Q'ty State of parts

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

Precautions Necessary tools Necessary equipment

Part No. Part name Q'ty State of parts

1. Guide the slung bare machine to above the rear axle.

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

Section of frame Lever block

Lever block for 3/4 ton

Part No. Part name Q'ty State of parts

1. Remove the pins and spacers installed to the chassis temporarily.

Precautions Necessary tools Necessary equipment

Remote grease tube

Part No. Part name Q'ty State of parts

Precautions Necessary tools Necessary equipment

Part No. Part name Q'ty State of parts

These 4 hoses are

Precautions Necessary tools Necessary equipment

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.

Installed to front axle temporarily

Part No. Part name Q'ty State of parts