Komatsu HD465-5 HD605-5 Dump Truck Field Assembly Instruction Manual - PDF DOWNLOAD

CONTENTS LIST OF JIGS AND WEAR PARTS FOR LOCAL ASSEMBLY .......................................................................... 3 TOUCH-UP PAINT LIST FOR DUMP BODY .................................................................................................... 4 SKETCHES OF SPECIAL TOOLS ..................................................................................................................... 5 MAN-HOURS, WORKERS NEEDED FOR LOCAL ASSEMBLY ....................................................................... 9 PROCEDURE FOR FIELD ASSEMBLY ........................................................................................................... 10 1. Lifting and lowering rear axle assembly ......................................................................................... 10 2. Lifting chassis assembly .................................................................................................................. 12 3. Installing chassis to rear axle ........................................................................................................... 14 4. Installing rear axle ............................................................................................................................ 16 5. Installing rear suspension ................................................................................................................ 18 6. Setting stand on front side ............................................................................................................... 20 7. Connecting parking brake and brake hoses .................................................................................... 22 8. Connecting brake cooling hoses ..................................................................................................... 24 9. Installing front axle (1) ...................................................................................................................... 26 10. Installing front axle (2) ...................................................................................................................... 28 11. Installing front axle and steering cylinder tie rod ........................................................................... 30 12. Installing fuel tank ............................................................................................................................ 32 13. Installing front and rear supports .................................................................................................... 34 14. Installing fender ................................................................................................................................ 36 15. Installing tire assembly .................................................................................................................... 38 16. Installing right-hand platform .......................................................................................................... 40 17. Installing air intake tube ................................................................................................................... 42 18. Fitting radiator subtank piping and connecting grounding wires ................................................. 44 19. Connecting wires under right-hand platform ................................................................................. 46 20. Installing drive shaft ......................................................................................................................... 48 21. Installing exhaust tube ..................................................................................................................... 50 22. Installing side guard of cabin ........................................................................................................... 52 23. Installing ROPS guard ...................................................................................................................... 54 24. Installing catwalk guard mirror ........................................................................................................ 56 25. Installing hoist cylinder greasing piping ......................................................................................... 58 26. Removing blind flange from hoist cylinder .................................................................................... 60 27. Checking oil and water ..................................................................................................................... 62 28. Bleeding air from front and rear brakes .......................................................................................... 64 29. Installing spill guard and guards ..................................................................................................... 66 30. Installing dump body........................................................................................................................ 68 31. Adjusting dump body bottom mount ............................................................................................. 70 32. Installing dump body accessories .................................................................................................. 72 33. Adjusting dump body positioner ..................................................................................................... 74 34. Installing the protective cover for field welding ............................................................................. 76 35. Field welding (Dump body lock) ...................................................................................................... 78 36. Field welding (Exhaust flange)......................................................................................................... 80 37. Field welding (Dump body front mount and stopper pin bracket) ................................................ 82 38. Painting ............................................................................................................................................. 84 39. Adjusting suspension ....................................................................................................................... 86 PROCEDURE FOR WELDING AND ASSEMBLING THREE SEPARATED BODY PARTS HD465-5 ..................................................................................................................................................... 87 HD605-5 ................................................................................................................................................... 105 APPENDIX FIELD ASSEMBLY INSPECTION REPORT

1

39. ADJUSTING SUSPENSION 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

Front

Rear

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 When cylinder is fully 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 suspension 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.

2.

3.

4.

5.

Precautions Necessary tools Name Q'ty Bleed air from the cylinders.

Suspension gas filler unit 1 Fill both suspension cylinders simultaneously.

(7926-10-1000) Do not extract the suspension cylinders to the stroke end.

After moving the truck forward and in reverse, stop it without applying the brake.

Do not steer the truck before finishing this adjust- Other remarks ment. (If it is steered, the piping may be broken.)

86

Necessary equipment Name Q'ty

HD465-5 PROCEDURE FOR WELDING AND ASSEMBLING THREE SEPARATED BODY PARTS

CONTENTS Preparatory work for assembling three separated body parts ...............................................................88 Welding process for three separated body parts ....................................................................................92 Welding of the body assembly ............................................................................................................... 102

87

PREPARATORY WORK FOR ASSEMBLING THREE SEPARATED BODY PARTS Process drawing

Welding machine

Genetator

Lowering separated body

88

CO2 welding machine

Order of work

Work procedure

1. Select the place for welding work.

•

The total of floor or ground area moust be at least 169 m2 (13 m x 13 mm).

2. Prepare the welding machine, ganerator, and tools.

•

The flatness of the floor or ground must be less than 0.05 m over 10 m.

3. Unload the body. (Unload in the specified condition.)

•

Set the separated body on suitable wooden blocks.

•

If there is a plate holding the protector, remove it with a gass cutter.

•

A range of 15 mm along the whole line for the body mating portion.

•

Burn off with a gas heater, or grind off the primer and paint with a grinder.

4. Remove the protector stored in the body.

5. Place to remove primer and paint.

6. Turn over the separated body.

7. Set supports on the ground where the separated body is to be assembled as shown in the deagram below.

89

Process drawing

(Front)

90

(Bottom)

Order of work

Work procedure

1. Set one part of the separated body on the support stand.

2. Set the opposite side of the separated body on the suopprt stand so that the clearance is constant.

•

If the two pieces do not match properly, use a hydraulic cylinder to adjust them.

•

After tack welding, remove the bolt, washer, nut, and tube.

•

If the separated parts do not match properly, correct with a hydraulic cylinder.

•

When correcting, check that the tighening bolts are loosened.

3. Use brackets 568-74-11610 (front) and 56183-69430 (bottom), and join the set pieces of the body with the following parts.      

01011-52000 01643-32060 01580-12016 581-74-11630

 Bolt  Washer   Nut  Tube 

4. Mark the position of the temporarily attached poke ejector bracket 569-74-61210 (LH) before detaching the bracket.

5. Pass the alignment pin through the bottom hinge brackets (561-74-61181, 561-74-61191), check the height and position, then remove the pin.

6. Tack weld the body.

7. Position the brackets (569-74-61460), then tack weld.

8. Tack weld the brackets (569-74-61210) to the position of the marking-off.

91

WELDING PROCESS FOR THREE SEPARATED BODY PARTS Process drawing

92

Order of work

Work procedure

1. Weld the front (X portion).

(Large sheet connection portion and channel connection poortion)

•

Use arc welding for the front with vertical welding.

(Follow the vertical welding conditions in Table 1.)

2. Next, position 2 plates (561-83-69450), 1 plate (561-83-69490) on the channel, and weld in position.

•

Weld the inside of the channel also.

•

Insert backup material in the joints between channel and channel.(Only joint of bottom plates) (For backup material, use SS400B 9.)

3. Set the cottom (Y portion) horizontal and weld.

(Large sheet connection portion, channel connection portion and two brackets 569-7461460, 1 bracket 569-74-61210).

•

Insert a support under bottom rear.

•

Perform backstep weldign for bead joint and start of the arc.

4. Next, position 5 plates (569-83-69470), 2 plates (569-83-69460), and 1 plate (569-8369550) on the channel, and weld in position.

5. When the welding is finished, remove the spatter with a grinder and finish the bead.

93

Process drawing

94

Process drawing

95

Process drawing

96

Order of work

Work procedure

8. Check for any welding defects.

(1) Depositive metal check (2) Undercuts, overlaps, adhesion of spatter (3) Lack of welding leg (Minus leg length is rejectde) 9. Turn over Hoist the hinge bracket (569-74-61181, 61191) and start the turning over process.

(Turning procedure)

10. Keep the body at the position according to the illustration at left (state being raised by the crane) and weld the front seam.

11. Weld the mating portion of the bottom.

Table 1. Welding conditions Method CO2 gas chield welding

Arc welding

Welding posture

Flat position (F)

Welding current

320 – 350 A 380 – 420 A

220 – 260 A 130 – 160 A

Preheating, Unnecessary postheating

Unnecessary

• Remarks

Flat position (1) Do not use vertical position (V) CO2 gas welding if the wind Welding rod d1.2, d1.6 d5.0,d 4.0 speed is JIS Z3312 YGW11 JIS Z3312D5016  more than 2 or equivalent  – 3 m/sec. or equivalent

Gasshield amount

CO2 25 – 35 l/ min.

—

•

•

•

Place timber under front and back portions of bottom.

Connect ground for welding securely with main body.

Normally use CO2 gas shield welding. If CO2 gas shield welding is difficult, arc welding may be used.

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

(2) Remove all moisture, dirt, and paint from the locations to be welded.

12. Finish Use a grinder to remove the spatter and finich the head.

97

Process drawing

98

Order of work

Work procedure

13. Welding the protector (1) Place the protector on the top of the side plate and front plate with a crane.

Weight of protector : Approx. 977 kg Crane : Must have capacity of 2.0 tons and lift of 7m or higher.

Wire rope, chain, chain block : Must have breaking strength of 2.0 tons or higher.

•

Area of the floor or ground must be at least 126m2 (9m x 14m).

•

Level difference of the floor or ground must be 0.05m maximum in 10m.

•

Place wood blocks around the bottom plate so that both side plates will be almost parallel with each other.

(2) Position the protector side plate in parallel with end of the body side plate.

•

If the protector is secured with any plate, cut it with gas.

(3) When positioning, gas-cut the front and side of the protector so that the top of the body side plate will be parallel with the top of the protector.

•

Remove by heating with gas or cut with a grinder.

•

When welding the side plate of the protector, hang with a crane so that the front of the protector will be raised about 1° (Check visually) after welded as shown above.

Note : The protector and front plate are deformed by welding as shown below.

Accordingly, the front and side plates of the protector must be cut with gas to minimize the gap that may be made by welding. (Gap must be 3mm maximum.)

(4) After positioning, secure the front of the protector by tack-welding.

(5) Weld the protector.

Welding order : Weld side plates (on both sides) first.

Welding symbol : Shown at right.

Welding condition : Shown in Table 1.

99

Process drawing (6) After completing welding, remove spatters and finish bead joints using a grinder.

(7) Check if any welding failure is not found.

1 Check the fused metal.

2 Check the undercoat, overlap and spatter adhesion.

3 Check if the welding leg length is not too short.

7. Re-install the body onto the vehicle.

Table 2 Welding method

CO2 shielding welding

Arc welding

Using welding wire or rod

JIS Z3312 YGW equivalent

JIS Z3312 D5016 equivalent

Wire or rod diameter

d1.2

d 4.0

Welding current

320 – 350 A

130 – 160 A

Pre-heating or after-heating

Not necessary

Not necessary

Gas shielding volume

25 – 35 l/min.

—

100

Remarks • Do not perform CO2 welding when the atmospheric wind velocity exceeds 2 – 3 m/ sec.

• Remove moisture, rust coating, etc. from the welding surface.

Order of work

Work procedure •

•

•

•

Welding direction should basically be horizontal welding or vertical welding.

(Only when a safe scaffolding can be secured at a high elevation, downward welding may be performed turning over the body.)

Employ back-step process for welding.

Use CO2 welding as the standard welding method. However, for locations where it is difficult to perform CO2 welding, arc welding may be used.

Drying conditions of the arc welding (1) Temperature : 150 to 200°C (2) Duration : 120 min

101

WELDING OF THE BODY ASSEMBLY Process drawing

102

Order of work

Work procedure

1. Install the body to the frame, set in the dumping position, and adjust.

(When installing, see the assembly procedure.)

2. Adjust the dimension between the body and frame with shims before hand.

3. Welding of front body mount (561-46-2831)(2 units) • Set the 2 btackets (569-46-62831) on top of the frame, and weld so that the cleatance from the body brackets is 57 mm.

•

Move the body to the dump position while doing this.

4. Welding of stopper 2 brackets (569-74-61812) • Weld so that the clearance between the body and frame is 1 – 2 mm.

(See section G-G)

103

HD605-5 PROCEDURE FOR WELDING AND ASSEMBLING THREE SEPARATED BODY PARTS

CONTENTS Preparatory work for assembling three separated body parts ............................................................. 106 Welding process for three separated body parts .................................................................................. 110 Welding of the body assembly ............................................................................................................... 120

105

PREPARATORY WORK FOR ASSEMBLING THREE SEPARATED BODY PARTS Process drawing

Welding machine

Genetator

Lowering separated body

106

CO2 welding machine

Order of work

Work procedure

1. Select the place for welding work.

•

The total of floor or ground area moust be at least 169 m2 (13 m x 13 mm).

2. Prepare the welding machine, ganerator, and tools.

•

The flatness of the floor or ground must be less than 0.05 m over 10 m.

3. Unload the body. (Unload in the specified condition.)

•

Set the separated body on suitable wooden blocks.

•

If there is a plate holding the protector, remove it with a gass cutter.

•

A range of 15 mm along the whole line for the body mating portion.

•

Burn off with a gas heater, or grind off the primer and paint with a grinder.

4. Remove the protector stored in the body.

5. Place to remove primer and paint.

6. Turn over the separated body.

7. Set supports on the ground where the separated body is to be assembled as shown in the deagram below.

107

Process drawing

108

Order of work

Work procedure

1. Set one part of the separated body on the support stand.

2. Set the opposite side of the separated body on the suopprt stand so that the clearance is constant.

•

If the two pieces do not match properly, use a hydraulic cylinder to adjust them.

•

After tack welding, remove the bolt, washer, nut, and tube.

•

If the separated parts do not match properly, correct with a hydraulic cylinder.

•

When correcting, check that the tighening bolts are loosened.

3. Use brackets 568-74-11610 (front) and 56183-69430 (bottom), and join the set pieces of the body with the following parts.      

01011-52000 01643-32060 01580-12016 581-74-11630

 Bolt  Washer   Nut  Tube 

4. Mark the position of the temporarily attached poke ejector bracket 569-74-61210 (LH) before detaching the bracket.

5. Pass the alignment pin through the bottom hinge brackets (561-74-61181, 561-74-61191), check the height and position, then remove the pin.

6. Tack weld the body.

7. Position the brackets (569-74-61460), then tack weld.

109

WELDING PROCESS FOR THREE SEPARATED BODY PARTS Process drawing

110

Order of work

Work procedure

1. Weld the front (X portion).

(Large sheet connection portion and channel connection poortion)

•

Use arc welding for the front with vertical welding.

(Follow the vertical welding conditions in Table 1.)

2. Next, position 2 plates (561-83-69450), 1 plate (561-83-69490) on the channel, and weld in position.

•

Weld the inside of the channel also.

•

Insert backup material in the joints between channel and channel.(Only joint of bottom plates) (For backup material, use SS40B 9.)

3. Set the cottom (Y portion) horizontal and weld.

(Large sheet connection portion, channel connection portion and two brackets 561-7461460, 1 bracket 569-74-61210).

•

Insert a support under bottom rear.

•

Perform backstep weldign for bead joint and start of the arc.

4. Next, position 5 plates (569-83-69470), 2 plates (569-83-69460), and 1 plate (569-8369550) on the channel, and weld in position.

5. When the welding is finished, remove the spatter with a grinder and finish the bead.

111

Process drawing

112

Process drawing

113

Process drawing

114

Order of work

Work procedure

8. Check for any welding defects.

(1) Depositive metal check (2) Undercuts, overlaps, adhesion of spatter (3) Lack of welding leg (Minus leg length is rejectde) 9. Turn over Hoist the hinge bracket (569-74-61181, 61191) and start the turning over process.

(Turning procedure)

10. Keep the body at the position according to the illustration at left (sate being raised by the crane) and weld the front seam.

11. Weld the mating portion of the bottom.

Table 1. Welding conditions Method CO2 gas chield welding

Arc welding

• Remarks

•

Welding posture

Flat position (F)

Flat position (1) Do not use vertical position (V) CO2 gas welding if the wind Welding rod d1.2, d1.6 d5.0,d 4.0 speed is JIS Z3312 YGW11 JIS Z3312D5016  more than 2 or equivalent or equivalent  – 3 m/sec.

Welding current

320 – 350 A 380 – 420 A

220 – 260 A 130 – 160 A

Preheating, Unnecessary postheating

Unnecessary

Gasshield amount

CO2 25 – 35 l/ min.

•

—

Connect ground for welding securely with main body.

Normally use CO2 gas shield welding. If CO2 gas shield welding is difficult, arc welding may be used.

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

(2) Remove all moisture, dirt, and paint from the locations to be welded.

12. Finish Use a grinder to remove the spatter and finich the head.

115

Process drawing

116

Order of work

Work procedure

13. Welding the protector (1) Place the protector on the top of the side plate and front plate with a crane.

Weight of protector : Approx. 1,550 kg Crane : Must have capacity of 2.0 tons and lift of 7m or higher.

Wire rope, chain, chain block : Must have breaking strength of 2.0 tons or higher.

•

Area of the floor or ground must be at least 126m2 (9m x 14m).

•

Level difference of the floor or ground must be 0.05m maximum in 10m.

•

Place wood blocks around the bottom plate so that both side plates will be almost parallel with each other.

(2) Position the protector side plate in parallel with end of the body side plate.

•

If the protector is secured with any plate, cut it with gas.

(3) When positioning, gas-cut the front and side of the protector so that the top of the body side plate will be parallel with the top of the protector.

•

Remove by heating with gas or cut with a grinder.

•

When welding the side plate of the protector, hang with a crane so that the front of the protector will be raised about 1° (Check visually) after welded as shown above.

Note : The protector and front plate are deformed by welding as shown below.

Accordingly, the front and side plates of the protector must be cut with gas to minimize the gap that may be made by welding. (Gap must be 3mm maximum.)

(4) After positioning, secure the front of the protector by tack-welding.

(5) Weld the protector.

Welding order : Weld side plates (on both sides) first.

Welding symbol : Shown at right.

Welding condition : Shown in Table 1.

117

Process drawing (6) After completing welding, remove spatters and finish bead joints suing a grinder.

(7) Check if any welding failure is not found.

1 Check the fused metal.

2 Check the undercoat, overlap and spatter adhesion.

3 Check if the welding leg length is not too short.

7. Re-install the body onto the vehicle.

Table 2 Welding method

CO2 shielding welding

Arc welding

Using welding wire or rod

JIS Z3312 YGW equivalent

JIS Z3312 D5016 equivalent

Wire or rod diameter

d1.2

d 4.0

Welding current

320 – 350 A

130 – 160 A

Pre-heating or after-heating

Not necessary

Not necessary

Gas shielding volume

25 – 35 l/min.

—

118

Remarks • Do not perform CO2 welding when the atmospheric wind velocity exceeds 2 – 3 m/ sec.

• Remove moisture, rust coating, etc. from the welding surface.

Order of work

Work procedure •

•

•

•

Welding direction should basically be horizontal welding or vertical welding.

(Only when a safe scaffolding can be secured at a high elevation, downward welding may be performed turning over the body.)

Employ back-step process for welding.

Use CO2 welding as the standard welding method. However, for locations where it is difficult to perform CO2 welding, arc welding may be used.

Drying conditions of the arc welding (1) Temperature : 150 to 200°C (2) Duration : 120 min

119

WELDING OF THE BODY ASSEMBLY Process drawing

120

Order of work

Work procedure

1. Install the body to the frame, set in the dumping position, and adjust.

(When installing, see the assembly procedure.)

2. Adjust the dimension between the body and frame with shims before hand.

3. Welding of front body mount (561-4662831)(2 units) • Set the btackets (561-46-62831) on top of the frame, and weld so that the cleatance from the body brackets is 57 mm.

•

Move the body to the dump position while doing this.

4. Welding of stopper 2 brackets (569-74-61812) • Weld so that the clearance between the body and frame is 1 – 2 mm.

(See section G-G)

121

1/6 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

HD465-5 HD605-5

Machine Serial No.

User Unit No.

Engine Model

Engine Serial No.

SAA6D170E-2

Service Meter Reading

Date of Inspection Attachment 1

Location of Machine at Inspection

2

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

! ..... 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.

Printed in Japan

2/6

No.

Inspection item

Check Mainte- Remarks nance

Judgment procedure and standards

1 2

Frame No.

Write down serial No. (No. ) * The stamped mark must be clear. HD465 (or 605)-5-XXXX

3

Front axle No.

Write down No. (Left: ) (Right: * The stamped mark must be clear.

4

Rear axle No.

Write down No. (No. * The stamped mark must be clear.

) )

Check oil and water levels.

5

Engine oil level (Check with Level must be between (H) and (H – 10 mm). engine stopped)

6

Hydraulic oil level

Level must be within inspection window range.

7

Transmission oil level

Level must be between (H) and (center between H and L). * Check with engine at low idling.

8

Front brake oil level

Level must be between Full and Low.

9

Coolant level

Level must be at center between Full and Low or higher.

Oil or fuel must not be mixed in coolant.

10 Battery fluid level

Level must be at 10 – 12 mm above plates.

11 Windshield washer fluid level

Level must be 2/3 of tank or above.

Turn switch ON. 12 Function of horn

Sound must be proper in volume and must not have beat noise. (Sensory check)

13 Function of back buzzer

Sound must be proper in volume and must not have beat noise. (Sensory check)

14 Safety function (1)

Engine must not start when transmission lever is set to any position other than N position. At this time, transmission mechatronic caution lamp must flash, centralized warning lamp must light up, and centralized alarm buzzer must sound. * User code and error code must not be displayed.

When parking lever is set to ON and transmission lever is set to any position other than N position, centralize warning lamp must light up and centralized alarm buzzer must sound.

Safety function (3) When dump lever is set to any position other than FLOAT and transmis* Check with engine started sion lever is set to any position other than N position, centralized warnand parking brake turned off. ing lamp must light up and centralized alarm buzzer must sound.

Safety function (4) When dump lever is set to any position other than FLOAT * Check with engine started and transmission lever is set to any position of D to L, gear and parking brake turned off. can be shifted but cannot be shifted in R. Safety function (5) When body is not seated (lever is at FLOAT) and transmission lever is shifted to D – L, * Check with engine started "only 2nd speed must be selected at D and only 1st speed must be selected at 5 to L". and parking brake turned off. * Truck can move in reverse even if body is not seated.

When light switch is turned ON (1st, 2nd stage), front right Function of clearance lamp and left clearance lamps and rear right, center, and left clearance lamps (3 lamps) must light up.

15 Safety function (2) 16 17 18 19

20 Check of headlamps 21

When light switch is turned ON (2nd stage), 2 headlamps (right and left) must light up.

When dimmer switch is operated with headlamps ON, lamps Check of high beam (Function must change (2 lamps ↔ 4 lamps). (Irradiating direction of dimmer switch) must change.)

22 Function of turn signal lamps

When turn signal lever is operated, front and rear turn signal lamps must flash on correct side.

3/6

No.

Inspection item

Judgment procedure and standards

23 Function of hazard lamp

When hazard lamp switch is turned to ON, right and left turn signal lamps and pilot (arrow) lamp inside operator's cab must flash. In this case, if key switch is turned to OFF, pilot lamp must not flash.

24 Function of back-up lamps

When transmission shift lever is set to at R, back-up lamps must light up.

When brake pedal is depressed, 3 red rear brake lamps (right, center, and left) must light up.

25 Function of brake lamps

When retarder lever is pulled, 2 red rear brake lamps (right and left) must light up. Center lamp must not light up at this time.

When light switch is ON and brake is turned ON, brightness of brake lamp must change (become brighter).

26 Function of room lamp

When switch is ON, lamp must light up.

When dump lever is set to any position other than FLOAT or body is Check of function of body opnot seated, This lamp must light up. * Centralized warning lamp eration caution lamp must not light up and centralized alarm buzzer must not sound.

When stroke sensor is projected, this lamp must light up. At this time, Check of function of rear brake 28 centralized warning lamp must light up and centralized alarm buzzer must stroke end caution lamp sound and user code "E-04" and error code "b0-F6" must be displayed.

27

Start engine.

29 Abnormal noise from engine

No abnormal noise must be generated. (Sensory check)

Engine speed * Engine coolant temperature: In green range * Engine oil temperature: 30 70 – 80°C * Torque converter oil temperature: 70 – 80°C

Low idling speed, Measured value: ( / ) rpm Standard value: 945 ± 25 rpm (LiH), 720 ± 25 rpm (LiL)

31 Low idling regulation 32 Exhaust gas color

High idling speed, Measured value: ( / ) rpm Standard value: 2400 ± 50 rpm (Power), 2200 ± 50 rpm (Economy) Torque converter stall speed, Measured value: ( / ) rpm Standard value: 1850 ± 100 rpm (Power), 1850 ± 100 rpm (Economy) When truck is steered to end, engine must not stop at low idling speed. Engine oil pressure caution lamp must not light up.

Exhaust gas color must be proper during sharp acceleration (Li → Hi). Sensory check.

(Standard value: 6 bosch or less)

33 Exhaust gas leakage

Exhaust gas must not leak from exhaust pipe joint, exhaust shutter, etc.

34 Heating of parking brake

After truck travels inside yard, check by touching with hand that parking brake is not heated.

35

Heating of front brake discs After truck travels inside yard, check by touching with hand that front brake discs are not heated.

(Both sides)

After truck travels 7 km, drainage from each side must be 30 Drainage from floating seals cc or less.

(Both sides) Measured values: Left ( ) cc, Right ( ) cc (1) When lockup operates and brake is turned ON (rear brake pilot lamp lights up), exhaust brake must operate (regardless of operation of exhaust brake switch).

(2) When lockup operates and accelerator pedal is turned Function of exhaust brake 37 OFF, exhaust brake must operate (only when exhaust brake (Overseas opt.) switch is ON).

36

When (1) or (2) occurs, exhaust brake pilot lamp must light up.

38 Function of parking brake

Truck must not move at "F2" stall (1430 rpm or above).

Measured value (F : rpm)

39 Function of service brake

Truck must not move at "F2" stall (1850 rpm or above).

Measured value (F : rpm)

40 Function of retarder brake

Truck must not move at "F2" stall (1320 rpm or above).

Measured value (F : rpm)

41 Function of emergency brake

When emergency brake switch is turned ON, service brake and parking brake must be applied. (Check that pilot lamp lights up.)

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Judgment procedure and standards Write down limit where truck moves.

Measured value (F : rpm)

41 Function of emergency brake When air pressure lowers below 0.22 kPa {2.24 kg/cm2}, emergency brake must operate automatically.

42 Operating effort of dump lever

Check that operation is correct (FLOAT → RAISE: 59 N {6.0 kg}, FLOAT → LOWER: 69 N {7.0 kg}). Evaluate by sensing.

(1) Check that order of operation from top is RAISE → HOLD → FLOAT → LOWER. (2) Check that dump lever is held at desired position at HOLD. (3) Operate lever to RAISE position and check that it returns to HOLD when released (When positioner is not installed).

43 Function of dump lever (4) Operate lever to LOWER position and check that it returns to FLOAT when released.

(5) Pressure must be adjusted at RAISE and LOWER positions.

(6) Safety stopper must be applied without hitch at HOLD position.

44

Shock made when dump body When dump body is seated, unpleasant shock must not be is lower to end made. (Sensory check)

Operate lever to RAISE position and check that it does not return to HOLD when released.

Function of body positioner 45 (Overseas opt.)

Operate lever to RAISE position to raise dump body and check that it automatically returns to HOLD at a point 50 – 100 mm before end of hoist cylinder stroke.

When dump body is raised fully, it must not sway to right or left. (Difference in dimension between right and left hoist cylinders: Max. 7 mm) 46

Alignment of dump body on When dump body is lower fully, it must come in contact right and left with mount evenly. (Contact area must be at least 80%.)

When dump body is lower fully, it must come in contact with vibration stopper evenly.

Engine speed: Rated speed (2000rpm) Standard (HD465): 11.5 ± 1.5 sec, Measured value: ( Standard (HD605): 11.5 ± 1.5 sec, Measured value: ( Body lowering speed (Lever at Engine speed: Low idling speed (720rpm) Standard (HD465): 13.5 ± 1.5 sec, Measured value: ( 48 FLOAT, Oil temperature: 50 – 70°C Standard (HD605): 15.5 ± 1.5 sec, Measured value: ( Hydraulic drift in 5 minutes must be 85 mm or less.

49 Hydraulic drift of dump body (From point where cylinder No. 2 is extended by 100 Measured value: ( ) mm 47

50

Body lifting speed (Oil temperature: 80°C

) sec ) sec ) sec ) sec mm)

Function of lifting dump body Stop engine and check that dump body can be lifted with emergency steering motor. with emergency starting motor * Do not operate emergency steering motor for more than 90 seconds continuously.

Stop truck on level ground and measure.

Length of suspension cylinder 51 (Front) * Measure with dump body empty.

Length of suspension cylinder 52 (Rear) * Measure with dump body empty.

Length must be shorter than dimension A. Dimension A: 249 (Position of label) ± 10 mm Measured value: Left ( ) mm, Right ( Length must be shorter than dimension A. Dimension A: 220 (Position of label) ± 10 mm Measured value: Left ( ) mm, Right (

) mm ) mm

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

53

Automatic suspension control function (Opt.) (2): When service brake or emergency brake is turned ON, Measure with dump body display must change from [Soft] to [Medium]. empty.

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

Inspect each part.

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54 Function of safety pin

Safety pin must be inserted without obstruction in right and left stopper holes.

55 Storage function of safety pin

Safety pin must be removed from, installed to, and locked at storage position securely.

Locknut must not be loosened.

Installation of dump control 56 linkage

Boots (Rubber covers) of cable must not be twisted. (At right side of cab, hoist valve, and positioner)

Installation of drive shaft All mounting bolts must be free from looseness and abnor57 (Transmission → Differential) mal play.

58 Front support (Right)

Mounting bolts must be free from looseness.

Rear support 59 (Right disconnecting point)

Mounting bolts must be free from looseness.

60 Fuel tank

Mounting bolts must be free from looseness.

61 Inspection around engine

No oil and water leakage.

Inspection around transmis62 sion No oil and water leakage.

63 Fuel leakage from fuel system No leakage.

Oil leakage from hydraulic oil 64 system (tank, cylinder, pump, No leakage. piping) 65 Oil leakage from brake system No leakage.

Air leakage from pneumatic 66 devices (including piping) No leakage.

67 Air leakage

Air pressure drop must be 49 kPa {0.5 kg/cm2}/30 min or less.

Measured value: ( kpa) { kg/cm2}/30 min

68 Function of air tank drain valve Impurities must be drained securely.

(1) Front left: Retighten.

Tightness of tire hub nuts Tightening torque: (2) Front right: Retighten.

1079 – 1323 Nm 69 (Target: 1206 Nm) * When nothing is applied to (3) Rear left: Retighten. threads.

(4) Rear right: Retighten.

Standard: Shown at left Measured value: Front left ( ) MPa, Front right ( ) MPa Tire inflation pressure (When Standard: Shown at left dump body is empty) Measured value: Front left inside ( ) MPa, Front right 70 (Write down values when inside ( ) MPa shipped.)

Standard: Shown at left Measured value: Front left outside ( ) MPa, Front right outside ( ) MPa 71 Flaw of tires

Tires must be free from flaw and tear.

72 Tension of fan belt

When belt is pushed with thumb (approx. 6 kg), its deflection must be 10 – 15 mm. Belt must be free from flaw and twist.

Plated surfaces must be free from rust, harmful flaw, spat73 Steering cylinders (Both sides) ter, paint, etc.

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74 Hoist cylinders (Both sides)

Judgment procedure and standards Plated surfaces must be free from rust, harmful flaw, spatter, paint, etc.

75

Suspension cylinders (Both sides, front)

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

76

Suspension cylinders (Both sides, rear)

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

77 Appearance of cab glass

Glass must be free from flaw, paint, etc.

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