Komatsu HD785-5 Dump Truck Field Assembly Instruction Manual SN 4001 and up – PDF DOWNLOAD

Description

Komatsu HD785-5 Dump Truck Field Assembly Instruction Manual

TABLE OF CONTENTS:

Komatsu HD785-5 Dump Truck Field Assembly Instruction Manual 

COVER..........................................................................................................  1
CONTENTS.......................................................................................................  2
Front Axle, F/T, Chassis, HD785-5 (common to all specifi cations)..............................................  4
Tire Assembly (including Tires), Rear Axle, HD785-5............................................................  5
R.H. Platform, Cabin, HD785-5..................................................................................  6
Body Assembly (Including Body), HD785-5........................................................................  7
LIST OF JIGS, TOOLS, AND CONSUMABLES FOR FIELD ASSEMBLING (1/3)................................................  8
LIST OF JIGS, TOOLS, AND CONSUMABLES FOR FIELD ASSEMBLING (2/3)................................................  9
LIST OF JIGS, TOOLS, AND CONSUMABLES FOR FIELD ASSEMBLING (3/3)................................................ 10
LIST OF TOUCH-UP COATING ON BODY FOR OVERSEAS SPECIFICATIONS................................................... 10
SKETCHES OF SPECIAL TOOLS...................................................................................... 11
MAN-HOURS, WORKERS NEEDED FOR LOCAL ASSEMBLY................................................................... 15
ASSEMBLING PROCEDURES ON SITE.................................................................................. 17
	1. LIFTING AND MOUNTING REAR AXLE ASSEMBLY................................................................. 17
	2. LIFTING CHASSIS ASSEMBLY................................................................................ 19
	3. TRANSFERRING CHASSIS ASSEMBLY ONTO REAR AXLE ASSEMBLY................................................... 21
	4. CONNECTING RODS TO REAR AXLE SUSPENSION................................................................. 23
	5. PLACING MOUNT FOR FRONT SIDE............................................................................ 25
	6. CONNECTING REAR AXLE AND PARKING BRAKE LINE............................................................. 26
	7. LIFTING FRONT AXLE ASSEMBLY............................................................................. 27
	8. ASSEMBLING FRONT AXLE................................................................................... 29
	9. CONNECTING TIE ROD OF STEERING CYLINDER................................................................. 31
	10. CONNECTING FRONT AXLE HOSES............................................................................ 33
	11. INSTALLING STEPS ON A-SHAPED ARM AND BUMPER............................................................ 35
	12. INSTALLING FRONT TIRES................................................................................. 37
	13. INSTALLING PROPELLER SHAFT............................................................................. 39
	14. INSTALLING FUEL TANK (1/2)............................................................................. 41
	15. INSTALLING FUEL TANK (2/2)............................................................................. 43
	16. INSTALLING LEFT- AND RIGHTHAND STAYS OF FRAME.......................................................... 45
	17. INSTALLING LEFT- AND RIGHTHAND FENDERS................................................................. 47
	18. INSTALLING FRONT SUPPORTS.............................................................................. 49
	19. INSTALLATION OF FRONT SUPPORT (-40 °C SPECIFICATION FOR POLYUS)........................................ 51
	20. INSTALLATION OF FRONT SUPPORT (DIAGONAL LADDER + LARGE-CAPACITY AIR CLEANER SPECIFICATION)............. 53
	21. INSTALLATION OF AIR CLEANER ASSEMBLY INDICATOR HOSES (LARGE-CAPACITY AIR CLEANER SPECIFICATION)........ 55
	22. INSTALLATION OF RIGHT FRONT SUPPORT AIR CLEANER ASSEMBLY (LARGE-CAPACITY AIR CLEANER SPECIFICATION).... 57
	23. CONNECTING STEERING OIL LINE........................................................................... 59
	24. CONNECTION OF AIR CLEANER PIPING (LARGE-CAPACITY AIR CLEANER SPECIFICATION)............................ 61
	25. REMOVING ENGINE HOOD................................................................................... 63
	26. INSTALLING RIGHT-HAND PLATFORM HANDRAIL................................................................ 64
	27. INSTALLING RIGHT-HAND PLATFORM......................................................................... 65
	28. FIXING OF AIR CLEANER PIPING (LARGE-CAPACITY AIR CLEANER SPECIFICATION)................................ 67
	29. WIRING ALONG RIGHT-HAND PLATFORM SIDE.................................................................. 69
	30. WIRING IN BATTERY BOX.................................................................................. 71
	31. INSTALLATION OF DIAGONAL LADDER (1/3) (DIAGONAL LADDER + LARGE-CAPACITY AIR CLEANER SPECIFICATION)..... 73
	32. INSTALLATION OF DIAGONAL LADDER (2/3) (DIAGONAL LADDER + LARGE-CAPACITY AIR CLEANER SPECIFICATION)..... 75
	33. INSTALLATION OF DIAGONAL LADDER (3/3) (DIAGONAL LADDER + LARGE-CAPACITY AIR CLEANER SPECIFICATION)..... 77
	34. REPLACING SIDE BRACKET OF CABIN........................................................................ 79
	35. INSTALLING HANDRAIL OF CABIN........................................................................... 80
	36. INSTALLING CABIN....................................................................................... 81
	37. CONNECTING STEERING COLUMN............................................................................. 83
	38. CLAMPING DRAIN HOSE OF AIR CONDITIONER................................................................. 85
	39. INSTALLING ROPS AND PAYLOAD LAMP....................................................................... 86
	40. CONNECTING DUMP CONTROL................................................................................ 87
	41. INSTALLING AIR INTAKE (1/2)............................................................................ 89
	42. INSTALLING AIR INTAKE (2/2)............................................................................ 90
	43. INSTALLING AIR INTAKE (1/2) (FRONT AIR INTAKE SPECIFICATION)........................................... 91
	44. INSTALLING EXHAUST PIPE................................................................................ 92
	45. DRAWING HARNESS INTO INSIDE OF CABIN................................................................... 93
	46. CONNECTING HARNESSES INSIDE CABIN (1/2)................................................................ 94
	47. CONNECTING HARNESSES INSIDE CABIN (2/2)................................................................ 95
	48. CONNECTING AIR CONDITIONER HOSES....................................................................... 97
	49. INSTALLING WASHER TANK................................................................................. 98
	50. INSTALLING AND CONNECTING AIR HORN..................................................................... 99
	51. WIRING AROUND CABIN (1/2)..............................................................................100
	52. WIRING AROUND CABIN (2/2)..............................................................................101
	53. INSTALLATION AND CONNECTION OF FUEL FILTER (-40 °C SPECIFICATION FOR POLYUS)...........................103
	54. CONNECTING RIGHT-HAND FRONT BRAKE AND RADIATOR SURGE TANK..............................................105
	55. WIRING FOR HEAD LAMP...................................................................................107
	56. CONNECTING AIR CHARGE LINE.............................................................................109
	57. AIR PIPING.............................................................................................111
	58. CONNECTING LEFT-HAND FRONT BRAKE.......................................................................113
	59. INSTALLING PARTS AROUND HOOD...........................................................................114
	60. CHECKING FOR OIL AND COOLING WATER.....................................................................115
	61. FILLING GAS INTO AIR CONDITIONER.......................................................................116
	62. BLEEDING AIR FROM BRAKE................................................................................117
	63. REMOVING PARTS FROM HOST CYLINDER AFTER TRANSPORTATION.................................................119
	64. EQUIPPING MACHINE BODY.................................................................................121
	65. INSTALLING GREASE TUBES ON HOIST CYLINDER..............................................................123
	66. ADJUSTMENT OF BODY BOTTOM MOUNT........................................................................125
	67. ADJUSTMENT OF BODY POSITIONER..........................................................................127
	68. WELDING BY DETERMINING DIMENSIONS WITH ACTUAL PARTS (BODY FRONT MOUNT).................................129
	69. WELDING BY DETERMINING DIMENSIONS WITH ACTUAL PARTS (SWING PREVENTION OF BODY).........................131
	70. WELDING BY DETERMINING DIMENSIONS WITH ACTUAL PARTS (EXHAUST FLANGE)...................................132
	71. INSTALLING BODY SEATING SWITCH.........................................................................133
	72. INSTALLING BODY ACCESSORIES............................................................................134
	73. PAINTING...............................................................................................135
	74. BODY STOPPER PINS......................................................................................137
	75. ADJUSTMENT OF SUSPENSION...............................................................................138
	76. SMOOTHING OF FLOATING SEAL.............................................................................139
PROCEDURE FOR WELDING AND ASSEMBLING THREE SEPARATED BODY PARTS................................................140
WORK PROCEDURES FOR TURNING OVER THE BODY......................................................................155
2900 mm transportation posture (If equipped)...................................................................158
FIELD ASSEMBLY INSPECTION REPORT...............................................................................188

KOMATSU HD785-5 DUMP TRUCK FIELD ASSEMBLY INSTRUCTION MANUAL SN 4001 AND UP – PDF DOWNLOAD:

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