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Komatsu HD785-7 Dump Truck Field Assembly Instruction Manual 7001 and up – PDF DOWNLOAD
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Komatsu HD785-7 Dump Truck Field Assembly Instruction Manual
SERIAL NUMBERS 7001 and up
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Description
Komatsu HD785-7 Dump Truck Field Assembly Instruction Manual
FILE DETAILS:
Komatsu HD785-7 Dump Truck Field Assembly Instruction Manual
Brands: Komatsu
Equipment Type: Dump Truck
Manuals Type: Field Assembly Instruction Manual
Machine Model: HD785-7
Serial Number: 7001 and up
Book Code: GEN00058-08
Language: English
Pages: 221
File Format: Portable Document Format (PDF)
KOMATSU HD785-7 DUMP TRUCK FIELD ASSEMBLY INSTRUCTION MANUAL 7001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Komatsu HD785-7 Dump Truck Field Assembly Instruction Manual
COVER....................................................................................................................................................... 1 CONTENTS.................................................................................................................................................... 2 1. Outline of division (Only main components)............................................................................................................... 8 2. Dimensions of main components............................................................................................................................ 9 3. Layout of work space..................................................................................................................................... 10 4. Rough schedule of assembly and welding................................................................................................................... 0 4-1. Rough schedule of assembly and welding (1st day)................................................................................................... 11 4-2. Rough schedule of assembly and welding (2nd day) .................................................................................................. 12 4-3. Rough schedule of assembly and welding (3rd day)................................................................................................... 13 4-4. Rough schedule of assembly and welding (4th day)................................................................................................... 14 4-5. Rough schedule of assembly and welding (5th day)................................................................................................... 15 5. List of jigs, tools, and consumables for field assembling................................................................................................ 0 5-1 List of jigs, tools, and consumables for field assembling (1/2)..................................................................................... 16 5-2 List of jigs, tools, and consumables for field assembling (2/2)..................................................................................... 17 5-3. Tools and consumables.............................................................................................................................. 19 6. Assembly process......................................................................................................................................... 0 0010 Oil, grease, and coolant.......................................................................................................................... 23 0020 Levels of oil, grease, and coolant................................................................................................................ 24 0030 Positioning rear axle assembly.................................................................................................................... 25 0040 Slinging and moving of bare machine............................................................................................................... 26 0050 Connection of rod and rear suspension............................................................................................................. 27 0060 Positioning bare machine.......................................................................................................................... 28 0070 Connection of rear axle cooling hose.............................................................................................................. 29 0080 Connection of rear axle brake hose................................................................................................................ 30 0085 Connection of rear axle brake hose (ASR specification: If equipped)............................................................................... 31 0086 Connection of valve sub-assembly wiring harness (ASR specification: If equipped).................................................................. 32 0087 Connection and fixing of piping going to rear axle (Sand terrain/ASR specification: If equipped).................................................. 33 0090 Connection and fixing of rear grease piping and supply of grease.................................................................................. 34 0100 Preparation for installing front axle............................................................................................................. 35 0110 Installation of front axle........................................................................................................................ 36 0120 Connection of front axle suspension pressure sensor............................................................................................... 37 0125 Connection of front axle wheel speed sensor (ABS specification: If equipped)...................................................................... 38 0130 Connection of steering cylinder and tie rod....................................................................................................... 39 0140 Connection of front axle brake cooling hoses...................................................................................................... 40 0150 Connection of front axle brake hoses.............................................................................................................. 41 0160 Connection of front axle auto suspension piping................................................................................................... 42 0165 Fixing of front axle auto suspension piping....................................................................................................... 43 0166 Fixing of front axle auto grease piping (If equipped: Auto grease specification).................................................................. 44 0167 Connection of left front axle auto grease piping (If equipped: Auto grease specification)......................................................... 45 0168 Connection of right front axle auto grease piping (If equipped: Auto grease specification)........................................................ 46 0170 Installation of bumper and front axle steps....................................................................................................... 47 0171 Installation of front axle step (EU specification)................................................................................................ 48 0180 Installation of tire and wheel assembly........................................................................................................... 49 0190 Installation of drive shaft....................................................................................................................... 50 0200 Installation of oil quick charge box (If equipped: Oil quick charge specification)................................................................ 51 0260 Installation of fuel tank wiring harness cover.................................................................................................... 52 0270 Installation of toolbox and tool kit.............................................................................................................. 53 0275 Installation of fuel tank step (If equipped)...................................................................................................... 54 0280 Installation of rear support...................................................................................................................... 55 0281 Installation of rear support (Muffler specification: If equipped)................................................................................. 56 0282 Installation of rear support (ABS specification: If equipped)..................................................................................... 57 0283 Installation of rear support (Sand terrain specification: If equipped)............................................................................ 58 0290 Installation of muffler........................................................................................................................... 59 0291 Installation of muffler (Body heating-less/Exhaust selector box specification: If equipped)....................................................... 60 0300 Installation of fire prevention cover............................................................................................................. 61 0310 Installation of front support..................................................................................................................... 62 0315 Installation of front support (Fog lamp specification: If equipped)............................................................................... 63 0317 Installation of front support (Fog lamp, beacon lamp, HID headlamp specification: If equipped).................................................... 64 0320 Installation of steering valve.................................................................................................................... 65 0330 Preparation for installing cab.................................................................................................................... 66 0340 Installation of cab............................................................................................................................... 67 0345 Connection of ABS piping (If equipped)............................................................................................................ 68 0350 Connection of column.............................................................................................................................. 69 0355 Installation of washer tank....................................................................................................................... 70 0370 Connection of cab wiring.......................................................................................................................... 71 0375 Connection of cab wiring (ASR/ABS specification: If equipped)..................................................................................... 72 0376 Connection of engine prelubrication harness to cab (If equipped: Engine prelubrication specification)............................................. 73 0377 Connection and fixing of engine compartment lamp wiring harness (if equipped)..................................................................... 74 0378 Connection of auto grease harness to cab (If equipped: Auto grease specification)................................................................. 75 0379 Connection of engine stop harness to cab (If equipped: Engine emergency stop specification)....................................................... 76 0380 Installation and fixing of steering hoses......................................................................................................... 77 0385 Fixing of air conditioner drain hose.............................................................................................................. 78 0390 Installation of steering hose cover............................................................................................................... 79 0395 Connection of air conditioner and heater hoses.................................................................................................... 80 0400 Connection of cab floor wiring.................................................................................................................... 81 0405 Fixing of ASR/ABS wiring harness (If equipped).................................................................................................... 82 0406 Connection and fixing of ABS wiring harness (ABS specification: If equipped)...................................................................... 83 0410 Installation of cover under cab................................................................................................................... 84 0415 Wiring of front glass with heater wire (If equipped).............................................................................................. 85 0420 Installation of cab seal.......................................................................................................................... 86 0430 Installation of ambient temperature sensor wiring harness......................................................................................... 87 0440 Installation of undercab wiring harness connector................................................................................................. 88 0445 Connection and fixing of rear view camera wiring harness (if equipped)............................................................................ 89 0450 Installation of R.H platform assembly............................................................................................................. 90 0470 Installation of right fender...................................................................................................................... 91 0472 Installation of right fender (If equipped: Body heating-less muffler specification)............................................................... 92 0475 Installation of fuel tank quick charge-less hose (If equipped).................................................................................... 93 0476 Installation of fuel tank quick chargeless hose: Muffler specification (If equipped: muffler specification)....................................... 94 0480 Installation of cab step.......................................................................................................................... 95 0481 Assembly of diagonal ladder (if equipped)......................................................................................................... 96 0482 Installation of cab step: Diagonal ladder specification (if equipped)............................................................................. 97 0483 Installation of diagonal ladder 1 (if equipped)................................................................................................... 98 0484 Installation of diagonal ladder 2 (if equipped)................................................................................................... 99 0485 Installation of diagonal ladder 3 (if equipped)...................................................................................................100 0486 Installation of diagonal ladder (EU specification)................................................................................................101 0487 Installation of diagonal ladder-2 (EU specification)..............................................................................................102 0488 Installation of diagonal ladder-3 (EU specification)..............................................................................................103 0490 Installation of L.H underview mirror (If equipped)................................................................................................104 0500 Installation of fire extinguisher (If equipped)...................................................................................................105 0510 Installing radio antenna and fixing its cable.....................................................................................................106 0520 Installation of L.H fender........................................................................................................................107 0530 Installation of left side mudguard................................................................................................................108 0540 Installation of grille guard......................................................................................................................109 0550 Installation of left payload lamp (If equipped)...................................................................................................110 0555 Installation of left side lamp (If equipped)......................................................................................................111 0560 Installation of right payload lamp (If equipped)..................................................................................................112 0565 Installation of right side lamp (If equipped).....................................................................................................113 0570 Installation of left fender side lamp wiring harness (If equipped)................................................................................114 0580 Installation of right fender side lamp wiring harness (If equipped)...............................................................................115 0581 Installation of right fender side lamp wiring harness (If equipped: Body heating-less muffler, exhaust gas selector box muffler specification)....116 0590 Installation of KOMTRAX (If equipped).............................................................................................................117 0595 Fixing of ORBCOMM antenna (If equipped)...........................................................................................................118 0597 Connection and fixing of harness and hose going to auto grease pump - 1 (If equipped: Auto grease specification)..................................119 0598 Connection and fixing of harness and hose going to auto grease pump - 2 (If equipped: Auto grease specification)..................................120 0600 Removal of hoist cylinder fixing bracket..........................................................................................................121 0610 Connection of hoist cylinder piping...............................................................................................................122 0620 Welding of body...................................................................................................................................123 0630 Sticking of body decal............................................................................................................................124 0640 Supply of oil.....................................................................................................................................125 0650 Slinging of body..................................................................................................................................126 0660 Installation of hinge pin.........................................................................................................................127 0670 Connecting hoist cylinder.........................................................................................................................128 0680 Hoist cylinder grease piping......................................................................................................................129 0685 Fixing of auto grease piping to body (If equipped: Auto grease specification).....................................................................130 0700 Installation of field welding protection cover....................................................................................................131 0710 Installation of body mount........................................................................................................................132 0720 Procedure for adjusting body mount shim...........................................................................................................133 0730 Field welding of exhaust tube.....................................................................................................................134 0740 Assembly of body heater cover.....................................................................................................................135 0770 Installation of poke ejector......................................................................................................................136 0780 Installation of poke ejector storage pin..........................................................................................................137 0790 Installation of body mudguard.....................................................................................................................138 0800 Installation of body lock pin.....................................................................................................................139 0810 Installation of transmission underguard...........................................................................................................140 0830 Installation of front handle......................................................................................................................141 0850 Connection of dump sensor.........................................................................................................................142 0860 Procedure for adjusting dump sensor...............................................................................................................143 0870 Calibrating dump control..........................................................................................................................144 0880 Adjustment of optical axis of light...............................................................................................................145 0900 Bleeding air from brake...........................................................................................................................146 0901 Bleeding air from brake of ASR specification (ASR specification: If equipped).....................................................................147 0905 Bleeding air from ABS circuit (ABS specification: If equipped)....................................................................................148 0910 Adjusting suspension..............................................................................................................................149 0920 Charging air conditioner with refrigerant.........................................................................................................150 0930 Fitting of floating seal..........................................................................................................................151 0950 Painting..........................................................................................................................................152 0960 Touchup...........................................................................................................................................153 1000 Sticking of front axle decal......................................................................................................................154 1020-1 Operating procedure of prelubrication system (If equipped: Engine prelubrication specification).................................................155 1020-2 Operating procedure of prelubrication system (If equipped: Engine prelubrication specification).................................................156 1100 Installation of chocks (If equipped)..............................................................................................................157 1200 Installation of radiator curtain (If equipped)....................................................................................................158 1300 Installation and connection of beacon lamp (If equipped: Yellow beacon lamp specification)........................................................159 1400 Assembly of power ladder step -1 (If equipped)....................................................................................................160 1410 Assembly of power ladder step -2 (If equipped)....................................................................................................161 1420 Assembly of power ladder step -3 (If equipped)....................................................................................................162 1430 Assembly of power ladder main part -1 (If equipped)...............................................................................................163 1440 Assembly of power ladder main part -2 (If equipped)...............................................................................................164 1450 Assembly of power ladder main part -3 (If equipped)...............................................................................................165 1460 Assembly of power ladder main part -4 (If equipped)...............................................................................................166 1470 Assembly of power ladder main part -5 (If equipped)...............................................................................................167 1480 Assembly of power ladder main part -6 (If equipped)...............................................................................................168 1490 Assembly of power ladder main part -7 (If equipped)...............................................................................................169 1500 Assembly of power ladder main part -8 (If equipped)...............................................................................................170 1510 Assembly of power ladder main part -9 (If equipped)...............................................................................................171 1520 Assembly of power ladder main part -10 (If equipped)..............................................................................................172 1530 Assembly of power ladder main part -11 (If equipped)..............................................................................................173 1540 Assembly of power ladder main part -12 (If equipped)..............................................................................................174 1550 Assembly of power ladder main part -13 (If equipped)..............................................................................................175 1560 Assembly of power ladder main part -14 (If equipped)..............................................................................................176 1570 Assembly of power ladder main part -15 (If equipped)..............................................................................................177 1580 Assembly of power ladder main part -16 (If equipped)..............................................................................................178 1590 Refilling power ladder with oil...................................................................................................................179 1600 Adjustment of power ladder operating time.........................................................................................................180 1610 Installation of additional under-view mirror......................................................................................................181 7. Adjustment procedure..................................................................................................................................... 0 T-0010 Bleeding air from fuel circuit 1 (If equipped: Extra low-grade fuel specification)..............................................................182 T-0020 Bleeding air from fuel circuit 2 (If equipped: Extra low-grade fuel specification)..............................................................183 T-0030 Setting of machine monitor......................................................................................................................184 T-0040 Selection of machine model......................................................................................................................185 T-0050 Selection of optional component.................................................................................................................186 T-0060 Selection of option.............................................................................................................................187 T-0070 Option setting/no-setting selection screen - Saving of change of option selection...............................................................188 T-0080 OFF setting of corrosion resistor with maintenance monitor......................................................................................189 T-0090 Adjustment of body positioner sensor............................................................................................................190 T-0100 Deletion of electrical system fault history (1).................................................................................................191 T-0110 Deletion of electrical system fault history (2).................................................................................................192 8. Welding procedure........................................................................................................................................ 0 C-0010 Preparation of welding body.....................................................................................................................193 C-0020 Assembly of split body (1/2)....................................................................................................................194 C-0030 Assembly of split body (2/2)....................................................................................................................195 C-0040 Tack welding body...............................................................................................................................196 C-0050 Welding body (1/2)..............................................................................................................................197 C-0060 Welding body (2/2)..............................................................................................................................198 C-0070 Welding body instruction (1/2)..................................................................................................................199 C-0080 Welding body instruction (2/2)..................................................................................................................200 C-0090 Turn over the body..............................................................................................................................201 C-0100 Welding body protector (1/2)....................................................................................................................202 C-0110 Welding body protector (2/2)....................................................................................................................203 C-0120 Finishing and painting welded parts of body.....................................................................................................204 C-0130 Welding front body mount bracket................................................................................................................205 Appendix.................................................................................................................................................... 0 Field assembly inspection report........................................................................................................................206
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1 review for Komatsu HD785-7 Dump Truck Field Assembly Instruction Manual 7001 and up – PDF DOWNLOAD
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Peter Paul –
Lots and lots of useful data