Komatsu HD785-7 Dump Truck Field Assembly Manual A10001 & UP – PDF DOWNLOAD

Description

Komatsu HD785-7 Dump Truck Field Assembly Manual

FILE DETAILS:

Komatsu HD785-7 Dump Truck Field Assembly Manual

Brands: Komatsu
Equipment Type: Dump Truck
Manuals Type: Field Assembly  Manual
Machine Model: HD785-7
Serial Number: A10001 & UP
Book Code: CEAW004806
Language: English
Pages: 202
File Format: Portable Document Format (PDF)

KOMATSU HD785-7 DUMP TRUCK FIELD ASSEMBLY MANUAL A10001 & UP – PDF DOWNLOAD:

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TABLE OF CONTENTS:

Komatsu HD785-7 Dump Truck Field Assembly Manual

COVER......................................................................................................................................................  1
CONTENTS...................................................................................................................................................  3
1. Outline of division (Only main components)..............................................................................................................  7
2. Dimensions of main components...........................................................................................................................  8
3. Layout of work space....................................................................................................................................  9
4. Rough schedule of assembly and welding.................................................................................................................. 10
5. List of jigs, tools, and consumables for field assembling............................................................................................... 15
6. Assembly process No..................................................................................................................................... 22
	0010 Oil, grease, and coolant.......................................................................................................................... 22
	0020 Levels of oil, grease, and coolant................................................................................................................ 23
	0030 Positioning rear axle assembly.................................................................................................................... 24
	0040 Slinging and moving of bare machine............................................................................................................... 25
	0050 Connection of rod and rear suspension............................................................................................................. 26
	0060 Positioning bare machine.......................................................................................................................... 27
	0070 Connection of rear axle cooling hose.............................................................................................................. 28
	0080 Connection of rear axle brake hose................................................................................................................ 29
	0085 Connection of rear axle brake hose (ASR specification: If equipped)............................................................................... 30
	0086 Connection of valve sub-assembly wiring harness (ASR specification: If equipped).................................................................. 31
	0087 Connection and fixing of piping going to rear axle (Sand terrain/ASR specification: If equipped).................................................. 32
	0090 Connection and fixing of rear grease piping and supply of grease.................................................................................. 33
	0100 Preparation for installing front axle............................................................................................................. 34
	0110 Installation of front axle........................................................................................................................ 35
	0120 Connection of front axle suspension pressure sensor............................................................................................... 36
	0125 Connection of front axle wheel speed sensor (ABS specification: If equipped)...................................................................... 37
	0130 Connection of steering cylinder and tie rod....................................................................................................... 38
	0140 Connection of front axle brake cooling hoses...................................................................................................... 39
	0150 Connection of front axle brake hoses.............................................................................................................. 40
	0160 Connection of front axle auto suspension piping................................................................................................... 41
	0165 Fixing of front axle auto suspension piping....................................................................................................... 42
	0166 Fixing of front axle auto grease piping (If equipped: Auto grease specification).................................................................. 43
	0167 Connection of left front axle auto grease piping (If equipped: Auto grease specification)......................................................... 44
	0168 Connection of right front axle auto grease piping (If equipped: Auto grease specification)........................................................ 45
	0170 Installation of bumper and front axle steps....................................................................................................... 46
	0171 Installation of front axle step (EU specification)................................................................................................ 47
	0180 Installation of tire and wheel assembly........................................................................................................... 48
	0190 Installation of drive shaft....................................................................................................................... 49
	0200 Installation of oil quick charge box (If equipped: Oil quick charge specification)................................................................ 50
	0260 Installation of fuel tank wiring harness cover.................................................................................................... 51
	0270 Installation of toolbox and tool kit.............................................................................................................. 52
	0275 Installation of fuel tank step (If equipped)...................................................................................................... 53
	0280 Installation of rear support...................................................................................................................... 54
	0281 Installation of rear support (Muffler specification: If equipped)................................................................................. 55
	0282 Installation of rear support (ABS specification: If equipped)..................................................................................... 56
	0283 Installation of rear support (Sand terrain specification: If equipped)............................................................................ 57
	0290 Installation of muffler........................................................................................................................... 58
	0291 Installation of muffler (Body heating-less/Exhaust selector box specification: If equipped)....................................................... 59
	0300 Installation of fire prevention cover............................................................................................................. 60
	0310 Installation of front support..................................................................................................................... 61
	0315 Installation of front support (Fog lamp specification: If equipped)............................................................................... 62
	0317 Installation of front support (Fog lamp, beacon lamp, HID headlamp specification: If equipped).................................................... 63
	0320 Installation of steering valve.................................................................................................................... 64
	0330 Preparation for installing cab.................................................................................................................... 65
	0340 Installation of cab............................................................................................................................... 66
	0345 Connection of ABS piping (If equipped)............................................................................................................ 67
	0350 Connection of column.............................................................................................................................. 68
	0355 Installation of washer tank....................................................................................................................... 69
	0360 Connection of cab piping.......................................................................................................................... 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 (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 Operating procedure of prelubrication system (If equipped: Engine prelubrication specification)...................................................155
	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
7. Adjustment procedure....................................................................................................................................160
	T-0010 Bleeding air from fuel circuit 1 (If equipped: Extra low-grade fuel specification)..............................................................160
	T-0020 Bleeding air from fuel circuit 2 (If equipped: Extra low-grade fuel specification)..............................................................161
	T-0030 Setting of machine monitor......................................................................................................................162
	T-0040 Selection of machine model......................................................................................................................163
	T-0050 Selection of optional component.................................................................................................................164
	T-0060 Selection of option.............................................................................................................................165
	T-0070 Option setting/no-setting selection screen - Saving of change of option selection...............................................................166
	T-0080 OFF setting of corrosion resistor with maintenance monitor......................................................................................167
	T-0090 Adjustment of body positioner sensor............................................................................................................168
	T-0100 Deletion of electrical system fault history (1).................................................................................................169
	T-0110 Deletion of electrical system fault history (2).................................................................................................170
8. Welding procedure.......................................................................................................................................171
	C-0010 Preparation of welding body.....................................................................................................................171
	C-0020 Assembly of split body (1/2)....................................................................................................................172
	C-0030 Assembly of split body (2/2)....................................................................................................................173
	C-0040 Tack welding body...............................................................................................................................174
	C-0050 Welding body (1/2)..............................................................................................................................175
	C-0060 Welding body (2/2)..............................................................................................................................176
	C-0070 Welding body instruction (1/2)..................................................................................................................177
	C-0080 Welding body instruction (2/2)..................................................................................................................178
	C-0090 Turn over the body..............................................................................................................................179
	C-0100 Welding body protector (1/2)....................................................................................................................180
	C-0110 Welding body protector (2/2)....................................................................................................................181
	C-0120 Finishing and painting welded parts of body.....................................................................................................182
	C-0130 Welding front body mount bracket................................................................................................................183
Field assembly inspection report...........................................................................................................................185

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