Description
Komatsu HD785-8 Dump Truck Field Assembly Manual (GEN00183-10)
Komatsu HD785-8 Dump Truck Index:
1-1. FOREWORD
2-1. PRECAUTIONS FOR FIELD ASSEMBLY
2-2. DISPOSAL OF REMOVED PARTS
3-1. ASSEMBLY/WELDING PROCEDURES, NECESSARY EQUIPMENT, AND SCHEDULE
3-2. LAYOUT OF KIT (WORK SPACE LAYOUT)
3-3. PARTS OVERVIEW (ONLY FOR MAIN COMPONENTS)
3-4. DIMENSIONS OF MAIN COMPONENTS
3-5. SPECIFICATIONS
4-1. TOOL LIST FOR FIELD ASSEMBLY
4-2. STANDARD TIGHTENING TORQUE TABLE
4-3. COATING MATERIALS LIST
4-4. SELECTION OF WIRE ROPES USED FOR ASSEMBLY
4-5. SELECTION OF NYLON SLINGS USED FOR ASSEMBLY
4-6. RELATIONSHIP BETWEEN WORK NUMBER OF ASSEMBLY PROCEDURE AND PACKING TAG
4-7. HOW TO SECURE MACHINE
5. FIELD ASSEMBLY PROCEDURE
00001 Using fuel, coolant, and lubricating oil corresponding to ambienttemperature
00002 Oil and grease, coolant amount
00003 Lifting and movement of bare machine
00005 Installation of left front support
00010 Preparation for installation of cab
00015 Installation of left front support harness
00017 Preparation for installation of right platform
00020 Installation of right front support
00030 Installation of left rear support
00040 Installation of right rear support and exhaust pipe
00041 Installation of right rear support and exhaust pipe (with bodyheating)
00050 Installation of fire prevention cover under exhaust pipe
00055 Installation of exhaust pipe (without body heating)
00060 Installation of exhaust pipe
00069 Adjustment procedure of exhaust pipe
00070 Installation of steering hose
00080 Fixing and connection of steering hose
00082 Installation of steering hose cover
00090 Installation of right front axle assembly
00091 Installation of tie rod – front axle (right)
00094 Sticking of right front axle assembly decal (2ZZ03)
00096 Sticking of right front axle assembly decal (2ZZ26A)
00100 Installation of left front axle assembly
00101 Installation of tie rod – front axle (left)
00104 Sticking of left front axle assembly decal (2ZZ03)
00106 Sticking of left front axle assembly decal (2ZZ26A)
00110 Installation of right and left front axle steps
00120 Fixing and connection of left front axle sensor
00130 Fixing and connection of right front axle sensor
00135 Connection and fixing of left front axle hose
00140 Connection of front axle brake cooling hose
00145 Connection and fixing of right front axle hose
00150 Installation of left front support step
00160 Connection of rear drive shaft
00170 Installation of rear propeller shaft guard
00180 Connection of cab – left accumulator hose
00183 Connection of cab brake hose
00185 Connection of brake hose under the air cleaner to CAB
00190 Installation of right fender
00191 Connection of right fender side lamp
00192 Installation of cover under right platform
00200 Installation of left fender
00201 Connection of left fender side lamp
00210 Installation of rear axle – 1
00220 Installation of rear axle – 2
00225 Connection of rear axle hose
00230 Connection of rear axle cooling hose
00232 Connection and fixing of rear axle harness
00235 Installation of right platform
00237 Installation of right platform mudguard
00250 Fixing and connection of rear suspension oil pressure sensor
00280 Installation of air conditioner hose fixing bracket
00281 Fixing of air conditioner drain hose
00290 Connection of radiator heater hose
00300 Installation of left payload meter harness
00350 Installation of radio antenna – 1
00360 Installation of radio antenna – 2
00370 Installation of cover under cab – 1
00372 Installation of under CAB mudguard
00380 Installation of cover under cab – 2
00385 Installation of battery disconnect box (without jump start)
00400 Installation of diagonal ladder step – 1-1
00401 Installation of diagonal ladder step – 1-2 (shipping by travel)
00402 Installation of diagonal ladder step – 1-3 (Packing style for land
transportation shipping)
00410 Installation of diagonal ladder step – 2
00420 Installation of diagonal ladder step – 3
00430 Installation of diagonal ladder step – 4
00440 Installation of diagonal ladder step – 5
00445 Installation of diagonal ladder step – 6
00450 Installation of diagonal ladder step – 7
00460 Installation of diagonal ladder step – 8
00470 Installation of diagonal ladder step – 9
00480 Installation of diagonal ladder step – 10 (without radar)
00500 Fixing of catwalk mirror
00510 Fixing and connection of right fender side lamp harness
00520 Fixing and connection of left fender side lamp harness
00530 Installation of battery isolator cable cover
00550 Wiring of engine emergency stop box harness
00560 Installation of cover in front of cab
00570 Installation of step support in front of cab
00580 Installation of catwalk mount – 1
00590 Installation of catwalk mount – 2
00600 Installation of catwalk – 1
00601 Installation of catwalk – 2
00610J Installation of step in front of cab
00620 Installation of catwalk mount cover
00630 Installation of front tire
00640 Installation of rear tire – 1 (Inner)
00641 Installation of rear tire – large bore valve – 1 (Inner)
00650 Installation of rear tire – 2
00651 Installation of rear tire – large bore valve – 2
00655 Installation of front wheel valve
00656 Installation of front wheel valve – large bore valve
00660 Installation of engine underguard
00670 Installation of transmission underguard
00690 Installation of mudguard for left KomVision camera
00700J Installation of mudguard for right KomVision camera
00709 Fixing of KomVision camera harness
00710 Installation of KomVision harness cover (Left)
00712 Installation of KomVision harness cover (Right)
00720 Wiring of right heater mirror harness – 1
00730 Wiring of right heater mirror harness – 2
00740 Installation of heater mirror (upper)
00750 Installation of heater mirror (lower)
00755 Wiring of left heater mirror harness
00765 Installation of right platform sub assembly
00767 Installation of right platform sub assembly mirror
00770 Installation of upper handrail of radiator guard
00780 Installation of fire extinguisher
00790 Installation of fire prevention cover of right platform
00800 Installation of left front support mudguard
00810 Installation of right front support mudguard
00820 Installation of chock
00830 Installation of battery disconnect box
00840 Installation of engine emergency stop box
01000 Installation of cab
01001 Installation procedure of cab – 1
01002 Installation procedure of cab – 2
01003 Connection of harness under cab – 1
01004 Connection of harness under cab – 2
01005 Connection of harness under cab – 3
01006 Connection of harness under cab – 4
01007 Connection of harness under cab – 5
01008 Connection of harness under cab – 6
01009 Connection of harness under cab – 7
01011 Connection of harness under cab – 9
01012 Connection of harness under cab – 10
01013 Connection of harness under cab – 11
01014 Connection of harness under cab – 12
01015 Connection of harness under cab – 13
01016 Connection of harness under cab – 14
01017 Connection of harness under cab – 15
01018 Connection of harness under cab – 16
01019 Connection of harness under cab – 17
01020 Connection of ground – 1
01021 Connection of ground – 2
01022 Fixing of hydraulic tank hose
01025 Installation of cab – engine harness – 1
01027 Installation of cab – engine harness – 2
01029 Connection of cab – engine harness
01050 Installation of washer tank
01051 Installation procedure of washer tank
01060 Connection of floor column
01100J Installation of KomVision camera (right)
01101J Installation of KomVision camera (left)
01102 Installation of KomVision camera (on step front) – 1
01103 Installation of KomVision camera (on step front) – 2
01105 Connection of payload meter (left)
01500 Wiring of GPS, iridium, and ORBCOMM – 1
01501 Wiring of GPS, iridium, and ORBCOMM – 2
01502 Wiring of GPS, iridium, and ORBCOMM – 3
01503 Wiring of GPS, iridium, and ORBCOMM – 4
01504 Wiring of GPS, iridium, and ORBCOMM – 5
01505 Wiring of GPS, iridium, and ORBCOMM – 6
01506 Wiring of GPS, iridium, and ORBCOMM – 7
01507 Wiring of GPS, iridium, and ORBCOMM – 8
01900 Assembly of ORBCOMM antenna – 1
01901 Assembly of ORBCOMM antenna – 2
01902 Assembly of ORBCOMM antenna – 3
02000 Fixing of ORBCOMM antenna – 1
02001 Fixing of ORBCOMM antenna – 2
02002 Fixing of ORBCOMM antenna – 3
02003 Fixing of ORBCOMM antenna – 4
02004 Fixing of ORBCOMM antenna – 5
02005 Fixing of ORBCOMM antenna – 6
02006 Fixing of ORBCOMM antenna – 7
02007 Fixing of ORBCOMM antenna – 8
02008 Installation of wireless LAN modem
02009 Connection of wireless LAN modem sub
02010 Installation of right support rear cover – 1
02020 Installation of fuel tank ladder
02030 Installation of radiator curtain and limbus
03000 Preparation of body
03001 Installation of body cab guard
03002 Installation of body platform guard
03003 Installation of rear grease piping
03004 Connection of hoist cylinder grease piping
03005 Connection of hoist cylinder piping
03006 Installation of hinge pin
03007 Connection of hoist cylinder
03008 Installation of body mount -1
03009 Installation of body mount -2
03010 Installation procedure of body mount
03011 Installation of rock ejector – 1
03012 Installation of rock ejector – 2
03013 Installation of body mudguard
03014 Installation of safety pin
03015 Installation of closed bolt – 1
03016 Installation of closed bolt – 2
03017 Installation of body positioner sensor rod
03018 Adjustment procedure of angle sensor
03019 Dump control calibration
03020 Adjustment of rear suspension
03021 Sticking of body decal – 1
03022 Sticking of body decal – 2
03023 Sticking of body decal – 3
03024 Sticking of body decal – 4
03100 Installation of body guard
03300 Installation of ABS valve sub assembly
03310 Installation of ABS valve sub assembly tube
03320 Installation of ABS main harness of right front axle part
03330 Installation of ABS main harness of left front axle part
03340 Installation of ABS main harness of under the cab – 1
03350 Installation of ABS main harness of under the cab – 2
03400 Installation of scoreboard harness – 1 – 1
03410 Installation of scoreboard harness – 1 – 3
03420 Installation of scoreboard harness of cab – 1
03430 Installation of scoreboard harness of cab – 2
03440 Installation of scoreboard harness of right platform harness
05000 Sticking of front suspension decal
05001 Sticking of front suspension decal (5AC11)
05010 Sticking of fender decal
05011 Sticking of fender decal EU
06000 KomVision setting
06010 KomVision setting – 1
06020 KomVision setting – 2
06030 KomVision setting – 3
06040 KomVision setting – 4
06050 KomVision setting – 5
06060 KomVision setting – 6
06100 Charging of air conditioner gas
06110 Procedure of installation and adjustment of front suspension
06120 Procedure of installation and adjustment of rear suspension
06130 Air bleeding procedure of brake
06140 Procedure of air bleeding from steering cylinder
06150 Procedure of air bleeding from hoist cylinder
06160 Grease lubrication – 1
06161 Grease lubrication – 2
06170 Adjustment procedure of light optical axis
07000 Replacement of brake cooling filter
09000 Safety-critical section check sheet
09010 Method for checking and inflating tire
C-0010 Preparation of body welding
C-0020 Assembly work of body – 1
C-0030 Assembly work of body – 2
C-0040 Temporary Installation of body
C-0050 Welding of body – 1
C-0060 Welding of body – 2
C-0070 Welding procedure of body – 1
C-0080 Welding procedure of body – 2
C-0090 Turning over of body
C-0100 Welding of body protector – 1
C-0110 Welding of body protector – 2
C-0111 Welding of body protector – 3
C-0120 Weld finishing and painting of body
C-0130 Welding of front body mount bracket
C-0140 Replacement of bracket for installing rock ejector (for failurehandling)
C-0150 Making of scaffolding for welding body protector – 1
C-0151 Making of scaffolding for welding body protector – 2
C-0152 Making of scaffolding for welding body protector – 3
6. Machine check sheet for field assembly
