Description
Komatsu HD785-8R Dump Truck Field Assembly Manual (GEN00213-06)
Komatsu HD785-8R Dump Truck Index:
. 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
3-3. PARTS OVERVIEW
3-4. DIMENSIONS OF MAIN COMPONENTS
3-5. SPECIFICATIONS
4-1-1. 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 PROCEDUREAND PACKING TAG
ASSEMBLY PROCEDURE
00001R Using fuel, coolant, and lubricating oil corresponding to ambienttemperature
00002R Oil and grease, coolant amount
00003R Lifting and movement of bare machine
00005R Preparation for installation of cab
00010R Installation of left front support
00015R Installation of left front support harness
00017R Preparation for installation of right platform
00020R Installation of right front support
00025R Installation of right diagonal ladder mount
00030R Installation of left rear support
00040R Installation of right rear support and exhaust pipe
00041R Installation of right rear support and exhaust pipe (with bodyheating)
00070R Installation of steering hose
00080R Connection and fixing of steering hose
00082R Installation of steering hose cover
00090R Installation of right front axle assembly
00091R Installation of tie rod – front axle (right)
00095R Sticking of decal on right front axle assembly
00100R Installation of left front axle assembly
00101R Installation of tie rod – front axle (left)
00105R Sticking of decal on left front axle assembly
00110R Installation of right and left front axle steps
00120R Connection and fixing of left front axle sensor
00130R Connection and fixing of right front axle sensor
00135R Connection and fixing of left front axle hose
00140R Connection of front axle brake cooling hose
00145R Connection and fixing of right front axle hose
00150R Installation of left front support step
00160R Connection of rear propeller shaft
00170R Installation of rear propeller shaft guard
00180R Connection of cab – left accumulator hose
00183R Connection of cab brake hose
00185R Connection of air cleaner hose under cab
00190R Installation of right fender
00191R Connection of right fender side lamp harness
00192R Installation of right fender side lamp harness cover
00200R Installation of left fender
00210R Installation of rear axle – 1
00220R Installation of rear axle – 2
00223R Installation of rear axle auto grease piping (machine with auto grease)
00225R Connection of rear axle hose
00230R Connection of rear axle cooling hose
00231R Connection of auto grease and hoist cylinder
00232R Connection and fixing of rear axle harness
00235R Installation of right platform
00237R Installation of right platform mudguard
00240R Installation of cover under right platform – 1
00243R Installation of cover under right platform – 2
00245R Installation of right platform handrail
00250R Connection and fixing of rear suspension oil pressure sensor
00270R Rear axle breather piping (sandy and dusty specification)
00281R Fixing of air conditioner drain hose
00290R Connection of radiator heater hose
00295R Connection of air conditioner hose
00350R Installation of radio antenna – 1
00360R Installation of radio antenna – 2
00400R Installation of diagonal ladder step – 1-1
00402R Installation of diagonal ladder step – 1-2
00410R Installation of diagonal ladder step – 2-1
00415R Installation of diagonal ladder step – 2-2
00420R Installation of diagonal ladder step – 3
00430R Installation of diagonal ladder step – 4
00440R Installation of diagonal ladder step – 5
00445R Installation of diagonal ladder step – 6
00446R Installation of diagonal ladder step – 6 6HH51AC specification
00450R Installation of diagonal ladder step – 7
00460R Installation of diagonal ladder step – 8
00470R Installation of diagonal ladder step – 9
00480R Installation of diagonal ladder step – 10 (without radar)
00485R Installation of diagonal ladder step – 11 (without radar)
00490R Installation of left ladder lamp
00500R Fixing of catwalk under mirror
00520R Connection and fixing of left fender side lamp harness
00530R Installation of battery disconnect cable cover
00570R Installation of step support in front of cab
00580R Installation of catwalk mount – 1
00590R Installation of catwalk mount – 2
00600R Installation of catwalk – 1
00601R Installation of catwalk – 2
00610R Installation of step in front of cab
00620R Installation of catwalk mount cover
00630R Installation of front tire
00640R Installation of rear tire – 1
00650R Installation of rear tire – 2
00655R Installation of front wheel valve
00660R Installation of engine underguard
00670R Installation of transmission underguard
00709R Fixing of KomVision camera harness
00710R Installation of KomVision harness cover (Left)
00712R Installation of KomVision harness cover (Right)
00713R Installation of mudguard for left KomVision camera
00714R Installation of mudguard for right KomVision camera
00765R Installation of right platform sub assembly
00767R Installation of right platform sub assembly mirror
00770R Installation of upper handrail of radiator guard
00775R Installation of radiator guard upper lamp
00780R Installation of fire extinguisher
00790R Installation of fire prevention cover of right platform
00800R Installation of left front support mudguard
00810R Installation of right front support mudguard
00820R Installation of chock
00835R Installation of battery disconnect box (without jump start)
00840R Installation of engine emergency stop box
00900R Connection of front axle auto suspension piping (machine with autosuspension)
00910R Connection of right front axle auto suspension piping (machinewith auto suspension)
00920R Connection of left front axle auto suspension piping (machine withauto suspension)
00930R Connection of front axle auto grease piping (machine with autogrease)
00940R Connection of left front axle auto grease piping (machine with autogrease)
00950R Connection of right front axle auto grease piping (machine withauto grease)
01000R Installation of cab
01001R Installation procedure of cab – 1
01002R Installation procedure of cab – 2
01003R Connection of harness under cab – 1
01004R Connection of harness under cab – 2
01005R Connection of harness under cab – 3
01006R Connection of harness under cab – 4
01007R Connection of harness under cab – 5
01008R Connection of harness under cab – 6
01009R Connection of harness under cab – 7
01011R Connection of harness under cab – 9
01012R Connection of harness under cab – 10
01013R Connection of harness under cab – 11
01014R Connection of harness under cab – 12
01015R Connection of harness under cab – 13
01016R Connection of harness under cab – 14
01017R Connection of harness under cab – 15
01018R Connection of harness under cab – 16
01019R Connection of harness under cab – 17
01020R Connection of ground – 1
01021R Connection of ground – 2
01025R Connection of cab – engine harness – 1
01027R Connection of cab – engine harness – 2
01029R Connection of cab – engine harness – 3
01040R Installation of cover under cab – 1
01041R Installation of cover under cab – 2
01050R Installation of washer tank
01051R Installation procedure of washer tank
01060R Connection of floor column
01061R Connection of floor column – 1 (machine with auto suspension)
01062R Connection of floor column – 2 (machine with auto suspension)
01063R Connection of floor column – 3 (machine with auto suspension)
01100R Installation of KomVision camera (right)
01101R Installation of KomVision camera (left)
01102R Installation of KomVision camera (on step front) – 1
01103R Installation of KomVision camera (on step front) – 2
01105R Connection of payload meter (left)
01200R Installation of fuel tank – 1
01210R Installation of fuel tank – 2
01220R Connection of fuel tank piping
01230R Connection and fixing of fuel tank harness
01240R Connection and fixing of fuel tank harness cover
01250R Installation of tool box
01260R Installation of sling bracket to right and left rear support tie rod
01300R Installation of remote breather upper fuel tank – 1
01305R Installation of remote breather upper fuel tank – 1 (with body heating)
01310R Installation of remote breather upper fuel tank – 1
01320R Installation of remote breather upper fuel tank – 3
01325R Installation of remote breather upper fuel tank – 3 (with body heating)
01330R Installation of remote breather upper fuel tank – 4
01340R Installation of remote breather upper fuel tank – 5 (ABS specification)
01345R Installation of remote breather upper fuel tank – 5
01500R Wiring of GPS and iridium wireless LAN – 1
01501R Wiring of GPS and iridium wireless LAN – 2
01502R Wiring of GPS and iridium wireless LAN – 3
01503R Wiring of GPS and iridium wireless LAN – 4
01504R Wiring of GPS and iridium wireless LAN – 5
01505R Wiring of GPS and iridium wireless LAN – 6
01506R Wiring of GPS and iridium wireless LAN – 7
01900R Fixing of antenna – 1
01901R Fixing of antenna – 2
01902R Fixing of antenna – 3
02000R Fixing of antenna – 1
02001R Fixing of antenna – 2
02002R Fixing of antenna – 3
02003R Fixing of antenna – 4
02004R Fixing of antenna – 5
02005R Fixing of antenna – 6
02006R Fixing of antenna – 7 (Work lamp)
02007R Fixing of antenna – 8 (Work lamp)
02008R Installation of wireless LAN modem
02009R Connection of wireless LAN modem sub
02010R Installation of right support rear cover
02020R Installation of fuel tank ladder
02095R Installation of beacon lamp sub
02100R Installation of beacon lamp
02110R Connection and fixing of beacon lamp
02200R Wiring of right heater mirror harness – 1
02201R Wiring of right heater mirror harness – 2
02202R Installation of right heater mirror (upper)
02203R Installation of right heater mirror (lower)
02204R Wiring of left heater mirror harness
02300R Installation of refill system box
02301R Connection of refill system box
02302R Fixing of refill system piping – 1
02303R Fixing of refill system piping – 2
02304R Fixing of refill system piping – 3
02305R Fixing of refill system piping – 4
02306R Fixing of refill system piping – 5
02307R Fixing of refill system piping – 6
02308R Refill system piping cover – 7
02309R Refill system piping cover – 8
02310R Installation of auto grease right platform
03000R Preparation of body
03001R Installation of body cab guard
03002R Installation of body platform guard
03003R Installation of rear grease piping
03004R Connection of hoist cylinder grease piping
03005R Connection of hoist cylinder piping
03006R Installation of hinge pin
03007R Connection of hoist cylinder
03008R Installation of body mount – 1
03009R Installation of body mount -2
03010R Installation procedure of body mount
03011R Installation of rock ejector – 1
03012R Installation of rock ejector – 2
03013R Installation of body mudguard
03014R Installation of pin
03015R Installation of closed bolt – 1
03016R Installation of closed bolt – 2
03017R Installation of body positioner sensor rod
03018R Adjustment procedure of angle sensor
03019R Dump control calibration
03020R Adjustment of rear suspension
03021R Sticking of body decal – 1
03022R Sticking of body decal – 2
03023R Sticking of body decal – 3
03024R Sticking of body decal – 4
03030R Auto grease piping left side fixed (body)
03040R Auto grease piping right side fixed (body)
03200R Exhaust pipe tube gauging welding
03210R Installation of cover of the exhaust pipe installation part lower
05010R Sticking of fender decal
06000R KomVision setting
06010R KomVision setting – 1
06020R KomVision setting – 2
06030R KomVision setting – 3
06040R KomVision setting – 4
06050R KomVision setting – 5
06060R KomVision setting – 6
06100R Charging of air conditioner gas
06110R Procedure of installation and adjustment of front suspension
06120R Procedure of installation and adjustment of rear suspension
06130R Air bleeding procedure of brake
06140R Procedure of air bleeding from steering cylinder
06150R Procedure of air bleeding from hoist cylinder
06160R Grease lubrication-1
06161R Grease lubrication-2
06170R Light optical axis adjustment procedure
06180R Auto grease operation and adjustment procedure
06190R Refill system operation procedure
07000R Replacement of brake cooling filter
09000R Safety-critical section check sheet
09010R 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-0080Welding 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
Machine check sheet for field assembly
