Komatsu HD1500-8 Dump Truck Field Assembly Service Manual (GEN00162-13)

- Parts overview (main components only)
- Dimensions of main components
- Rough schedule of assembling and welding (for normal disassembly packing)
- Layout of work space
 Facility, jig and consumable parts list
Field assembly instruction
 Oil, grease and coolant
 Amount of oil, grease and coolant
A Rear axle assembly
A Installation of tire and wheel assembly (inner)
A Installation of tire and wheel assembly (outer)
A Bare machine stationary and rear axle connection
A Installation of rear suspension
A Installation of R.H. front support
A Installation of exhaust pipe sub-assembly
A Installation of exhaust pipe sub-assembly – 
A Part No. Part name Q’ty State of parts() --B V-COUPLING Unit shipmentImpact wrenchSocketsInstallation of exhaust pipe sub-assembly – 
A Installation of exhaust pipe fire prevention cover
A Fixing of exhaust pipe
A Installation of exhaust pipe lower cover
A Installation of rear axle rod
A Installation of fuel tank
A Installation of fuel tank
A Installation of front axle assembly (R.H.)
A Installation of front axle assembly (L.H.)
A Installation of hub odometer to front axle assembly (L.H.)
A Installation of tie rod and steering cylinder to front axle (R.H.)
A Installation of tie rod and steering cylinder to front axle (L.H.)
A Fixing of the front axle (R.H.) connector
A Fixing of front axle (L.H.) connector
A Installation of tire and wheel assembly (front)
A Connection of grease hose to rear suspension pin of rear axle
A Fixing of upper rod
A Installation of rear axle rods (lower)
A Installation of transmission – rear axle flow drive shaft
A Installation of rear propeller guard
A ASR valve assembly – rear axle pipe connection
A ASR valve assembly – rear axle pipe connection and fixing
A Connection of fuel hose
A Connection of fuel hose
A Left side pipe installation of auto grease injector sub-assembly
A Left side pipe installation of auto grease injector sub-assembly
A Right side pipe installation of auto grease injector sub-assembly
A Right side pipe installation of auto grease injector sub-assembly
A Pipe installation of auto grease injector sub-assembly
A Pipe connection of front axle (L.H.) oil cooling
A Pipe connection of front axle (R.H.) oil cooling
A Installation of battery isolator
A Installation of battery isolator cover
A Cable wiring of battery isolator
A Cable wiring of battery isolator
A Connection of fuel tank harness
A Connection of front axle (L.H.) and front brake lineaxle (L.H.)
A Connection of front axle (R.H.) and front brake lineaxle (R.H.)
A Grease tube fixing of front axle (L.H.)
A Grease tube fixing of front axle (R.H.)
A Fixing of grease injector hose (R.H.)
A Fixing of grease injector hose (R.H.)
A Fixing of grease injector hose (R.H.)
A Fixing of grease injector hose (L.H.)
A Fixing of grease injector hose (L.H.)
A Fixing of grease injector hose (L.H.)
A Fixing of grease injector hose (L.H.)
A Installation of air cleaner assembly
A Grease tube fixing of front axle (L.H.) upper pin
A Grease tube fixing of front axle (R.H.) upper pin
A Grease tube fixing of front axle (R.H.) lower pin
A Hose connection of hydraulic oil tank
A Hose connection of hydraulic oil tank
A Hose connection of rear cooling pump
A Installation of hydraulic oil tank
A Installation of hydraulic oil tank
A Ground connection of hydraulic oil tank
A Pipe connection of rear cooling pump – hydraulic oil tank
A Cooling line connection of rear axle – brake
A Pipe connection of hydraulic oil tank – transmission
A Hose connection of front cooling pump – hydraulic oil tank
A Suction tube connection of hydraulic oil tank
A Hose connection of hydraulic oil tank – transmission
A Connection of brake cooling tube (L.H.)
A Connection of brake cooling tube (L.H.)
A Wiring connection of battery cable
A Wiring of main harness and breather line
A Wiring of main harness and breather line
A Wiring of breather line
A Wiring of breather line
A Wiring of breather line
A Pump pipe connection of hydraulic oil tank – transmission
A Connection and fixing of transmission – drain hose
A Hose connection of hydraulic oil tank – engine and radiator
A Installation of battery box
A Battery box wiring -
A Battery box wiring -
A Battery box wiring -
A Battery box wiring -
A Connection of R.H. and L.H. front brake lines
A Installation of accumulator
A Connection of accumulator hose
A Connection of accumulator hose at right of battery box -
A Connection of accumulator hose at right of battery box -
A Battery box bottom right piping disaster prevention cover assembly
A Battery box right side protection cover assembly
A Installation of auto grease pump
A Fixing of wiring harness for auto grease pump
A Connection of auto grease pump – main harness
A Connection of auto grease pump – main harness (Graco specification)
A Upper harness connection of front axle (R.H.)
A Installation of engine room switch
A Harness wiring under R.H. platform
A Harness wiring under R.H. platform
A Harness wiring under R.H. platform
A Installation of CAB support
A Installation of CAB support
A Installation of refill control box
A Hose connection of refill control box
A Connection and fixing of heater hose
A Installation of guard bracket under air intake
A Installation of R.H. guard under air intake
A Installation of L.H. guard under air intake
A Installation of L.H. front support
A Installation of R.H. front support
A Installation of air intake
A Installation of air intake
A Installation of air intake
A Installation of air intake
A Fixing and connection of air intake wiring harness
A Installation of bracket upper air intake
A Fixing of air intake tube
A Installation of VHMS box
A Installation of VHMS box
A Installation of diagonal ladder step
A Installation of diagonal ladder step
A Installation of diagonal ladder step
A Installation of diagonal ladder step
A Installation of diagonal ladder step
A Installation of lower step toe guard
A Installation of diagonal ladder step
A Installation of diagonal ladder step
A Installation of diagonal ladder step HAA
A Installation of diagonal ladder step HAB
A Sub-assembly of diagonal ladder step and radar
A Installation of diagonal ladder step
A Installation of reflector box
A Installation of diagonal ladder step HAB
A Sub-assembly of R.H. radar
A Sub-assembly of R.H. radar
A Installation of diagonal ladder step
A Installation of R.H. platform (R.H. support)
A Installation of R.H. platform (R.H. support)
A Installation of mudguard under R.H. platform
A Installation of R.H. side ladder step
A Harness wiring under R.H. platform
A Harness wiring under R.H. platform
A Harness wiring under R.H. platform
A Installation of rear ladder
A Installation of R.H. handrail
A Installation of R.H. handrail
A Installation of side camera
A Installation of side camera HAB
A Installation of CAB assembly
A Installation of radiator
A Installation of R.H. and L.H. rods of radiator
A Adjustment procedure of fan and radiator shroud
A Connection of hose between radiator and oil cooler
A Installation of fan guard
A Installation of radiator piping -
A Installation of radiator piping -
A Installation of radiator piping -
A Installation of radiator piping -
A Installation of radiator piping -
A Fixing of radiator drain hose and installation of cover
A Fixing of radiator drain hose and connection of hydraulic tank hose
A Connection and fixing of air conditioner hose -
A Connection and fixing of air conditioner hose -
A Installation of top hood support
A Installation of top hood
A Battery box bottom left piping disaster prevention cover assembly
A Connection and fixing of heater hose -
A Connection and fixing of heater hose -
A Fixing of radiator hose water tube
A Installation of L.H. radiator guard
A Installation of R.H. radiator guard
A Installation of radiator guard upper cover and handrail
A Installation of radiator grille
A Installation of radiator curtain
A Installation of washer tank
A Installation of CAB assembly
A Installation of CAB step
A Installation of catwalk
A Installation of catwalk
A Installation of catwalk
A Installation of catwalk
A Installation of catwalk toe guards
A Installation of catwalk assembling step
A Mounting of CAB assembly
A Mounting of CAB assembly
A Wiring of L.H. mirror with heater
A Installation of CAB assembly and drain hose
A Main harness and transmission harness wiring
A Wiring procedure between cab and antenna pole 
A Wiring procedure between cab and antenna pole 
A GPS harness and KOMTRAX harness connection
A GPS harness and KOMTRAX harness connection
A GPS harness and KOMTRAX harness connection
A GPS/KOMTRAX/Antenna harness wiring
A GPS/KOMTRAX/Antenna harness wiring
A GPS/KOMTRAX/Antenna harness wiring
A GPS/KOMTRAX/Antenna harness wiring
A Modem-GPS/KOMTRAX/Antenna harness wiring
A Installation of modem cover
A Connection of modem and wireless LAN harness
A Installation of GPS/KOMTRAX/Antenna harness cover
A GPS/KOMTRAX/Antenna harness wiring
A Installation of R.H. platform ORBCOMM pole
A Wiring and installation of R.H. platform antennas
A Wiring and installation of R.H. platform antennas
A GPS/KOMTRAX/Antenna harness wiring
A GPS/KOMTRAX/Antenna harness wiring
A GPS/KOMTRAX/Antenna harness wiring
A GPS/KOMTRAX/Antenna harness wiring
A Fixing of main harness under right CAB
A Fixing of main harness under CAB
A Fixing of main harness under CAB – CN-SUFL
A Fixing of main harness under CAB
A Fixing of main harness under right CAB
A Fixing of main harness under right CAB
A Fixing of main harness under right CAB
A Fixing of main harness under right CAB
A Fixing of main harness under right CAB
A Fixing of main harness under right CAB
A Installation of engine shutdown switch box
A Installation of junction box
A Installation of heater fuse box
A Main harness fixing of front L.H. light support
A Main harness fixing of front L.H. light support
A Main harness fixing of front L.H. light support
A Main harness fixing of front L.H. light support
A Connection of air compressor wiring harness
A Connection of air compressor wiring harness
A Wiring of harness leading to radiator
A Wiring of harness leading to radiator
A Wiring of harness leading to radiator
A Wiring of harness leading to radiator
A Monitor harness wiring (under R.H. platform)
A Installation of ladder lamp
A Wiring of harness leading to R.H. fender lamp
A Installation of protection bracket for harness leading to R.H. fender lamp
A Installation of mudguard
A Installation of rear mudguard for catwalk
A Installation of R.H. platform mudguard
A Installation of L.H. fender
A Installation of L.H. fender
A Installation of R.H. fender
A Installation of R.H. fender
A Installation of L.H. fender mudguard
A Installation of R.H. fender mudguard
A L.H. fender harness wiring
A L.H. fender harness wiring
A L.H. fender harness wiring
A Wiring of R.H. fender working lamp harness
A Wiring of L.H. fender working lamp harness
A Installation of front light covers, L.H. and R.H.
A Installation of L.H. fog lamp
A Installation of R.H. fog lamp
A Installation of catwalk
A Installation of catwalk mirror
A Connection and fixing of wiring harness for L.H. mirror with heater
A Installation of R.H. platform mirror
A Installation of R.H. platform mirror
A Connection and fixing of wiring harness for R.H. mirror with heater
A Installation of transmission under guard
A Installation of cab front step cover
A Installation of covers under the cab
A Installation of covers under the cab
A Installation of quick charge hose
A Installation of quick charge hose
A Installation of quick charge box
A Installation of radiator curtain
A Installation of fire extinguisher
A Installation of fire extinguisher
A Installation of L.H. side cover – 
A Installation of L.H. side cover -
A Installation of L.H. side cover -
A Installation of R.H. side cover – 
A Installation of R.H. side cover – 
A Installation of R.H. side cover -
A Installation of L.H. side cover
A Installation of tire stopper
A Air bleeding procedure of brake
A Starting engine
A Air bleeding of steering cylinders
A Air conditioner gas filling
A Preparation for mounting of dump body
A Preparation for mounting of dump body
A Preparation for mounting of dump body
A Preparation for mounting dump body
A Preparation for mounting dump body
A Preparation for mounting dump body
A Preparation for mounting dump body – Installation of dust seals
A Mounting of dump body
A Mounting of dump body – Removal of extension/ retraction prevention plate
A Mounting of dump body – Adjustment of bottom mount
A Preparation for welding mount on dump body front side
A Mounting of dump body – Welding of body mount
A Mounting of dump body – Welding of dump body heating tube
A Mounting of dump body – Welding of dump body heating tube
A Dump body mounting – Installation of exhaust pipe cover
A Mounting of dump body – Installation of exhaust pipe cover 
A Mounting of dump body – Installation of exhaust pipe cover 
A Dump body mounting – Grease piping
A Dump body mounting – Installation of dump body mudguard
A Fixing of positioner sensor rod
A Installation procedure for dump body angle sensor and lever
A Adjustment procedure of suspension gas – Front
A Adjustment procedure of suspension gas – Rear
A Procedure for bleeding air from hoist cylinder
A KomVision
A KomVision
A KomVision
A KomVision
A KomVision
A Check before starting KomVision
A Sticking tie-off decal
A Sticking dump body tie-off decals – 
A Sticking dump body tie-off decals – 
A Sticking tie-off decals to dump body for compliancewith Australian regulations – 
A Sticking tie-off decals to dump body for compliancewith Australian regulations – 
B Installation of power ladder lower step
B Installation of power ladder lower step handrail
B Fixing handrail of power ladder lower step
B Installation of power ladder
B Installation of power ladder angle sensor
B Installation of power ladder angle sensor cover
B Installation of power ladder handrail
B Installation of power ladder pump piping 
B Installation of power ladder pump piping 
B Installation of power ladder piping cover
B Installation of power ladder upper step
B Installation of diagonal ladder of power ladder
B Installation of emergency ladder of power ladder
B Installation of power ladder handrail
B Installation of emergency ladder gate of power ladder
B Installation of power ladder surrounding monitor
B Connection of power ladder step harness
B Sub-assembly of power ladder step monitor
B Installation of power ladder surrounding monitor 
B Sub-assembly of R.H. monitor
B Sub-assembly of R.H. monitor 
B Installation of step for going up and down
B Installation of power ladder front camera
B Oil refilling of power ladder
B Adjustment of power ladder operation time
C- Preparation of dump body welding
C- Assembly work of dump body
C- Assembly work of dump body
C- Tack welding of dump body
C- Dump body welding 
C- Dump body welding 
C- Dump body welding procedure
C- Dump body welding procedure
C- Turning over of dump body
C- Welding of dump body protector
C- Welding of dump body protector
C- Welding of dump body protector
C- Weld finishing and painting of dump body
C- Preparation of dump body welding (Side extension)
C- Dump body welding – (Side extension)
C- Dump body welding – (Side extension)
C- Dump body welding – (Side extension)
C- Dump body welding – (Side extension)
C- Dump body welding procedure – (Side extension)
C- Dump body welding procedure – (Side extension)
C- Dump body welding procedure – (Side extension)
C- Weld finishing and painting of dump body (Side extension)
– Method for checking and inflating tire
- Parts overview (main components only)
- Dimensions of main components
- Rough schedule of assembling and welding (for normal disassembly packing)
- Layout of work space
 Facility, jig and consumable parts list
Field assembly instruction
 Oil, grease and coolant
 Amount of oil, grease and coolant
 Bare machine stationary and rear axle connection
 Installation of tire and wheel assembly 
 Installation of tire and wheel assembly 
 Installation of diagonal ladder step
 Installation of diagonal ladder step
 Installation of diagonal ladder step
 Installation of diagonal ladder step
 Installation of diagonal ladder step
 Installation of diagonal ladder step
 Installation of diagonal ladder step
S Sub-assembly of diagonal ladder step and radar
 Installation of diagonal ladder step
 Installation of diagonal ladder step
 Installation of R.H. side ladder
 Installation of side camera
 Installation of ladder lamp
 Installation of rear ladder
 Installation of R.H. handrail
 Installation of R.H. handrail 
 Installation of R.H. platform mirror
 Installation of R.H. platform ORBCOMM pole
 Wiring and installation of R.H. platform antennas
 Wiring and installation of R.H. platform antennas
 Installation of R.H. platform mudguard
 Preparation for mounting of CAB assembly
 Installation of CAB assembly
 Installation of CAB assembly
 Installation of CAB assembly 
 Installation of CAB step
 Installation of CAB assembly 
 Installation of washer tank
 Restoration of hood after mounting the CAB assembly
 Installation of catwalk
 Installation of catwalk
 Installation of catwalk
 Installation of catwalk
 Installation of catwalk
 Installation of transmission under guard
 Installation of muffler
 Air bleeding procedure of brake
 Starting engine
 Air bleeding of steering cylinders
 Preparation of mounting of dump body
 Preparation for mounting of dump body 
 Preparation for mounting dump body
 Preparation for mounting dump body 
 Preparation for mounting dump body 
A Preparation for assembling dump body , Installation of dust seals
 Mounting dump body 
 Mounting of dump body -, Removal of extension/retraction prevention plate
 Mounting of dump body (Adjustment of bottom mount)
 Preparation for welding mount on dump body front side
 Mounting dump body , Welding of body mount
 Mounting dump body , Welding of dump body heating tube
 Mounting of dump body – Welding of dump body heating tube
 Dump body mounting – Installation of exhaust pipe cover
 Mounting of dump body – Installation of exhaust pipe cover 
 Mounting of dump body – Installation of exhaust pipe cover 
 Dump body mounting – Grease piping
 Dump body mounting – Installation of dump body mudguard
 Fixing of positioner sensor rod
 Installation procedure for dump body angle sensor and lever
 Adjustment procedure of front suspension gas
 Adjustment procedure of rear suspension gas
 Procedure for bleeding air from hoist cylinder
 KomVision
 KomVision
 KomVision
 KomVision
 KomVision
 Check before starting KomVision
 Method for checking and inflating tire
C- Preparation of dump body welding
C- Assembly work of dump body
C- Assembly work of dump body
C- Tack welding of dump body
C- Dump body welding
C- Dump body welding
C- Dump body welding procedure
C- Dump body welding procedure
C- Turning over of dump body
C- Welding of dump body protector
C- Welding of dump body protector
C- Welding of dump body protector
C- Weld finishing and painting of dump body
Appendix : Machine check sheet for field assembl

Pages: 507
Language: English
Format: PDF

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