Komatsu HD785-8E0 Dump Truck Field Assembly Service Manual (GEN00209-07)

FOREWORD
- PRECAUTIONS FOR FIELD ASSEMBLY
- DISPOSAL OF REMOVED PARTS
- ASSEMBLY/WELDING PROCEDURES, NECESSARY EQUIPMENT, AND SCHEDULE
- LAYOUT OF KIT (WORK SPACE LAYOUT)
- PARTS OVERVIEW (ONLY FOR MAIN COMPONENTS)
- DIMENSIONS OF MAIN COMPONENTS
- SPECIFICATIONS
- TOOL LIST FOR FIELD ASSEMBLY
- STANDARD TIGHTENING TORQUE TABLE
- COATING MATERIALS LIST
- SELECTION OF WIRE ROPES USED FOR ASSEMBLY
- SELECTION OF NYLON SLINGS USED FOR ASSEMBLY
- RELATIONSHIP BETWEEN WORK NUMBER OF ASSEMBLY PROCEDUREAND PACKING TAG
- HOW TO SECURE MACHINE
 FIELD ASSEMBLY PROCEDURE
 Using fuel, coolant, and lubricating oil corresponding to ambienttemperature
 Oil and grease, coolant amount
 Lifting and movement of bare machine
 Installation of left front support
 Preparation for installation of cab
 Installation of left front support harness
 Preparation for installation of right platform
 Installation of right front support
 Installation of left rear support
 Installation of right rear support and exhaust pipe
 Installation of right rear support and exhaust pipe (with bodyheating)
 Installation of fire prevention cover under exhaust pipe
 Installation of exhaust pipe (without body heating)
 Installation of exhaust pipe
 Adjustment procedure of exhaust pipe
 Installation of steering hose
 Fixing and connection of steering hose
 Installation of steering hose cover
 Installation of right front axle assembly
 Installation of tie rod – front axle (right)
 Installation of left front axle assembly
 Installation of tie rod – front axle (left)
 Installation of right and left front axle steps
 Fixing and connection of left front axle sensor
 Fixing and connection of right front axle sensor
 Connection and fixing of left front axle hose
 Connection of front axle brake cooling hose
 Connection and fixing of right front axle hose
 Installation of left front support step
 Connection of rear drive shaft
 Installation of rear propeller shaft guard
 Connection of cab – left accumulator hose
 Connection of cab brake hose
 Connection of brake hose under the air cleaner to CAB
 Installation of right fender
 Connection of right fender side lamp
 Installation of cover under right platform
 Installation of left fender
 Connection of left fender side lamp
 Installation of rear axle – 
 Installation of rear axle – 
 Connection of rear axle hose
 Connection of rear axle cooling hose
 Connection and fixing of rear axle harness
 Installation of right platform
 Installation of right platform mudguard
 Fixing and connection of rear suspension oil pressure sensor
 Installation of air conditioner hose fixing bracket
 Fixing of air conditioner drain hose
 Connection of radiator heater hose
 Installation of left payload meter harness
 Installation of radio antenna – 
 Installation of radio antenna – 
 Installation of cover under cab – 
 Installation of under CAB mudguard
 Installation of cover under cab – 
 Installation of battery disconnect box (without jump start)
 Installation of diagonal ladder step – -
 Installation of diagonal ladder step – - (shipping by travel)
 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 – 
 Installation of diagonal ladder step – 
 Installation of diagonal ladder step – 
 Installation of diagonal ladder step – (without radar)
 Fixing of catwalk mirror
 Fixing and connection of right fender side lamp harness
 Fixing and connection of left fender side lamp harness
 Installation of battery isolator cable cover
 Wiring of engine emergency stop box harness
 Installation of cover in front of cab
 Installation of step support in front of cab
 Installation of catwalk mount – 
 Installation of catwalk mount – 
 Installation of catwalk – 
 Installation of catwalk – 
J Installation of step in front of cab
 Installation of catwalk mount cover
 Installation of front tire
 Installation of rear tire – (Inner)
 Installation of rear tire – large bore valve – (Inner)
 Installation of rear tire – 
 Installation of rear tire – large bore valve – 
 Installation of front wheel valve
 Installation of front wheel valve – large bore valve
 Installation of engine underguard
 Installation of transmission underguard
 Installation of mudguard for left KomVision camera
J Installation of mudguard for right KomVision camera
 Fixing of KomVision camera harness
 Installation of KomVision harness cover (Left)
 Installation of KomVision harness cover (Right)
 Wiring of right heater mirror harness – 
 Wiring of right heater mirror harness – 
 Installation of heater mirror (upper)
 Installation of heater mirror (lower)
 Wiring of left heater mirror harness
 Installation of right platform sub assembly
 Installation of right platform sub assembly mirror
 Installation of upper handrail of radiator guard
 Installation of fire extinguisher
 Installation of fire prevention cover of right platform
 Installation of left front support mudguard
 Installation of right front support mudguard
 Installation of chock
 Installation of battery disconnect box
 Installation of engine emergency stop box
 Installation of cab
 Installation procedure of cab – 
 Installation procedure of cab – 
 Connection of harness under cab – 
 Connection of harness under cab – 
 Connection of harness under cab – 
 Connection of harness under cab – 
 Connection of harness under cab – 
 Connection of harness under cab – 
 Connection of harness under cab – 
 Connection of harness under cab – 
 Connection of harness under cab – 
 Connection of harness under cab – 
 Connection of harness under cab – 
 Connection of harness under cab – 
 Connection of harness under cab – 
 Connection of harness under cab – 
 Connection of harness under cab – 
 Connection of harness under cab – 
 Connection of ground – 
 Connection of ground – 
 Fixing of hydraulic tank hose
 Installation of cab – engine harness – 
 Installation of cab – engine harness – 
 Connection of cab – engine harness
 Installation of washer tank
 Installation procedure of washer tank
 Connection of floor column
J Installation of KomVision camera (right)
J Installation of KomVision camera (left)
 Installation of KomVision camera (on step front) – 
 Installation of KomVision camera (on step front) – 
 Connection of payload meter (left)
 Wiring of GPS, iridium, and ORBCOMM – 
 Wiring of GPS, iridium, and ORBCOMM – 
 Wiring of GPS, iridium, and ORBCOMM – 
 Wiring of GPS, iridium, and ORBCOMM – 
 Wiring of GPS, iridium, and ORBCOMM – 
 Wiring of GPS, iridium, and ORBCOMM – 
 Wiring of GPS, iridium, and ORBCOMM – 
 Wiring of GPS, iridium, and ORBCOMM – 
 Assembly of ORBCOMM antenna – 
 Assembly of ORBCOMM antenna – 
 Assembly of ORBCOMM antenna – 
 Fixing of ORBCOMM antenna – 
 Fixing of ORBCOMM antenna – 
 Fixing of ORBCOMM antenna – 
 Fixing of ORBCOMM antenna – 
 Fixing of ORBCOMM antenna – 
 Fixing of ORBCOMM antenna – 
 Fixing of ORBCOMM antenna – 
 Fixing of ORBCOMM antenna – 
 Installation of wireless LAN modem
 Connection of wireless LAN modem sub
 Installation of right support rear cover
 Installation of fuel tank ladder
 Installation of radiator curtain and limbus
 Preparation of body
 Installation of body cab guard
 Installation of body platform guard
 Installation of rear grease piping
 Connection of hoist cylinder grease piping
 Connection of hoist cylinder piping
 Installation of hinge pin
 Connection of hoist cylinder
 Installation of body mount -
 Installation of body mount -
 Installation procedure of body mount
 Installation of rock ejector – 
 Installation of rock ejector – 
 Installation of body mudguard
 Installation of safety pin
 Installation of closed bolt – 
 Installation of closed bolt – 
 Installation of body positioner sensor rod
 Adjustment procedure of angle sensor
 Dump control calibration
 Adjustment of rear suspension
 Sticking of body decal – 
 Sticking of body decal – 
 Sticking of body decal – 
 Sticking of body decal – 
 Installation of body guard
 Installation of ABS valve sub assembly
 Installation of ABS valve sub assembly tube
 Installation of ABS main harness of right front axle part
 Installation of ABS main harness of left front axle part
 Installation of ABS main harness of under the cab – 
 Installation of ABS main harness of under the cab – 
 Installation of scoreboard harness – – 
 Installation of scoreboard harness – – 
 Installation of scoreboard harness of cab – 
 Installation of scoreboard harness of cab – 
 Installation of scoreboard harness of right platform harness
 Sticking of front suspension decal
 Sticking of front suspension decal (AC)
 Sticking of fender decal
 Sticking of fender decal EU
 KomVision setting
 KomVision setting – 
 KomVision setting – 
 KomVision setting – 
 KomVision setting – 
 KomVision setting – 
 KomVision setting – 
 Charging of air conditioner gas
 Procedure of installation and adjustment of front suspension
 Procedure of installation and adjustment of rear suspension
 Air bleeding procedure of brake
 Procedure of air bleeding from steering cylinder
 Procedure of air bleeding from hoist cylinder
 Grease lubrication – 
 Grease lubrication – 
 Adjustment procedure of light optical axis
 Replacement of brake cooling filter
 Safety-critical section check sheet
 Method for checking and inflating tire
C- Preparation of body welding
C- Assembly work of body – 
C- Assembly work of body – 
C- Temporary Installation of body
C- Welding of body – 
C- Welding of body – 
C- Welding procedure of body – 
C- Welding procedure of body – 
C- Turning over of body
C- Welding of body protector – 
C- Welding of body protector – 
C- Welding of body protector – 
C- Weld finishing and painting of body
C- Welding of front body mount bracket
C- Replacement of bracket for installing rock ejector (for failurehandling)
C- Making of scaffolding for welding body protector – 
C- Making of scaffolding for welding body protector – 
C- Making of scaffolding for welding body protector – 
 Machine check sheet for field assembly

Pages: 373
Language: English
Format: PDF

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