Komatsu HD785-8R Dump Truck Field Assembly Service Manual (GEN00213-06)

FOREWORD
- PRECAUTIONS FOR FIELD ASSEMBLY
- DISPOSAL OF REMOVED PARTS
- ASSEMBLY/WELDING PROCEDURES, NECESSARY EQUIPMENT, AND SCHEDULE
- LAYOUT OF KIT
- PARTS OVERVIEW
- 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
ASSEMBLY PROCEDURE
R Using fuel, coolant, and lubricating oil corresponding to ambienttemperature
R Oil and grease, coolant amount
R Lifting and movement of bare machine
R Preparation for installation of cab
R Installation of left front support
R Installation of left front support harness
R Preparation for installation of right platform
R Installation of right front support
R Installation of right diagonal ladder mount
R Installation of left rear support
R Installation of right rear support and exhaust pipe
R Installation of right rear support and exhaust pipe (with bodyheating)
R Installation of steering hose
R Connection and fixing of steering hose
R Installation of steering hose cover
R Installation of right front axle assembly
R Installation of tie rod – front axle (right)
R Sticking of decal on right front axle assembly
R Installation of left front axle assembly
R Installation of tie rod – front axle (left)
R Sticking of decal on left front axle assembly
R Installation of right and left front axle steps
R Connection and fixing of left front axle sensor
R Connection and fixing of right front axle sensor
R Connection and fixing of left front axle hose
R Connection of front axle brake cooling hose
R Connection and fixing of right front axle hose
R Installation of left front support step
R Connection of rear propeller shaft
R Installation of rear propeller shaft guard
R Connection of cab – left accumulator hose
R Connection of cab brake hose
R Connection of air cleaner hose under cab
R Installation of right fender
R Connection of right fender side lamp harness
R Installation of right fender side lamp harness cover
R Installation of left fender
R Installation of rear axle – 
R Installation of rear axle – 
R Installation of rear axle auto grease piping (machine with auto grease)
R Connection of rear axle hose
R Connection of rear axle cooling hose
R Connection of auto grease and hoist cylinder
R Connection and fixing of rear axle harness
R Installation of right platform
R Installation of right platform mudguard
R Installation of cover under right platform – 
R Installation of cover under right platform – 
R Installation of right platform handrail
R Connection and fixing of rear suspension oil pressure sensor
R Rear axle breather piping (sandy and dusty specification)
R Fixing of air conditioner drain hose
R Connection of radiator heater hose
R Connection of air conditioner hose
R Installation of radio antenna – 
R Installation of radio antenna – 
R Installation of diagonal ladder step – -
R Installation of diagonal ladder step – -
R Installation of diagonal ladder step – -
R Installation of diagonal ladder step – -
R Installation of diagonal ladder step – 
R Installation of diagonal ladder step – 
R Installation of diagonal ladder step – 
R Installation of diagonal ladder step – 
R Installation of diagonal ladder step – HHAC specification
R Installation of diagonal ladder step – 
R Installation of diagonal ladder step – 
R Installation of diagonal ladder step – 
R Installation of diagonal ladder step – (without radar)
R Installation of diagonal ladder step – (without radar)
R Installation of left ladder lamp
R Fixing of catwalk under mirror
R Connection and fixing of left fender side lamp harness
R Installation of battery disconnect cable cover
R Installation of step support in front of cab
R Installation of catwalk mount – 
R Installation of catwalk mount – 
R Installation of catwalk – 
R Installation of catwalk – 
R Installation of step in front of cab
R Installation of catwalk mount cover
R Installation of front tire
R Installation of rear tire – 
R Installation of rear tire – 
R Installation of front wheel valve
R Installation of engine underguard
R Installation of transmission underguard
R Fixing of KomVision camera harness
R Installation of KomVision harness cover (Left)
R Installation of KomVision harness cover (Right)
R Installation of mudguard for left KomVision camera
R Installation of mudguard for right KomVision camera
R Installation of right platform sub assembly
R Installation of right platform sub assembly mirror
R Installation of upper handrail of radiator guard
R Installation of radiator guard upper lamp
R Installation of fire extinguisher
R Installation of fire prevention cover of right platform
R Installation of left front support mudguard
R Installation of right front support mudguard
R Installation of chock
R Installation of battery disconnect box (without jump start)
R Installation of engine emergency stop box
R Connection of front axle auto suspension piping (machine with autosuspension)
R Connection of right front axle auto suspension piping (machinewith auto suspension)
R Connection of left front axle auto suspension piping (machine withauto suspension)
R Connection of front axle auto grease piping (machine with autogrease)
R Connection of left front axle auto grease piping (machine with autogrease)
R Connection of right front axle auto grease piping (machine withauto grease)
R Installation of cab
R Installation procedure of cab – 
R Installation procedure of cab – 
R Connection of harness under cab – 
R Connection of harness under cab – 
R Connection of harness under cab – 
R Connection of harness under cab – 
R Connection of harness under cab – 
R Connection of harness under cab – 
R Connection of harness under cab – 
R Connection of harness under cab – 
R Connection of harness under cab – 
R Connection of harness under cab – 
R Connection of harness under cab – 
R Connection of harness under cab – 
R Connection of harness under cab – 
R Connection of harness under cab – 
R Connection of harness under cab – 
R Connection of harness under cab – 
R Connection of ground – 
R Connection of ground – 
R Connection of cab – engine harness – 
R Connection of cab – engine harness – 
R Connection of cab – engine harness – 
R Installation of cover under cab – 
R Installation of cover under cab – 
R Installation of washer tank
R Installation procedure of washer tank
R Connection of floor column
R Connection of floor column – (machine with auto suspension)
R Connection of floor column – (machine with auto suspension)
R Connection of floor column – (machine with auto suspension)
R Installation of KomVision camera (right)
R Installation of KomVision camera (left)
R Installation of KomVision camera (on step front) – 
R Installation of KomVision camera (on step front) – 
R Connection of payload meter (left)
R Installation of fuel tank – 
R Installation of fuel tank – 
R Connection of fuel tank piping
R Connection and fixing of fuel tank harness
R Connection and fixing of fuel tank harness cover
R Installation of tool box
R Installation of sling bracket to right and left rear support tie rod
R Installation of remote breather upper fuel tank – 
R Installation of remote breather upper fuel tank – (with body heating)
R Installation of remote breather upper fuel tank – 
R Installation of remote breather upper fuel tank – 
R Installation of remote breather upper fuel tank – (with body heating)
R Installation of remote breather upper fuel tank – 
R Installation of remote breather upper fuel tank – (ABS specification)
R Installation of remote breather upper fuel tank – 
R Wiring of GPS and iridium wireless LAN – 
R Wiring of GPS and iridium wireless LAN – 
R Wiring of GPS and iridium wireless LAN – 
R Wiring of GPS and iridium wireless LAN – 
R Wiring of GPS and iridium wireless LAN – 
R Wiring of GPS and iridium wireless LAN – 
R Wiring of GPS and iridium wireless LAN – 
R Fixing of antenna – 
R Fixing of antenna – 
R Fixing of antenna – 
R Fixing of antenna – 
R Fixing of antenna – 
R Fixing of antenna – 
R Fixing of antenna – 
R Fixing of antenna – 
R Fixing of antenna – 
R Fixing of antenna – (Work lamp)
R Fixing of antenna – (Work lamp)
R Installation of wireless LAN modem
R Connection of wireless LAN modem sub
R Installation of right support rear cover
R Installation of fuel tank ladder
R Installation of beacon lamp sub
R Installation of beacon lamp
R Connection and fixing of beacon lamp
R Wiring of right heater mirror harness – 
R Wiring of right heater mirror harness – 
R Installation of right heater mirror (upper)
R Installation of right heater mirror (lower)
R Wiring of left heater mirror harness
R Installation of refill system box
R Connection of refill system box
R Fixing of refill system piping – 
R Fixing of refill system piping – 
R Fixing of refill system piping – 
R Fixing of refill system piping – 
R Fixing of refill system piping – 
R Fixing of refill system piping – 
R Refill system piping cover – 
R Refill system piping cover – 
R Installation of auto grease right platform
R Preparation of body
R Installation of body cab guard
R Installation of body platform guard
R Installation of rear grease piping
R Connection of hoist cylinder grease piping
R Connection of hoist cylinder piping
R Installation of hinge pin
R Connection of hoist cylinder
R Installation of body mount – 
R Installation of body mount -
R Installation procedure of body mount
R Installation of rock ejector – 
R Installation of rock ejector – 
R Installation of body mudguard
R Installation of pin
R Installation of closed bolt – 
R Installation of closed bolt – 
R Installation of body positioner sensor rod
R Adjustment procedure of angle sensor
R Dump control calibration
R Adjustment of rear suspension
R Sticking of body decal – 
R Sticking of body decal – 
R Sticking of body decal – 
R Sticking of body decal – 
R Auto grease piping left side fixed (body)
R Auto grease piping right side fixed (body)
R Exhaust pipe tube gauging welding
R Installation of cover of the exhaust pipe installation part lower
R Sticking of fender decal
R KomVision setting
R KomVision setting – 
R KomVision setting – 
R KomVision setting – 
R KomVision setting – 
R KomVision setting – 
R KomVision setting – 
R Charging of air conditioner gas
R Procedure of installation and adjustment of front suspension
R Procedure of installation and adjustment of rear suspension
R Air bleeding procedure of brake
R Procedure of air bleeding from steering cylinder
R Procedure of air bleeding from hoist cylinder
R Grease lubrication-
R Grease lubrication-
R Light optical axis adjustment procedure
R Auto grease operation and adjustment procedure
R Refill system operation procedure
R Replacement of brake cooling filter
R Safety-critical section check sheet
R 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: 389
Language: English
Format: PDF

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