Komatsu HD785-5 (SN from 04001) and HD785-5-LC (SN from A10144) Rigid Dump Trucks Field Assembly Manual (GEN00027-03)

Illustrated factory Field Assembly Manual for Komatsu Rigid Dump Trucks Models HD785-5 and HD785-5-LC.

This manual will assist you in for your rigid dump truck.
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Covered Models:
   HD785-5 (SN: 04001-)
   HD785-5-LC (SN: A10144-)

Format: PDF, 204 pages
Language: English
Table of Contents:
   Front Axle, F/T, Chassis, HD785-5 (common to all specifi cations)
   Tire Assembly (including Tires), Rear Axle, HD785-5
   R.H. Platform, Cabin, HD785-5
   Body Assembly (Including Body), HD785-5
   LIST OF JIGS, TOOLS, AND CONSUMABLES FOR FIELD ASSEMBLING (1/3)
   LIST OF JIGS, TOOLS, AND CONSUMABLES FOR FIELD ASSEMBLING (2/3)
   LIST OF JIGS, TOOLS, AND CONSUMABLES FOR FIELD ASSEMBLING (3/3)
   LIST OF TOUCH-UP COATING ON BODY FOR OVERSEAS SPECIFICATIONS
   SKETCHES OF SPECIAL TOOLS
   MAN-HOURS, WORKERS NEEDED FOR LOCAL ASSEMBLY
   ASSEMBLING PROCEDURES ON SITE
      LIFTING AND MOUNTING REAR AXLE ASSEMBLY
      LIFTING CHASSIS ASSEMBLY
      TRANSFERRING CHASSIS ASSEMBLY ONTO REAR AXLE ASSEMBLY
      CONNECTING RODS TO REAR AXLE SUSPENSION
      PLACING MOUNT FOR FRONT SIDE
      CONNECTING REAR AXLE AND PARKING BRAKE LINE
      LIFTING FRONT AXLE ASSEMBLY
      ASSEMBLING FRONT AXLE
      CONNECTING TIE ROD OF STEERING CYLINDER
      CONNECTING FRONT AXLE HOSES
      INSTALLING STEPS ON A-SHAPED ARM AND BUMPER
      INSTALLING FRONT TIRES
      INSTALLING PROPELLER SHAFT
      INSTALLING FUEL TANK (1/2)
      INSTALLING FUEL TANK (2/2)
      INSTALLING LEFT- AND RIGHTHAND STAYS OF FRAME
      INSTALLING LEFT- AND RIGHTHAND FENDERS
      INSTALLING FRONT SUPPORTS
      INSTALLATION OF FRONT SUPPORT (-40 C SPECIFICATION FOR POLYUS)
      INSTALLATION OF FRONT SUPPORT (DIAGONAL LADDER + LARGE-CAPACITY AIR CLEANER SPECIFICATION)
      INSTALLATION OF AIR CLEANER ASSEMBLY INDICATOR HOSES (LARGE-CAPACITY AIR CLEANER SPECIFICATION)
      INSTALLATION OF RIGHT FRONT SUPPORT AIR CLEANER ASSEMBLY (LARGE-CAPACITY AIR CLEANER SPECIFICATION)
      CONNECTING STEERING OIL LINE
      CONNECTION OF AIR CLEANER PIPING (LARGE-CAPACITY AIR CLEANER SPECIFICATION)
      REMOVING ENGINE HOOD
      INSTALLING RIGHT-HAND PLATFORM HANDRAIL
      INSTALLING RIGHT-HAND PLATFORM
      FIXING OF AIR CLEANER PIPING (LARGE-CAPACITY AIR CLEANER SPECIFICATION)
      WIRING ALONG RIGHT-HAND PLATFORM SIDE
      WIRING IN BATTERY BOX
      INSTALLATION OF DIAGONAL LADDER (1/3) (DIAGONAL LADDER + LARGE-CAPACITY AIR CLEANER SPECIFICATION)
      INSTALLATION OF DIAGONAL LADDER (2/3) (DIAGONAL LADDER + LARGE-CAPACITY AIR CLEANER SPECIFICATION)
      INSTALLATION OF DIAGONAL LADDER (3/3) (DIAGONAL LADDER + LARGE-CAPACITY AIR CLEANER SPECIFICATION)
      REPLACING SIDE BRACKET OF CABIN
      INSTALLING HANDRAIL OF CABIN
      INSTALLING CABIN
      CONNECTING STEERING COLUMN
      CLAMPING DRAIN HOSE OF AIR CONDITIONER
      INSTALLING ROPS AND PAYLOAD LAMP
      CONNECTING DUMP CONTROL
      INSTALLING AIR INTAKE (1/2)
      INSTALLING AIR INTAKE (2/2)
      INSTALLING AIR INTAKE (1/2) (FRONT AIR INTAKE SPECIFICATION)
      INSTALLING EXHAUST PIPE
      DRAWING HARNESS INTO INSIDE OF CABIN
      CONNECTING HARNESSES INSIDE CABIN (1/2)
      CONNECTING HARNESSES INSIDE CABIN (2/2)
      CONNECTING AIR CONDITIONER HOSES
      INSTALLING WASHER TANK
      INSTALLING AND CONNECTING AIR HORN
      WIRING AROUND CABIN (1/2)
      WIRING AROUND CABIN (2/2)
      INSTALLATION AND CONNECTION OF FUEL FILTER (-40 C SPECIFICATION FOR POLYUS)
      CONNECTING RIGHT-HAND FRONT BRAKE AND RADIATOR SURGE TANK
      WIRING FOR HEAD LAMP
      CONNECTING AIR CHARGE LINE
      AIR PIPING
      CONNECTING LEFT-HAND FRONT BRAKE
      INSTALLING PARTS AROUND HOOD
      CHECKING FOR OIL AND COOLING WATER
      FILLING GAS INTO AIR CONDITIONER
      BLEEDING AIR FROM BRAKE
      REMOVING PARTS FROM HOST CYLINDER AFTER TRANSPORTATION
      EQUIPPING MACHINE BODY
      INSTALLING GREASE TUBES ON HOIST CYLINDER
      ADJUSTMENT OF BODY BOTTOM MOUNT
      ADJUSTMENT OF BODY POSITIONER
      WELDING BY DETERMINING DIMENSIONS WITH ACTUAL PARTS (BODY FRONT MOUNT)
      WELDING BY DETERMINING DIMENSIONS WITH ACTUAL PARTS (SWING PREVENTION OF BODY)
      WELDING BY DETERMINING DIMENSIONS WITH ACTUAL PARTS (EXHAUST FLANGE)
      INSTALLING BODY SEATING SWITCH
      INSTALLING BODY ACCESSORIES
      PAINTING
      BODY STOPPER PINS
      ADJUSTMENT OF SUSPENSION
      SMOOTHING OF FLOATING SEAL
   PROCEDURE FOR WELDING AND ASSEMBLING THREE SEPARATED BODY PARTS
   WORK PROCEDURES FOR TURNING OVER THE BODY
   mm transportation posture (If equipped)
   FIELD ASSEMBLY INSPECTION REPORT