Komatsu HD785-7 (SN from 30001) Rigid Dump Trucks (Japan) Field Assembly Manual (GEN00119-01)

Illustrated factory Field Assembly Manual for Komatsu Rigid Dump Trucks Models HD785-7.

This manual will assist you in for your rigid dump truck.
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Covered Models (Japan):
   HD785-7 (SN: 30001-)

Format: PDF, 221 pages
Language: English
Table of Contents:
   Outline of division (Only main components)
   Dimensions of main components
   Layout of work space
   Rough schedule of assembly and welding
   List of jigs, tools, and consumables for field assembling
   Assembly process
      Oil, grease, and coolant
      Levels of oil, grease, and coolant
      Positioning rear axle assembly
      Slinging and moving of bare machine
      Connection of rod and rear suspension
      Positioning bare machine
      Connection of rear axle cooling hose
      Connection of rear axle brake hose
      Connection of rear axle brake hose (ASR specification: If equipped)
      Connection of valve sub-assembly wiring harness (ASR specification: If equipped)
      Connection and fixing of piping going to rear axle (Sand terrain/ASR specification: If equipped)
      Connection and fixing of rear grease piping and supply of grease
      Preparation for installing front axle
      Installation of front axle
      Connection of front axle suspension pressure sensor
      Connection of front axle wheel speed sensor (ABS specification: If equipped)
      Connection of steering cylinder and tie rod
      Connection of front axle brake cooling hoses
      Connection of front axle brake hoses
      Connection of front axle auto suspension piping
      Fixing of front axle auto suspension piping
      Fixing of front axle auto grease piping (If equipped: Auto grease specification)
      Connection of left front axle auto grease piping (If equipped: Auto grease specification)
      Connection of right front axle auto grease piping (If equipped: Auto grease specification)
      Installation of bumper and front axle steps
      Installation of front axle step (EU specification)
      Installation of front axle step
      Installation of front axle step: Diagonal ladder specification (If equipped)
      Installation of tire and wheel assembly
      Installation of drive shaft
      Installation of oil quick charge box (If equipped: Oil quick charge specification)
      Installation of fuel tank wiring harness cover
      Installation of toolbox and tool kit
      Installation of fuel tank step (If equipped)
      Installation of rear support
      Installation of rear support (Muffler specification: If equipped)
      Installation of rear support (ABS specification: If equipped)
      Installation of rear support (Sand terrain specification: If equipped)
      Installation of muffler
      Installation of muffler (Body heating-less/Exhaust selector box specification: If equipped)
      Installation of fire prevention cover
      Installation of front support
      Installation of front support (Fog lamp specification: If equipped)
      Installation of front support (Fog lamp, beacon lamp, HID headlamp specification: If equipped)
      Installation of steering valve
      Preparation for installing cab
      Installation of cab
      Connection of ABS piping (If equipped)
      Connection of column
      Installation of washer tank
      Connection of cab wiring
      Connection of cab wiring (ASR/ABS specification: If equipped)
      Connection of engine prelubrication harness to cab (If equipped: Engine prelubrication specification)
      Connection and fixing of engine compartment lamp wiring harness (If equipped)
      Connection of auto grease harness to cab (If equipped: Auto grease specification)
      Connection of engine stop harness to cab (If equipped: Engine emergency stop specification)
      Installation and fixing of steering hoses
      Fixing of air conditioner drain hose
      Installation of steering hose cover
      Connection of air conditioner and heater hoses
      Connection of cab floor wiring
      Fixing of ASR/ABS wiring harness (If equipped)
      Connection and fixing of ABS wiring harness (ABS specification: If equipped)
      Installation of cover under cab
      Wiring of front glass with heater wire (If equipped)
      Installation of cab seal
      Installation of ambient temperature sensor wiring harness
      Installation of undercab wiring harness connector
      Connection and fixing of rear view camera wiring harness (if equipped)
      Installation of hand rail and mirror to the R.H. platform assembly
      Installation of right fender
      Installation of right fender (If equipped: Body heating-less muffler specification)
      Installation of fuel tank quick charge-less hose (If equipped)
      Installation of fuel tank quick chargeless hose: Muffler specification (If equipped: muffler specification)
      Assembly of diagonal ladder (if equipped)
      Installation of cab step: Diagonal ladder specification (if equipped)
      Installation of diagonal ladder
      Installation of cab step
      Installation of L.H. under view mirror (If equipped)
      Installation of fire extinguisher (If equipped)
      Installing radio antenna and fixing its cable
      Installation of L.H. fender
      Installation of left side mudguard
      Installation of grille guard
      Installation of left payload lamp (If equipped)
      Installation of left side lamp (If equipped)
      Installation of right payload lamp (If equipped)
      Installation of right side lamp (If equipped)
      Installation of left fender side lamp wiring harness (If equipped)
      Installation of right fender side lamp wiring harness (If equipped)
      Installation of right fender side lamp wiring harness. (If equipped: Body heating-less muffler, exhaust gas selector box muffler specification)
      Installation of KOMTRAX (If equipped)
      Fixing of ORBCOMM antenna (If equipped)
      Connection and fixing of harness and hose going to auto grease pump -1 (If equipped: Auto grease specification)
      Connection and fixing of harness and hose going to auto grease pump - 2 (If equipped: Auto grease specification)
      Removal of hoist cylinder fixing bracket
      Connection of hoist cylinder piping
      Welding of body
      Sticking of body decal
      Supply of oil
      Slinging of body
      Installation of hinge pin
      Connecting hoist cylinder
      Hoist cylinder grease piping
      Fixing of auto grease piping to body (If equipped: Auto grease specification)
      Installation of field welding protection cover
      Installation of body mount
      Procedure for adjusting body mount shim
      Field welding of exhaust tube
      Assembly of body heater cover
      Installation of poke ejector
      Installation of poke ejector storage pin
      Installation of body mudguard
      Installation of body lock pin
      Installation of transmission underguard
      Installation of front handle
      Connection of dump sensor
      Procedure for adjusting dump sensor
      Calibrating dump control
      Adjustment of optical axis of light
      Bleeding air from brake
      Bleeding air from brake of ASR specification (ASR specification: If equipped)
      Bleeding air from ABS circuit (ABS specification: If equipped)
      Adjusting suspension
      Charging air conditioner with refrigerant
      Fitting of floating seal
      Painting
      Touchup
      Sticking of front axle decal
      Operating procedure of prelubrication system (If equipped: Engine prelubrication specification)
      Installation of chocks (If equipped)
      Installation of radiator curtain (If equipped)
      Installation and connection of beacon lamp (If equipped: Yellow beacon lamp specification)
      Assembly of power ladder step
      Refilling power ladder with oil
      Adjustment of power ladder operating time
      Installation of additional under view mirror
   Adjustment procedure
      T-0010 Bleeding air from fuel circuit 1 (If equipped: Extra low-grade fuel specification)
      T-0020 Bleeding air from fuel circuit 2 (If equipped: Extra low-grade fuel specification)
      T-0030 Setting of machine monitor
      T-0040 Selection of machine model
      T-0050 Selection of optional component
      T-0060 Selection of option
      T-0070 Option setting/no-setting selection screen - Saving of change of option selection
      T-0080 OFF setting of corrosion resistor with maintenance monitor
      T-0090 Adjustment of body positioner sensor
      T-0100 Deletion of electrical system fault history (1)
      T-0110 Deletion of electrical system fault history (2)
   Welding procedure
      C-0010 Preparation of welding body
      C-0020 Assembly of split body (1/2)
      C-0030 Assembly of split body (2/2)
      C-0040 Tack welding body
      C-0050 Welding body (1/2)
      C-0060 Welding body (2/2)
      C-0070 Welding body instruction (1/2)
      C-0080 Welding body instruction (2/2)
      C-0090 Turn over the body
      C-0100 Welding body protector (1/2)
      C-0110 Welding body protector (2/2)
      C-0120 Finishing and painting welded parts of body
      C-0130 Welding front body mount bracket
   Appendix
      Field assembly inspection report