Field Assembly HD787!7!7001 Up

GEN00058-07
Field Assembly Instruction
DUMP TRUCK
HD785 -7
SERIAL NUMBERS
7001
and up
CONTENTS
1. Outline of division (Only main components)................................................................................................. 1 2. Dimensions of main components ................................................................................................................. 2 3. Layout of work space ................................................................................................................................... 3 4. Rough schedule of assembly and welding ................................................................................................... 4 5. List of jigs, tools, and consumables for field assembling............................................................................. 9
CONTENTS
6. Assembly process No.
No. 0010 Oil, grease, and coolant 0020 Levels of oil, grease, and coolant 0030 Positioning rear axle assembly 0040 Slinging and moving of bare machine 0050 Connection of rod and rear suspension 0060 Positioning bare machine 0070 Connection of rear axle cooling hose 0080 Connection of rear axle brake hose 0085 Connection of rear axle brake hose (ASR specification: If equipped) 0086 Connection of valve sub-assembly wiring harness (ASR specification: If equipped) 0087 Connection and fixing of piping going to rear axle (Sand terrain/ASR specification: If equipped) 0090 Connection and fixing of rear grease piping and supply of grease 0100 Preparation for installing front axle 0110 Installation of front axle 0120 Connection of front axle suspension pressure sensor 0125 Connection of front axle wheel speed sensor (ABS specification: If equipped) 0130 Connection of steering cylinder and tie rod 0140 Connection of front axle brake cooling hoses 0150 Connection of front axle brake hoses 0160 Connection of front axle auto suspension piping 0165 Fixing of front axle auto suspension piping 0166 Fixing of front axle auto grease piping (If equipped: Auto grease specification) 0167 Connection of left front axle auto grease piping (If equipped: Auto grease specification) 0168 Connection of right front axle auto grease piping (If equipped: Auto grease specification) 0170 Installation of bumper and front axle steps 0171 Installation of front axle step (EU specification) 0180 Installation of tire and wheel assembly 0190 Installation of drive shaft 0200 Installation of oil quick charge box (If equipped: Oil quick charge specification) 0260 Installation of fuel tank wiring harness cover 0270 Installation of toolbox and tool kit 0275 Installation of fuel tank step (If equipped) 0280 Installation of rear support 0281 Installation of rear support (Muffler specification: If equipped) 0282 Installation of rear support (ABS specification: If equipped) 0283 Installation of rear support (Sand terrain specification: If equipped) 0290 Installation of muffler 0291 Installation of muffler (Body heating-less/Exhaust selector box specification: If equipped) 0300 Installation of fire prevention cover 0310 Installation of front support 0315 Installation of front support (Fog lamp specification: If equipped) 0317 Installation of front support (Fog lamp, beacon lamp, HID headlamp specification: If equipped) 0320 Installation of steering valve 0330 Preparation for installing cab 0340 Installation of cab 0345 Connection of ABS piping (If equipped) 0350 Connection of column 0355 Installation of washer tank 0360 Connection of cab piping 0370 Connection of cab wiring 0375 Connection of cab wiring (ASR/ABS specification: If equipped) 0376 Connection of engine prelubrication harness to cab (If equipped: Engine prelubrication specification) 0377 Connection and fixing of engine compartment lamp wiring harness (if equipped) 0378 Connection of auto grease harness to cab (If equipped: Auto grease specification) 0379 Connection of engine stop harness to cab (If equipped: Engine emergency stop specification) 0380 Installation and fixing of steering hoses Item Page 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71
CONTENTS
No. 0385 Fixing of air conditioner drain hose 0390 Installation of steering hose cover 0395 Connection of air conditioner and heater hoses 0400 Connection of cab floor wiring 0405 Fixing of ASR/ABS wiring harness (If equipped) 0406 Connection and fixing of ABS wiring harness (ABS specification: If equipped) 0410 Installation of cover under cab 0415 Wiring of front glass with heater wire (If equipped) 0420 Installation of cab seal 0430 Installation of ambient temperature sensor wiring harness 0440 Installation of undercab wiring harness connector 0445 Connection and fixing of rear view camera wiring harness (if equipped) 0450 Installation of R.H platform assembly 0470 Installation of right fender 0472 Installation of right fender (If equipped: Body heating-less muffler specification) 0475 Installation of fuel tank quick charge-less hose (If equipped) 0476 Installation of fuel tank quick chargeless hose: Muffler specification (If equipped: muffler specification) 0480 Installation of cab step 0481 Assembly of diagonal ladder (if equipped) 0482 Installation of cab step: Diagonal ladder specification (if equipped) 0483 Installation of diagonal ladder 1 (if equipped) 0484 Installation of diagonal ladder 2 (if equipped) 0485 Installation of diagonal ladder 3 (if equipped) 0486 Installation of diagonal ladder (EU specification) 0487 Installation of diagonal ladder-2 (EU specification) 0488 Installation of diagonal ladder-3 (EU specification) 0490 Installation of L.H underview mirror (If equipped) 0500 Installation of fire extinguisher (If equipped) 0510 Installing radio antenna and fixing its cable 0520 Installation of L.H fender 0530 Installation of left side mudguard 0540 Installation of grille guard 0550 Installation of left payload lamp (If equipped) 0555 Installation of left side lamp (If equipped) 0560 Installation of right payload lamp (If equipped) 0565 Installation of right side lamp (If equipped) 0570 Installation of left fender side lamp wiring harness (If equipped) 0580 Installation of right fender side lamp wiring harness (If equipped) 0590 Installation of KOMTRAX (If equipped) 0595 Fixing of ORBCOMM antenna (If equipped) 0597 Connection and fixing of harness and hose going to auto grease pump - 1 (If equipped: Auto grease specification) 0598 Connection and fixing of harness and hose going to auto grease pump - 2 (If equipped: Auto grease specification) 0600 Removal of hoist cylinder fixing bracket 0610 Connection of hoist cylinder piping 0620 Welding of body 0630 Sticking of body decal 0640 Supply of oil 0650 Slinging of body 0660 Installation of hinge pin 0670 Connecting hoist cylinder 0680 Hoist cylinder grease piping 0685 Fixing of auto grease piping to body (If equipped: Auto grease specification) 0700 Installation of field welding protection cover 0710 Installation of body mount 0720 Procedure for adjusting body mount shim 0730 Field welding of exhaust tube Item Page 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128
0581 Installation of right fender side lamp wiring harness (If equipped: Body heating-less muffler, exhaust gas selector box muffler specification) 110
CONTENTS
No. 0740 Assembly of body heater cover 0770 Installation of poke ejector 0780 Installation of poke ejector storage pin 0790 Installation of body mudguard 0800 Installation of body lock pin 0810 Installation of transmission underguard 0830 Installation of front handle 0850 Connection of dump sensor 0860 Procedure for adjusting dump sensor 0870 Calibrating dump control 0880 Adjustment of optical axis of light 0900 Bleeding air from brake 0901 Bleeding air from brake of ASR specification (ASR specification: If equipped) 0905 Bleeding air from ABS circuit (ABS specification: If equipped) 0910 Adjusting suspension 0920 Charging air conditioner with refrigerant 0930 Fitting of floating seal 0950 Painting 0960 Touchup 1000 Sticking of front axle decal 1020 Operating procedure of prelubrication system (If equipped: Engine prelubrication specification) 1100 Installation of chocks (If equipped) 1200 Installation of radiator curtain (If equipped) 1300 Installation and connection of beacon lamp (If equipped: Yellow beacon lamp specification) Item Page 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 151 152 153
7. Adjustment procedure
No. Item Page 154 155 156 157 158 159 160 161 162 163 164 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)
8. Welding procedure
No. 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 Item Page 165 166 167 168 169 170 171 172 173 174 175 176 177
Appendix Field assembly inspection report
1. Outline of division (Only main components)

1. Bare machine 2. Dump body (Divided into 3)
3. Front axle assembly
4. Rear axle and tire assembly
5. Front tire and wheel assembly
6. Cab assembly
2. Dimensions of main components

No. 1 2 3 4 5 6 Bare machine Dump body Right and left front axle assembly Rear axle and tire assembly Front tire and wheel assembly (1 set) Cab Unit name Weight (kg) 21,600 15,400 2,400 17,000 2,000 3,000 Overall length (mm) 7,930 7,250 2,200 4,390 2,700 2,760 Overall width (mm) 3,190 3,100 1,700 2,700 750 2,010 Overall height (mm) 3,120 3,100 2,100 2,700 2,700 2,190
Drawing of bare machine on trailer
3,800 1,680 530 6,200 11,980

150
G.L. 3,000 2,780
Reference Specifications of completed truck

Specifications In selfpropelled travel HD785-7 Related items Weight (kg) 64,600 (Mass of machine) Overall length (mm) 10,290 (Front bumper End of body) Overall width (mm) 5,528 Overall height (mm) 5,047 (When empty)
3. Layout of work space

(The work space should be wider for the ease of work and must be at least 30 m square.) Caution: The work space must be level and drained well.
30M
Tire and wheel assembly
CAB
Front axle
Body
Bare machine
50-t crane
Rear axle assembly and tire assembly
Forklift
Light units keeping place

Platform, front support, mudguard, rear support, fire prevention cover, poke ejector, drive shaft, etc.
Compressor parts and tools keeping place

50-t crane
30M
4-1. Rough schedule of assembly and welding

Day Hour 1 2 3 4 1st day 5 6 7 8
Condition of chassis
Rough contents of assem- Positioning rear axle bly work Positioning chassis
Installing front axle Installing tires
Crane 490 kN {50 ton} 245 kN {25 ton} 245 kN {25 ton} (98 kN {10 ton})
Forklift
Approx. 2 m
4 ton * Fork length: Approx. 2 m Number of workers 2
Day Hour 1 2 3 4
1st day 5 6 7 8
Condition of body
Contents of welding work
Unloading Removal of stands and fixing parts
Positioning and fixing split body Welding back side
Crane 245 kN {25 ton} Number of workers 3 245 kN {25 ton}

Day Hour 1 2 3 4 2nd day 5 6 7 8
Rough contents of assem- Installing support bly work Installing cab
Piping and wiring
Crane 490 kN {50 ton} 490 kN {50 ton}
Forklift
Number of workers
Day Hour 1 2 3 4
2nd day 5 6 7 8
Condition of body
Positioning and fixing split body Welding back side
Turning over
Crane 245 kN {25 ton} Number of workers 3

Day Hour 1 2 3 4 3rd day 5 6 7 8
Rough contents of assem- Installing platform bly work Painting
Supply of oil and coolant Starting engine
Crane
Forklift
Number of workers
Day Hour 1 2 3 4
3rd day 5 6 7 8
Condition of body
Welding inside of body
Welding protector
Crane 245 kN {25 ton} Number of workers 3

Day Hour 1 2 3 4 4th day 5 6 7 8
Mounting body Rough contents of assemAdjusting shims bly work Field welding
Crane 490 kN {50 ton} Number of workers 2 245 kN {25 ton} 245 kN {25 ton} (98 kN {10 ton})
Day Hour 1 2 3 4
4th day 5 6 7 8
Condition of body
Crane
Number of workers

Day Hour 1 2 3 4 5th day 5 6 7 8
Installing exterior parts Rough contents of assemPainting bly work
Maintenance, adjustment Inspection
Crane 245 kN {25 ton} (98 kN {10 ton}) Number of workers 2
Day Hour 1 2 3 4
4th day 5 6 7 8
Condition of body
Crane
Number of workers
5-1 List of jigs, tools, and consumables for field assembling (1/2)
No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Item Truck crane Truck crane Forklift Gas cutting machine Torch Acetylene gas Oxygen gas Grinder (round) Grindstone Grinder Grindstone Dia. bar Dia. bar blade Semi-automatic welding machine Hand shield 14.7 MPa {150kg/cm} FG50L-1 SCW50 19 10 LISG-7S 180 6 22 CB7C105 6GH 500A GP-1S 1220N2 25 tons 50 tons 4 tons Specification Q'ty 2 2 1 1 1 1 1 1 1 1 3 1 1 3 3 80kg 2 1 1 1 1 1 3 1 1 1 1 5 kg 1 1 5 12 1 2 Empty drum can See Field Assembling Procedures. 5l 6 1m 1 1 5kg For refilling fuel For adding in subtank (to change mixing ratio depending on local weather) For air bleeding Protection for equipment * Quantity depends on using condition. For oil injection See Field Assembling Procedures. Injection into suspension Protection when field welding Use when welding exhaust flange in field For adjustment of dump body deviation For dump body For dump body For finishing For gas cutting machine For gas cutting machine Remarks See Field Assembling Procedures See Field Assembling Procedures See Field Assembling Procedures
Welding wire for semi-auto1.2 mm matic welding machine Chipper scaling hammer Port power Hydraulic jack Hydraulic jack Shaft Refractory cloth Spacer Nitrogen gas injector Nitrogen gas bottle Tire inflation gauge Grease pump gun Grease Footstool Footstool Blue sheet Wood block Oil jack Oil Oil sump, washing can Drained oil can Cloth Diesel fuel Antifreeze Air hose FCM-20F 300 mm for 10 tons 10 tons 5 tons WJ-H46-74001-023 1 m 10 m ATH-465-027 7926-10-1000 14.7 MPa {150 kg/cm} No. 2252 For 20kg can GL-2 3-step 6-step 5 m 10 m 300 mm square, 1 m long 5l See Field Assembling Procedures.
5-2 List of jigs, tools, and consumables for field assembling (2/2)
No. 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 Item Sanding machine for scaling-off coating Sandpaper Sandpaper Cup gun set Brush Air compressor Air hose Impact wrench Impact wrench Impact wrench Extension for impact wrench 38S Socket Socket Torque-wrench Torque-wrench Convex Locktite Vinyl tape Standard tool (ISO specification) Bar Pointed steel bar Large hammer Axle pin installation guide Shackle Shackle Chain Nylon shoe ring Nylon shoe ring Nylon shoe ring Nylon shoe ring Nylon shoe ring Pin Jig for slinging body Lever block Lever block Wire Wire Wire 10 lb ATH-785-078 BD10 for 500 kg BC40 for 10 tons ATH-465-042 100 mm wide 5 m 60 mm wide 3 m 100 mm wide 12 m 30 mm wide 2 m 100 mm wide 3 m 60 250 mm ATH-785-006 3/4 tons, LB008 2 tons, LB020 7m 28 4m 28 5m 28 700SX 1m Not less than 3.5 m or 7 kg/cm With mouthpiece of 12 UW-13SK KW-3800P UW-9SK 150 mm long 1 inch 46 mm 1 inch 30 mm 2800QL 21000QLE 5m LT-2 914B #80 #180 W87-20R2S Specification Q'ty 1 100 10 1 1 1 5 2 1 2 1 1 1 1 1 1 1 1 2 1 1 1 2 4 4 1 2 2 1 3 1 2 4 3 1 2 2 2 1 2 1 For mounting body Multi purpose For mounting fuel tank For mounting support and small articles For mounting front tires For installing front axle For installing front axle For slinging chassis, rear side (Safety pin can substiture) For mounting body For installing front axle For installing front axle For slinging chassis For mounting body For installing body For mounting body For slinging chassis For slinging separated body For hole alignment Use to bundle harnesses For tightening tire For tightening support For drive shaft and body pin For tightening tire For impact grinder Use for coating Use to repair coating. Remarks
The following items may be substituted for No. 76 to 78. ATH-465-039 ATH-465-040 ATH-465-041
10
List of touch-up coating on body for overseas specifications

No. 1 2 3 4 5 6 7 8 Part Name Retane GP primer Retane GO hardener Retane GP thinner AX Mightylacq G2KB type natural yellow NAX Mightylacq G2KB type hardener X Mightylacq G2 500 standard thinner Acryliquid cloud gray Heat-resistance silver Unit 4kg 0.8kg 4l 16kg 15kg 17l Spray can Spray can Q'ty 1 1 1 1 1 1 1 1
11
5-3. Tools and consumables

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. Body alignment shaft
HEAT TREATMENT
MATERIAL
PART NAME
STKM13A
QTY
Shaft WJ-H46-74001-023
Body lifting pin
HEAT TREATMENT
MATERIAL
PART NAME
SS400
QTY
Body lifting pin AHT-785-006
12
Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. When welding by actually positioning exhaust flange on machine
HEAT TREATMENT
MATERIAL
PU-4
PART NAME
SS40
QTY
SPACER ATH-465-027
Body assembly lifting tool
HEAT TREATMENT
MATERIAL
PART NAME
QTY
Body assembly lifting tool ATH-465-039
13
Chassis lifting tool
HEAT TREATMENT
MATERIAL
PART NAME
QTY
Chassis lifting tool ATH-465-040
Dump body lifting tool
HEAT TREATMENT
MATERIAL
PART NAME
QTY
Split dump body lifting tool ATH-465-041
14
Universal lifting tool
HEAT TREATMENT
MATERIAL
PART NAME
QTY
Universal lifting tool ATH-465-042
Front axle installation guide
HEAT TREATMENT
MATERIAL
PART NAME
QTY
Front axle installation guide ATH-785-078
15
Assembly process No.
Oil, grease, and coolant
0010
Method of using fuel, lubricant, and coolant according to ambient temperature t Fuel, oil Use the correct type for the ambient temperature as shown in the table below. a Specified capacity: Total amount of oil including oil for components and oil in piping Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance. a When starting the engine in an ambient temperature of less than 0C, always use EOS0W30, or EOS5W40, even though the temperature goes up to 10C during the daytime. t Coolant Komatsu genuine super coolant (AF-NAC) is added to the cooling water, so there is no need to change it for temperatures down to -10C. If the temperature goes below -10C, adjust the density. For details, see CLEANING INSIDE OF COOLING SYSTEM in the WHEN REQUIRED Section of the Operation and Maintenance Manual.
a For details of the notes (e.g., Note. 1, Note.2
) in the table, see the Operation and Maintenance Manual.
16
Levels of oil, grease, and coolant
0020
Lubrication point Engine oil pan Transmission case (Including brake sub tank) Steering and hoist oil tank Front suspension
Type of oil Engine oil
Specified capacity (l) 134 404 270 29.8 each on right and left sides 16.5 each on right and left sides 137
Refill capacity (l) 129 241 175 137
Volume of refilled oil (l) 200 150
Power line oil Rear suspension Differential case Final drive case Fuel tank Cooling system Diesel fuel Coolant
64 each on right and 64 each on right and left sides left sides 1,308 283 279
Caution) Before starting the engine, be sure to check each oil/coolant level. Do not steer the machine largely before adjusting the suspension (If it is steered largely, the piping may be damaged).
Precautions
Necessary tools Name
Q'ty
Necessary equipment Name Q'ty
Other remarks
17
Positioning rear axle assembly
0030
Slinging of rear axle 1. Sling the rear axle and tire assembly with a 50 ton crane. Slinging position: Rod mounting portion on differential
Weight: 20 ton (Including sling)
Positioning of rear axle 1. Position the rear axle. See the following figure. (Secure the ground clearance under the coupling section so that the rear axle assembly will be horizontal.) When positioning the rear axle on the ground, prevent slanting of the machine caused by subsidence of the ground. 2. Lock the wheels with chocks to prevent the rear axle from moving.
Wood block 1,200
Necessary tools Name Lock the wheels with chocks to prevent the rear axle Nylon sling from moving. (250 mm wide 5 m)
Precautions
Necessary equipment Q'ty Name Q'ty 1 Crane (50 ton) 1
Other remarks
18
Slinging and moving of bare machine
0040
Sling of bare machine
Front 12.5 ton (Including sling) Crane: 50 ton Body lock pin
Rear 10.8 ton (Including sling) Crane: 25 ton
Slinging positions View f rom rear of bare machine
1. Apply cloths etc. to the body so that the body will not be damaged when it is slung. 2. Sling the bare machine with 2 cranes (Front side: 50 ton, Rear side: 25 ton). Sling : Chain sling (ATH-465-040) or 28 wire Slinging position on front side : Frame slinging bracket Slinging position on rear side : Body lock pin installing position * Insert the body lock pin from inside of the machine (See the above figure). 3. Raise the differential upper part installing rod (upper rod).
Raised upper rod
Moving of bare machine 1. Move the bare machine to above the rear axle.
Precautions Insert the body lock pin for slinging the rear side from inside of the machine. (If it is inserted from outside, it cannot be removed after the tire is installed.) Necessary tools Name Q'ty Necessary equipment Name Q'ty Cranes (50 ton, 25 ton) 1 each Sling (ATH-465-040) 2 Pin (60 250 mm) 2 Wire (7 m, 28 ) 2
Other remarks
19
Connection of rod and rear suspension
0050
Connection of rod and rear suspension Tack-weld nylon sling and lever block. (Used to fix lower arm)
* Carry out work simultaneously. 1. Connect A, B and C in order. Remove the pins installed temporarily and the spacers and bolts to be used in step 3.
A (1) (2) (3) B (4) (5) (6) C (7) (8) (9) Part No. 561-52-81210 01010-81430 569-40-61710 561-52-81210 01010-81430 569-40-61710 561-52-81210 01010-81425 569-40-61710 Part name Pin Bolt Washer Pin Bolt Washer Pin Bolt Washer Q'ty 2 2 2 2 2 2 2 2 2 Condition of parts Temporarily installed to rear axle A Temporarily installed to rear axle A Temporarily installed to rear axle A Temporarily installed to frame B Temporarily installed to frame B Temporarily installed to frame B Temporarily installed to rear axle C Temporarily installed to rear axle C Temporarily installed to rear axle C
2. 3. 4. 5. 6.
1. 2. 3. 4.
Adjust the pin holes and remove the rod from the pin holes temporarily. Put the spacer in the rubber part of the spherical bushing. (See the figure at right.) Adjust the pin holes and insert the pin. Install the lock bolt and washer. Supply grease.
Precautions Q'ty 2 2 Necessary equipment Name Q'ty
Necessary tools Name When adjusting the holes, take care not to catch Nylon sling your finger. If the spacer is installed forcibly, it is deformed. Take (60 mm wide 3 m) care. Lever block When hitting the pin, take care not to crash the (2 ton, LB020) grease fitting. Clean the pins installed temporarily and parts A, B and C. Other remarks
20
Positioning bare machine
0060
2,800
1,000
Wood block
Steel plate
Remove chock on front side.
Wood block
Sttel plate
1. Set the wooden blocks 1 m high under the vertical member as shown above. (If wooden blocks are set under the bumper, the machine is more stabilized.) When positioning the bare machine on the ground, place a steel plate under the wood blocks so that the bare machine will not sink and lean. 2. Remove the sling. 3. Discard the bolts and washers used to install the sling since they are not used any more.
Necessary tools Name Take care that the chassis will not move. Wood block Set the bare machine to proper height so that you can (300 mm square, 1 m) install the front tires. Steel plate Precautions Q'ty 6 1 Necessary equipment Name Q'ty
Other remarks
21
Connection of rear axle cooling hose
0070
Connection of rear axle cooling hose
Rear axle Hose plug on machine side, 2 pieces
Rear axle
Rear axle plug, 4 pieces
If flange is loosened a little and a plate is inserted before piping is disconnected, oil leakage is decreased (*1).
Fig.1
Flange
Plate
1. Remove all of the hose plugs on the machine side (2 pieces) and rear axle plugs (4 pieces). 2. Connect the hoses by using the following parts.
(1) (2) (3) (4) (5) (6) (7) (8) Part No. 07371-21465 07372-21245 01643-51232 07000-F3048 07371-32076 07372-21240 01643-51232 07000-F2060 Precautions Part name Flange Bolt Washer O-ring Flange Bolt Washer O-ring Q'ty 4 8 8 2 4 8 8 2
Note) Do not damage the O-ring. Condition of parts Installed parts Installed parts Installed parts Installed parts Installed parts Installed parts Installed parts Installed parts Necessary equipment Name Q'ty
3. Clean the parts stained with oil.

Necessary tools Name When connecting each hose, check that no dirt is in the Impact wrench hose and the O-ring is fitted securely. (For M12 mm) When removing each plug, set an oil drain case to Socket (19 mm) receive the leaking oil. *1. Dimension of plate (See "Fig 1") Large pipe: W = 63 mm Small pipe: W = 55 mm Q'ty 1 1
Other remarks
22
Connection of rear axle brake hose
0080
a b View Y c
Connection: From block to front side of valve (Reuse O-ring)
View Z
Connection: From tube to rear side of valve (Reuse O-ring)
1. Remove the plugs from each part. 2. Connect the 3 hoses. 3. Clean the parts stained with oil.
Caution: Install the hoses horizontally.
Precautions 1. Take care extremely not to mistake the connecting positions. 2. When removing each plug, do not lose the O-ring.
Q'ty
Other remarks
23
0085
Connection of rear axle brake hose (ASR specification: If equipped)
a
a
View Y
b c
Connection: From block to front side of valve (Reuse O-ring)
Connection: CNJ13
Connection: CNJ12
1. Remove the plugs from each part. 2. Connect the 3 hoses. 3. Connect connectors "CNJ12" and CNJ13". 4. Clean the parts stained with oil.
Caution: Install the hoses horizontally.
View Z
Connection: From tube to rear side of valve (Reuse O-ring)
Precautions 1. Take care extremely not to mistake the connecting positions. 2. When removing each plug, do not lose the O-ring.
Q'ty
Other remarks
24
0086
Connection of valve sub-assembly wiring harness (ASR specification: If equipped)
Connection of valve sub-assembly wiring harness

* Wiring harness length between a -- b: 600 mm Wiring harness length between c -- d: 600 mm
Rear view of machine body
Connect CN WSRR.
Connect CN WSRL.
Remove clip and bolt and fix wiring harness.
View Y
View Z
(1) (2) (3)
Part No. 04434-51512 01024-81016 08193-21012
Part name Clip Bolt, sems Clip
Q'ty 5 6 2
Condition of part (Parts list No.) Installed temporarily to machine Installed temporarily to machine Installed temporarily to machine
1. Remove the clips and bolts installed temporarily and fix the wiring harness. 2. Connect connectors "CN WSRR" and "CN "WSRL". 3. Fix the sensor on the back side of the valve sub-assembly.
Precautions Necessary tools Name Necessary equipment Name Q'ty
Q'ty
Other remarks
25
0087
Connection and fixing of piping going to rear axle (Sand terrain/ASR specification: If equipped)
Connection and fixing of piping going to rear axle

(190)
(225)
ASR valve
Rear axle slack adjuster
Rear axle
View X
Connection
Rear axle
View Z
1. Fix the hose going to the rear axle to the rear axle tube. (See view X.) 2. Connect the hose fixed in step 1 to the rear axle.
Part No. 416-88-11140 04434-52110 07095-20314 07283-32236 01643-31032 01580-11008 Precautions Part name Plate Clip Cushion Clip Washer Nut Q'ty 2 2 2 2 4 4 Condition of part (Parts list No.) Packed separately (HD785-7-087) Packed separately (HD785-7-087) Packed separately (HD785-7-087) Packed separately (HD785-7-087) Packed separately (HD785-7-087) Packed separately (HD785-7-087) Necessary tools Name Necessary equipment Name Q'ty
(1) (2) (3) (4) (5) (6)
Q'ty
Other remarks
26
0090
Connection and fixing of rear grease piping and supply of grease
Connection and fixing of rear grease piping and supply of grease
FWD
X Y
c
A
a View X
a b c
FWD
1. Connect 1 tube to part A (1 each on the right and left sides). (Left side: (2), Right side: (6)) 2. Install elbows (4) to the ends of tubes (2) and (6) (directing them straight down) and connect them to the frame. 3. Fix tubes (2) and (6) with clips (8) and bolts (9). 4. Supply grease (G2-LI) through part A. 5. Supply grease until it flows out of the lubricated spherical bushing, seal, or boot lip. 6. Grease must not ooze from the pipe joints
Part No. 561-52-82641 421-09-12540 561-52-82631 04434-50608 01024-80816 Precautions 1. Take care extremely not to mistake the connecting positions. Part name Tube Elbow Tube Clip Bolt sems Q'ty 1 2 1 4 4 Condition of part (Parts list No.) Packed separately (HD785-7-090) Packed separately (HD785-7-090) Packed separately (HD785-7-090) Packed separately (HD785-7-090) Packed separately (HD785-7-090) Necessary tools Name Necessary equipment Name Q'ty
a c
a b c
A
View Y
(2) (4) (6) (8) (9)
Q'ty
Other remarks
27
Preparation for installing front axle
0100
Preparation for installing front axle 1. Remove the packing materials for each part.
(1) (2) (3) (4) (5) (6) (7) (8) (9)
Part No. 561-40-61550 561-40-61560 566-52-41950 01010-81425 569-40-61710 561-40-81540 566-52-61150 01010-81425 569-40-61710
Part name Pin Pin Spacer Bolt Washer Pin Spacer Bolt Washer
Q'ty 2 2 4 4 4 2 4 2 2
Condition of parts Temporarily installed to machine (L = 260 mm) Temporarily installed to machine (L = 290 mm) Temporarily installed to machine Temporarily installed to machine Temporarily installed to machine Temporarily installed to machine Temporarily installed to machine Temporarily installed to machine Temporarily installed to machine
2. Sling the front axle (See the attached photo).
Necessary equipment Q'ty Name Q'ty 1. Dimensions of pin vary on each portion. Place pins Nylon sling (30 mm wide 2 m) 3 Crane (25 ton) 1 near relevant locations to install pins in place with Nylon sling (100 mm wide 3 m) 1 ease. 2. Adjust sling so that suspension cylinder becomes Lever block (3/4 ton, LB008) 3 vertical against ground. Lever block (2 ton, LB020) 1 Hook slings at suspension cylinder assembly and hub stud portion. Other remarks
Precautions
28
Installation of front axle
0110
Installation of frontxle
Fix with spacer, pin and lock bolt.
Move up.
o When installing steering cylinder
Move up.
How to sling
Fix with spacer, pin and lock bolt. Lever block
o When installing suspension cylinder
1. Move up the A-arm mounting part with a Fix to fuel tank crane. bracket. 2. While adjusting the crane and lever block, adjust the A-arm to the pin holes of the frame once and then lower it with the lever block. 3. Insert the removed spacers (8 pieces) in the rubber covers of the spherical bushings of the A-arm (4 places on right and left sides) and then adjust the pin holes again with the lever block. (Adjust the horizontal direction with the lever block, too. See the right upper photo.) 4. Install the spacers and pins and fix them with the lock bolts. (If you use the guide as shown at right, you can install easily.) 5. Remove the sling from the A-arm. 6. While adjusting the crane, install the upper part of the suspension similarly to the A-arm. 7. Remove the sling and supply grease to each part.
Precautions Necessary tools Name
Guide ATH-785-078
A-arm
Necessary equipment Q'ty Name Q'ty 1. Check spacer for deviation. Nylon sling (30 mm wide 2 m) 3 Crane (25 ton) 1 2. When making alignment, take care not to catch your Nylon sling (100 mm wide 3 m) 1 fingers in it. Lever block (3/4 ton, LB008) 3 3. Check for O-ring on spherical bushing. Lever block (2 ton, LB020) 1 Guide pin (ATH-785-078)
Other remarks
29
Connection of front axle suspension pressure sensor
0120
Connection of front axle suspension pressure sensor
Connection
Suspension oil pressure sensor (Left) CN SUFL Suspension oil pressure sensor (Right) CN SUFR
1. After installing the front axle, connect the suspension oil pressure sensor wiring harness. 2. Fix the suspension oil pressure sensor wiring harness of the left front axle with clips (1) and bolts (2). 3. Fix the suspension oil pressure sensor wiring harness of the right front axle with clips (1) and bolts (2).
Suspension oil pressure sensor (Right) CN SUFR
A
2
Suspension oil pressure sensor (left) CN SUFL View Z

Section A-A
(1) (2)
Part No. 04434-50810 01024-81020 Precautions
Part name Clip Bolt, sems
Q'ty 3 3
Condition of parts Temporarily installed to machine Temporarily installed to machine Necessary tools Name
Necessary equipment Q'ty Name Q'ty Nylon sling (30 mm wide 2 m) 3 Crane (25 ton) 1 Nylon sling (100 mm wide 3 m) 1 Lever block (3/4 ton, LB008) 3 Lever block (2 ton, LB020) 1
Other remarks
30
0125
Connection of front axle wheel speed sensor (ABS specification: If equipped)
Connection of front axle wheel speed sensor 1. Fix and connect the wheel speed sensor wiring harness with the clip installed to the front axle.
Connection: CN WSFL Wheel speed sensor (FL)
View Y Fixing with clip (installed to front axle)
30
Left front axle
Fixing with clip (installed to front axle): Direct down 5
Connecting: CN WSFR Wheel speed sensor (FR)
Fixing with clip (installed to front axle)
View Z
50
Right front axle

Fixing with clip (installed to front axle): Direct down 5
Precautions
Q'ty
Other remarks
31
Connection of steering cylinder and tie rod
0130
Connection of steering cylinder and tie rod
L = 260mm
Reconnection
Reconnection
L = 240mm
(1) (2) (3) (4) (5)
Part No. 561-40-61531 561-40-61570 01010-81425 569-40-61710 561-40-61631
Part name Pin Pin Bolt Washer Boot
Q'ty 2 2 4 4 8
Condition of parts Temporarily installed to front axle Temporarily installed to front axle Temporarily installed to front axle Temporarily installed to front axle Temporarily installed to front axle
1. Take out the remote grease tube from the top of the pin of the front axle lever and remove pins (1) and (2) and bellows (5). Remove the air cylinder cover, too. 2 Set the lever in parallel with the ground by adjusting the crane. 3. Set boots (5), adjust the pin holes, and install the pins. 4. Tighten the lock bolts. 5. Connect the remote grease tube again. 6. Supply grease to each part.
Necessary equipment Q'ty Name Q'ty 1. Check that the O-rings are fitted to the steering cylNylon sling (30 mm wide 2 m) 3 Crane (25 ton) 1 inder and tie rod spherical bushing. 2. Note that the lengths of the pins are different from Nylon sling (100 mm wide 3 m) 1 Lever block (3/4 ton, LB008) 3 one another. Lever block (2 ton, LB020) 1
Precautions
Other remarks
32
Connection of front axle brake cooling hoses
0140
Connection of front axle brake cooling hoses
Connection
Connect rear side to rear side.
Connection
Connect rear side to rear side.
Connect front side to front side
Connect front side to front side.
Left side
Right side
1. Remove all of the hose plugs on the machine side (2 pieces) and front axle plugs (4 pieces). 2. Connect the hoses by using the following parts. (Connect the right and left side similarly.)
Part No. 07371-21465 07375-21240 07000-F3048 Part name Flange Bolt O-ring Q'ty 8 16 4 Condition of parts Installed parts Installed parts Installed parts
(1) (2) (3)
3. Clean the parts stained with oil.
* Before connecting the front axle brake cooling hose, set the hose clamp as shown in the following figure.
(Flange face - center of clip width)
Frame seen from front

Precautions When removing each pipe plug, prepare a drain case to receive the leaking oil. Necessary tools Name
(Flange face - center of clip width)
Q'ty
Other remarks
33
Connection of front axle brake hoses
0150
Connection of front axle brake hoses
Connection
a a b
After connecting hose, reassemble.
Left front axle
Connection
b a
After connecting hose, reassemble.
Right front axle
1. Remove the plugs, clamps, cushions and bolts from each part. 2. Connect 4 hoses (2 pieces each on right and left sides) and install the clamps, cushions and bolts removed in step 1. 3. Clean the parts stained with oil.
Precautions 1. Take care extremely not to mistake the connecting positions. 2. When removing each plug, do not lose the O-ring. Necessary tools Name Q'ty Necessary equipment Name Q'ty
Other remarks
34
Connection of front axle auto suspension piping
0160
Connection of front axle auto suspension piping
Color of SOL B-A band: Black Color of SOL B-B band: Green
Color of SOL A-A band: Yellow
Color of SOL A-B band: Red
Section A-A
Connection
Color of SOL A-A band: Yellow
Color of SOL A-B band: Red Color of SOL B-A band: Black
Color of SOL A-B band: White
SOL B-B
Color of SOL B-B band: Green
Left front axle
Color of SOL B-A band: Blue Color of SOL A-A band: Brown
Section B-B
Color of SOL A-A band: Brown Color of SOL A-B band: White Color of SOL B-A band: Blue
Connection
SOL B-B
Right front axle
1. Remove the plugs from each part. 2. Connect 8 hoses (4 pieces on right side and 4 on left side). 3. Clean the parts stained with oil.
Precautions 1. Take care extremely not to mistake the connecting positions. 2. When removing each plug, do not lose the O-ring. Necessary tools Name Q'ty Necessary equipment Name Q'ty
Other remarks
35
Fixing of front axle auto suspension piping
0165
Fixing of front axle auto suspension piping 1. Fix the front axle and auto suspension piping. * For the clamp locations, see the following figure.
: 3 places
View Q
View P
: 8 places
View X: Left axle View Y: Right axle
420 (Actual length of center of brake hose) 193 (Actual length of center of brake hose)
107 (Actual length of center of brake hose)
268 (Actual length of center of auto suspension hose)
532 (Actual length of center of auto suspension hose)
Left axle seen from rear
Right axle seen from front
(1) (2) (3) (4) (5) (6) (7) (8)
Part No. 04434-53212 04434-53412 07095-00420 07095-00423 01024-81025 01580-11008 01024-81020 01643-31032 Precautions
Part name Clip Clip Cushion Cushion Bolt, sems Nut Bolt, sems Washer
Q'ty 8 4 1 3 4 4 4 4
Condition of part (Parts list No.) Packed separately (HD785-7-165) Packed separately (HD785-7-165) Packed separately (HD785-7-165) Packed separately (HD785-7-165) Packed separately (HD785-7-165) Packed separately (HD785-7-165) Packed separately (HD785-7-165) Packed separately (HD785-7-165) Necessary tools Name Q'ty Necessary equipment Name Q'ty
Other remarks
36
0166
Fixing of front axle auto grease piping (If equipped: Auto grease specification)
Fixing of front axle auto grease piping 1. Fix the front axle and auto grease piping. * For the clamp locations, see the following figure.
View Z
190 (Actual length of center of brake hose) 80 (Actual length of center of brake hose)
300 (Actual length of center of auto grease hose)
View X: Left axle
600 (Actual length of center of auto grease hose)
View Y: Right axle
(1) (2) (3) (4) (5) (6)
Part No. 04434-52310 04434-53412 07095-00420 01024-81025 01643-31032 01580-11008 Precautions
Part name Clip Clip Cushion Bolt, sems Washer Nut
Q'ty 4 4 4 4 4 4
Condition of part (Parts list No.) Packed separately (HD785-7-166) Packed separately (HD785-7-166) Packed separately (HD785-7-166) Packed separately (HD785-7-166) Packed separately (HD785-7-166) Packed separately (HD785-7-166) Necessary tools Name Q'ty Necessary equipment Name Q'ty
Other remarks
37
0167
Connection of left front axle auto grease piping (If equipped: Auto grease specification)
Connection of left front axle auto grease piping 1. Connect the left front axle and auto grease piping.
Connect: Band color "Yellow" L2 View Z Connect: Band color "Blue" L3
View W
Connect: Band color "Green" L6
Connect: Band color "Red" L1
Connect: Band color "White" L4 View Y
(1) (2) (3)
Part No. 561-95-63290 04434-51010 01024-81016 Precautions
Part name Elbow Clip Bolt, sems
Q'ty 3 1 1
Condition of part (Parts list No.) Installed to machine body Packed separately (HD785-7-167) Packed separately (HD785-7-167) Necessary tools Name Q'ty Necessary equipment Name Q'ty
Other remarks
38
0168
Connection of right front axle auto grease piping (If equipped: Auto grease specification)
Connection of right front axle auto grease piping 1. Connect the right front axle and auto grease piping.
Connect: Band color "Blue" R3
Section A-A
Connect: Band color "Black" R5
Connect: Band color "White" R4
Connect: Band color "Red" R1

Connect: Band color "Green" R6
View Y
View X
(1)
Part No. 561-95-63290
Part name Elbow
Q'ty 3
Condition of part (Parts list No.) Installed to machine body
Precautions
Q'ty
Other remarks
39
Installation of bumper and front axle steps
0170
Installation of bumper step
1. Remove bolts (1) from the bumper and install steps (2). 2. Install steps (4) with bolts (3).
(1) (2) (3) (4) Part No. 01024-81225 561-54-86871 01024-81230 561-54-31690 Part name Bolt, sems Step Bolt, sems Step Q'ty 8 2 8 2 Condition of part (Parts list No.) Installed to bumper Packed separately (HD785-7-170) Packed separately (HD785-7-170) Packed separately (HD785-7-170)
Installation of front axle steps
1. Install the steps to the right and left front axles.

(1) (2) (3) (4) (5) Part No. 561-54-86751 561-54-86761 01024-81225 561-54-86740 01024-81030 Precautions There are right and left front axles. Since they are stamped as shown below, check the stamps when installing. Part name Bracket L. H Bracket R. H Bolt Step Bolt Q'ty 2 2 8 2 8 Condition of part (Parts list No.) Packed separately (HD785-7-170) Packed separately (HD785-7-170) Packed separately (HD785-7-170) Packed separately (HD785-7-170) Packed separately (HD785-7-170) Necessary tools Name Q'ty Necessary equipment Name Q'ty
"R.H."
Other remarks
40
Installation of front axle step (EU specification)
0171
Installation of front axle step
1. Install the steps to the right and left front axles.

Part No. 561-54-88300 561-54-88400 01024-81225 Part name Step assembly, R.H Step assembly, L.H Bolt Q'ty 1 1 4 Condition of part (Parts list No.) Packed separately (HD785-7-172) Packed separately (HD785-7-172) Packed separately (HD785-7-172)
(1) (2) (3)
Precautions The right and left front axles are different. When installing them, confirm their part Nos.
Q'ty
Other remarks Sale code : 5AC11
41
Installation of tire and wheel assembly
0180
Installation of tire and wheel assembly <How to sling tire and wheel assembly>
Apply chock hitch.
Nylon sling
<<Reference>> If forklift is available, you can work easily as shown below.
Place wooden blocks under front axle (under king pin) and place steel plate under them.
Weight of tire: 1,500 kg

Wood block Steel plate
Secure tire with wire to prevent tire from falling.

Installed to front axle temporarily
3 : 1,519 -- 1,617 Nm
Note) If the block is projected out too much, it will interfere with the installed tire. Accordingly, set the block inside of the king pin.
{154.9 -- 164.8 kgm}
(1) (2) (3)
Part No. 569-22-72870 426-09-11520 561-30-80000
Part name Nut Washer Tire assembly
Q'ty 40 40 2
Condition of part (Parts list No.) Temporarily installed to front axle Temporarily installed to front axle Packed separately (HD785-7-180)
Take care of position of air valve.
1. Remove the nuts and washers installed to the front axle temporarily. 2. Install the tire with the forklift and install the nuts and washers in the order of the numbers shown at right. Note) Take care that the tire will not fall from the forklift. When positioning the tire, take care not to damage the valve for inflating the tire. 3. Tighten the nuts with the impact wrench temporarily. 4. Lift up the front part of the chassis with the crane and remove the wood blocks. 5. Tighten the tire mounting nuts with the torque wrench. (Tightening torque: 1,519 1,852 Nm {154.9 188.8 kgm}) 6. Touch up the tightened parts (to prevent rusting). (Use the yellow paint used for the body.)
Precautions
1,11 7 10 4
3 9 8 2
Necessary tools Necessary equipment Name Q'ty Name Q'ty 1. When carrying the tire, take care that it will not fall. Torque wrench 1 Crane (50 ton) 1 2 When positioning the tire, take care not to damage QLE21000 Forklift (4 ton) 1 the air valve. Nylon sling 1 Wire 1 (100 mm wide 12 m) Socket (1 inch 46 mm) 1
Other remarks
42
Installation of drive shaft
0190
Installation of drive shaft
Apply LT-2. 3: 343 -- 427 Nm {34.9 -- 43.5 kgm}
Install larger end to transmission.
(1) (2)
Part No. 561-20-72002 01050-61895
Part name Propeller shaft Bolt
Q'ty 1 8
Condition of part (Parts list No.) Packed separately (HD785-7-190) Packed separately (HD785-7-190)
1. Remove the drive shaft from the machine. 2. Sling the drive shaft with the crane and put it between the rear axle and transmission. 3. Lightly hit the drive shaft spider to fit the faucet joint securely. 4. Install and tighten the bolts in the diagonal order. (For the Fig. 1 tightening order, see Fig. 1. Apply LT-2 to the bolts.) 5. Tighten the bolt again with the torque wrench. Bolt (2) tightening torque: (Torque wrench: 343 627 Nm {34.9 43.5 kgm}) 343 427Nm 6. Install the guard again. {34.9 43.5kgm} Guard tightening torque: 7. Wipe off the grease from the mounting part and 1,180 1,470Nm degrease the bolts (coupling).
{120 150kgm} Necessary tools Name Install drive shaft from the front side and transmission Nylon sling side for the ease of work. (Tighten the bolts on the front (60 mm wide 3 m) side temporarily and fit the faucet joint securely.) Torque wrench, 2800QL When installing the rear side, install a chain block to the drive shaft to extend. Precautions
5,1
Necessary equipment Q'ty Name Q'ty 2 Crane (25 ton) 1 1
Other remarks
43
0200
Installation of oil quick charge box (If equipped: Oil quick charge specification)
Installation of oil quick charge box 1. Install box (1) with bolts (2).
Hydraulic tank
: 5 places
Transmission and brake cooling oil Engine oil
Brake control oil Steering and H/T oil
Section A-A
View Z
(1) (2)
Part No. X251156860 01024-81225
Part name Box, sub assembly Bolt, sems
Q'ty 1 5
Precautions
Q'ty
Other remarks
44
Installation of fuel tank wiring harness cover
0260
FUEL TANK
Wiring harness cover
Installation procedure for cover (1)
Installation of fuel tank wiring harness cover 1. Install cover (1) with the bolts installed to the fuel tank.
Part No. 561-04-81322 Part name Cover Q'ty 1 Condition of part (Parts list No.) Installed to fuel tank
(1)
Precautions
Q'ty
Other remarks
45
Installation of toolbox and tool kit
0270
Installation of toolbox
(1) (2) (3)
Part No. 561-98-86110 01024-81225 09460-00000
Part name Tool box, sab assembly Bolt Lock
Q'ty 1 4 1
Condition of part (Parts list No.) Packed separately (HD785-7-270) Temporarily installed to fuel tank Packed separately (HD785-7-270)
1. Remove the toolbox sub-assembly mounting bolts (installed to the fuel tank temporarily). 2. Fix toolbox sub-assembly (1) with the bolts removed in step 1. 3. Install the attached tool kit. 4. Close the cover of box (1) and tighten the wing screw. 5. Install lock (3).
Precautions
Q'ty
Other remarks
46
Installation of fuel tank step (If equipped)
0275
Installation of fuel tank step 1. Remove bolts (2) installed to the fuel tank. 2. Install ladder (1) with bolts (2) removed in step 1. 3. Install step (3) to ladder (1) with bolts (4).
EU specification
EU specification
EU specification reference drawing
EU specification reference drawing
(1) (2) (3) (4) (5) (6)
Part No. 561-54-8A981 01024-D1230 561-54-8A960 01024-D1230 561-54-8A982 561-54-8A900 Precautions
Part name Ladder Bolt Step Bolt Ladder Step
Q'ty 1 8 1 4 1 1
Condition of part (Parts list No.) Packed separately (HD785-7-275) Installed to fuel tank Packed separately (HD785-7-275) Packed separately (HD785-7-275) Packed separately (HD785-7-277) Packed separately (HD785-7-277) Necessary tools Name Q'ty Necessary equipment Name Q'ty
Other remarks Sales code: 6HH68-A or 5AC11
47
Installation of rear support
0280
Installation of rear support 1. Remove the bolts and washers installed to the machine body temporarily. 2. Install the rear support assembly. * For adjustment, keep bolts (2) and (5) tightened temporarily until installing the right platform and cab.
* Remove rust preventive paint from rear support ground face (on machine frame side).
* Remove rust preventive paint from rear support ground face (on machine frame side). (1) (2) (3) (4) (5) (6) Part No. 561-46-80200 01010-82475 01643-32460 561-46-81791 01010-81850 01643-31845 Part name Rear support LH Bolt Washer Rear support RH Bolt Washer Q'ty 18 18 18 1 7 7
Z
Condition of part (Parts list No.) Packed separately (HD785-7-280) Installed to frame Installed to frame Packed separately (HD785-7-280) Installed to frame Installed to frame
Fixing of air tube 1. Fix the air tube.

(7) (8) Part No. 04434-51210 01024-81020 Part name Clip Bolt Q'ty 18 18 Condition of part (Parts list No.) Packed separately (HD785-7-280) Packed separately (HD785-7-280)
View Z
Diagonal front view
Precautions
Necessary tools Name Nylon sling (60 mm wide 3 m) Torque wrench
Other remarks
48
0281
Installation of rear support (Muffler specification: If equipped)
Installation of rear support 1. Remove the bolts and washers installed to the machine body temporarily. 2. Install the rear support assembly. * For adjustment, keep bolts (2) and (5) tightened temporarily until installing the right platform and cab. Muffler specification
* Remove rust preventive paint from rear support ground face (on machine frame side).
* Remove rust preventive paint from rear support ground face (on machine frame side). (1) (2) (3) (4) (5) (6) Part No. 561-46-80200 01010-82475 01643-32460 561-84-84391 01010-81850 01643-31845 Part name Rear support LH Bolt Washer Rear support RH Bolt Washer Q'ty 18 18 18 1 7 7
Z
Condition of part (Parts list No.) Packed separately (HD785-7-281) Installed to frame Installed to frame Packed separately (HD785-7-281) Installed to frame Installed to frame

View Z
Diagonal front view
Precautions
Other remarks
49
0282
Installation of rear support (ABS specification: If equipped)
* Keep bolts (2) and (5) tightened lightly Installation of rear support for adjustment until the right platform and 1. Remove the bolts and washers installed to the machine. cab are installed. 2. Install the rear support assembly. (Before installing the left rear support assembly, install ABS assembly (9) with bolts (10).
* Remove rust preventive paint from rear support grounding surface (on machine frame side).
View Y
* Remove rust preventive paint from rear support grounding surface (on machine frame side). (1) (2) (3) (4) (5) (6) (9) (10) Part No. 561-46-80300 01010-82475 01643-32460 561-84-84391 01010-81850 01643-31845 561-88-80201 01024-81230 Part name Rear support LH Bolt Washer Rear support RH Bolt Washer ABS front sub assembly Bolt, sems Q'ty 18 18 18 1 7 7 1 4 Condition of part (Parts list No.) Packed separately (HD785-7-282) Installed to frame Installed to frame Packed separately (HD785-7-282) Installed to frame Installed to frame Packed separately (HD785-7-282) Packed separately (HD785-7-282)

Precautions
Other remarks
50
0283
Installation of rear support (Sand terrain specification: If equipped)
Installation of rear support 1. Remove the bolts and washers installed to the machine. 2. Install the rear support assembly. * Keep bolts (2) and (5) tightened lightly for adjustment until the right platform and cab are installed.
* Remove rust preventive paint from rear support grounding surface (on machine frame side).
* Remove rust preventive paint from rear support grounding surface (on machine frame side). Part No. 561-46-80200 01010-82475 01643-32460 X250783640 01010-81850 01643-31845 Part name Rear support LH Bolt Washer Rear support RH Bolt Washer Q'ty 1 18 18 1 7 7 Condition of part (Parts list No.) Packed separately (HD785-7-283) Installed to frame Installed to frame Packed separately (HD785-7-283) Installed to frame Installed to frame
(1) (2) (3) (4) (5) (6)

(7) (8) (9) Part No. 04434-51210 04434-51010 01024-81020 Part name Clip Clip Bolt Q'ty 2 1 1 Condition of part (Parts list No.) Packed separately (HD785-7-283) Packed separately (HD785-7-283) Packed separately (HD785-7-283)
Precautions
Other remarks
51
Installation of muffler
0290
Fire prevention cover <Points of work> * Before tightening the bolts permanently, install all the parts
X
3: 8.8 9.8 Nm {0.9 1.0 kgm} Part No. 561-02-81210 6502-12-1722 01024-81235 561-02-81350 01580-11008 01643-31032 Part name Tube V coupling Bolt Band Nut Washer Q'ty 1 1 2 1 4 2 * Tighten bolts to secure fire prevention cover. Condition of part (Parts list No.) Packed separately (HD785-7-290) Packed separately (HD785-7-290) Packed separately (HD785-7-290) Installed to frame Installed to frame Installed to frame
View Z
(1) (2) (3) (4) (5) (6)
1. Remove the fire prevention cover installed to machine body (rear support). 2. Remove parts (4) (6) installed to the frame temporarily and install tube (1) to the frame with parts (2) and (3). 3. Clamp tube (1) with parts (4) (6) removed in step 2. See "Tightening procedure for exhaust pipe band" (below). 4. Reinstall the fire prevention cover removed step 1. Tightening procedure for exhaust pipe band Tighten the nuts of exhaust pipe band ((4) 561-02-81350) according to the following procedure (See view X). 1) Tighten nut "a" to 13.7 Nm {1.5 kgm}. 2) Tighten nut "b" to 59 74 Nm {6 7 kgm} and then return nut "a" slightly.
Precautions Necessary tools Name
a b
Q'ty
View X
Other remarks
52
0291
Installation of muffler (Body heating-less/Exhaust selector box specification: If equipped)

3: 8.89.8Nm {0.91kgm}
a: 4 places
Rear view of machine
Front view of machine (Sectional view of rear support)
1. Install muffler sub-assembly (1) with bolts (2). 2. Install the exhaust pipe on the machine side and muffler sub-assembly (1) with V-coupling (3). See "Assembly procedure for exhaust pipe at muffler connecting part".
(1) (2) (3) (4) Part No. 561-84-80101 01024-81230 6502-12-1722 561-84-84341 Part name Muffler sub assembly Bolt, sem V coupling Tube Q'ty 1 4 1 1 Condition of part (Parts list No.) Packed separately (HD785-7-291) Packed separately (HD785-7-291) Packed separately (HD785-7-291) Installed to machine
Assembly procedure for exhaust pipe at muffler connecting part 1) When installing exhaust pipe (4) and muffler sub-assembly ((1)), 1. Install frame-side V-coupling (3) temporarily. * At this time, adjust the flexible pipe length to 336 9 mm. * If the flexible pipe is tightened after extended, its sealing performance may lower and it may be disconnected. Take care. If the flexible pipe needs to be shortened, shorten it while twisting it to the left. (Twisting distance: 3 5 mm) 2. Permanently tighten V-coupling (3) on the frame side.
Twisting distance to left: 3 5 mm Twisting distance to right: 0 mm
3369
A A
A-A
Precautions
Q'ty
Necessary equipment Name Q'ty 1
Other remarks
53
Installation of fire prevention cover
0300
Installation of fire prevention cover
<Point of work> * Install the fire prevention cover before installing the fender (for higher workability).
Part No. 561-89-86111 561-89-86120 01024-81230 01024-81225 Part name Cover Cover Bolt, sems Bolt, sems Q'ty 1 1 6 2 Condition of part (Parts list No.) Packed separately (HD785-7-300) Packed separately (HD785-7-300) Packed separately (HD785-7-300) Packed separately (HD785-7-300)
(1) (2) (3) (4)
1. Install the fire prevention cover to the right rear support.
Precautions
Q'ty
Other remarks
54
Installation of front support
0310
3: 662 829 Nm {67.5 84.5 kgm}
3: 662 829 Nm {67.5 84.5 kgm}
Connection of headlamp wiring harness
(1) (2) (3) (4) (5) (6)
Part No. 561-54-80301 01010-82270 01643-32260 561-54-80401 01010-82255 01643-32260
Part name Front support sub assembly LH Bolt Washer Front support sub assembly RH Bolt Washer
Q'ty 1 11 11 1 5 5
Condition of part (Parts list No.) Packed separately (HD785-7-310) Packed separately (HD785-7-310) Packed separately (HD785-7-310) Packed separately (HD785-7-310) Packed separately (HD785-7-310) Packed separately (HD785-7-310)
1. Install front support assemblies (1) and (4) with bolts (2) and (5) and washers (3) and (6). 2. Fix the wiring harness to the clip and connect connector (CN-RP and CN-LP3). 3. After installing the front support, touch it up.
Precautions Necessary tools Name Nylon sling (60 mm wide 3 m) Torque wrench Necessary equipment Q'ty Name Q'ty 1 Crane (25 ton) 1 1
Other remarks
55
0315
Installation of front support (Fog lamp specification: If equipped)
3: 662 829 Nm {67.5 84.5 kgm}
3: 662 829 Nm {67.5 84.5 kgm}
Connection of headlamp wiring harness
(1) (2) (3) (4) (5) (6)
Part No. 561-54-80100 01010-82270 01643-32260 561-54-80200 01010-82255 01643-32260
Part name Front support sub assembly LH Fog Bolt Washer Front support sub assembly RH Fog Bolt Washer
Q'ty 1 11 11 1 5 5
1. Install front support assemblies (1) and (4) with bolts (2) and (5) and washers (3) and (6). 2. Fix the wiring harness to the clip and connect connector (CN-RP and CN-LP3). 3. After installing the front support, touch it up.
Precautions Necessary tools Name Nylon sling (60 mm wide 3 m) Torque wrench Necessary equipment Q'ty Name Q'ty 1 Crane (25 ton) 1 1
Other remarks
56
0317
Installation of front support (Fog lamp, beacon lamp, HID headlamp specification: If equipped)
3:
3:
Connection of headlamp harness
(1) (2) (3) (4) (5) (6)
Part No. 561-85-80V00 01010-82270 01643-32260 561-85-80W00 01010-82255 01643-32260
Part name Front support sub assembly LH Bolt Washer Front support sub assembly RH Bolt Washer
Q'ty 1 11 11 1 5 5
1. Install front support assemblies (1) and (4) with bolts (2) and (5) and washers (3) and (6). 2. Fix the harness to the clips and connect connectors (CN-RP and CN-LP3). 3. After installing, touch up the damaged surfaces.
Precautions
Other remarks
57
Installation of steering valve
0320
Installation of steering valve 1. Remove the blind plugs and caps from the frame steering piping (5 places). 2. Install the steering valve to the left front support.
3 : 44.1 -- 58.8 Nm {4.5 -- 6.0 kgm}
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
Part No. 561-40-83300 561-40-42620 561-40-42630 561-40-42650 02010-20638 01643-31032 569-40-83470 569-40-83480 01024-80616 01643-30623 01580-10605
Part name Valve,steering Cushion Collar Plate Bolt Washer Bracket Seal Bolt, sems Washer Nut
Q'ty 1 4 4 4 4 4 2 1 2 2 2
Condition of part (Parts list No.) Packed separately (HD785-7-320) Packed separately (HD785-7-320) Packed separately (HD785-7-320) Packed separately (HD785-7-320) Packed separately (HD785-7-320) Packed separately (HD785-7-320) Packed separately (HD785-7-320) Packed separately (HD785-7-320) Packed separately (HD785-7-320) Packed separately (HD785-7-320) Packed separately (HD785-7-320)
3. Install the nipple to the steering valve.
View Z
(12) (13) (14) (15) (16) (17) Part No. 02896-21012 569-61-84770 437-40-22310 569-61-84780 418-62-11620 02896-21018 Precautions 1. Take care that the O-ring will not be projected. Part name O-ring Nipple O-ring Nipple O-ring O-ring Q'ty 1 2 2 2 2 4 Condition of part (Parts list No.) Packed separately (HD785-7-320) Packed separately (HD785-7-320) Packed separately (HD785-7-320) Packed separately (HD785-7-320) Packed separately (HD785-7-320) Packed separately (HD785-7-320) Necessary tools Name Q'ty Necessary equipment Name Q'ty
Other remarks
58
Preparation for installing cab
0330
Preparation for installing cab 1. Adjust the dimensions between the viscous mounts with the left front support and rear support as shown below.
Dimension measuring method
Slinging of cab 1. Sling the cab assembly. (Use a sling having capacity of at least 3 ton.)
(1)
Part No. 561-54-83200 Precautions
Part name Cab assembly
Q'ty 1
Condition of part (Parts list No.) Packed separately (HD785-7-330) Necessary equipment Q'ty Name Q'ty 1 Crane (50 ton) 1
Necessary tools Name Nylon sling (Capacity: Min. 3 ton)
Other remarks
59
Installation of cab
0340
Installation of cab
Clearance (A) adjusted with shim (Standard: 0 mm)
Section A-A
* After cab is installed, if clearance (A) is made, insert shims (7) and (8) by necessary quantity (up to 8 pieces for each place (t0.5 4, t1.0 4)). No shim may be used as standard. (1) 3: 245 309 Nm {25 31.5 kgm} (9) 3: 1,177 1,471 Nm {120 150 kgm}
(5) 3: 490 608 Nm {50 62 kgm}
* After the cab is mounted, if there is clearance (Standard: 0 mm), insert shims (4) as necessary [Number of shims prepared for each place: 4 (t1.0 x 4)]. No shim may be used as standard. Connect
1. Move the cab assembly to above the frame. 2. Remove parts (9) and (10) installed temporarily and then install the cab assembly with the following parts.
(1) (2) (4) (5) (6) (7) (8) (9) (10) Part No. 01010-81645 01643-31645 561-54-87221 01010-82055 01643-32060 561-54-87231 561-54-87241 01596-03024 01643-33080 Part name Bolt Washer Shim t=1.0 Bolt Washer Shim t=0.5 Shim t=1.0 Nut Washer Q'ty 8 8 4 8 8 8 8 1 1 Condition of part (Parts list No.) Packed separately (HD785-7-340) Packed separately (HD785-7-340) Packed separately (HD785-7-340) Packed separately (HD785-7-340) Packed separately (HD785-7-340) Packed separately (HD785-7-340) Packed separately (HD785-7-340) Installed to frame Installed to frame
Section B-B
3. Remove the sling. 4. Connect the ground wire to the rear of the cab assembly.
(12) (13) Part No. 08028-45025 01024-81016 Part name Cable Bolt, sems Q'ty 1 2 Condition of part (Parts list No.) Installed to cab assembly Packed separately (HD785-7-340)
Precautions 1. If there is clearance between the mount bracket and cab (clearance to be adjusted with shims), insert shims by necessary quantity (up to 8 pieces for each place). 2. The part to connect the ground wire must be free from stain or paint.
Q'ty
Other remarks
60
Connection of ABS piping (If equipped)
0345
Connection of ABS piping 1. Remove the plugs of each hose and tube. 2. Check that the correct O-ring is fitted to each tube and connect the hose on the ABS front box side.
Precautions
Q'ty
Other remarks
61
Connection of column
0350
Connection of column 1. Remove the bolt and washer and connect the column shaft to the steering valve. 2. Set the bolt removed in step 1 to the hollow of the steering valve joint and tighten it again. (See section A-A.)
Remove these bolt and washer.
A A
Bolt Set bolt to this "hollow".
Steering valve Section A-A
Precautions 1. Apply grease (LM-G) to the connecting parts. 2. When installing the parts, do not hit them with a hammer etc. or installing them forcibly.
Q'ty
Other remarks
62
Installation of washer tank
0355
Installation of washer tank
1. Take washer tank assembly (1) out of the cab and install it to the cab with bolts (2). 2. Fix washer hose (A) coming out of the cab with washer tank clips (marked with a) at 2 places so that it will not be flattened and then connect it to the washer tank. 3. Connect wiring harness (B) going to the washer motor to the washer tank. (CN FL04) 4. Fix washer hose (A) and wiring harness (B) going to the washer motor with band (3) at 80 mm from the bracket end (on the cab side) so that the hose will not be flattened.
(1) (2) (3)
Part No. 569-06-6115A 01024-81020 08034-40521
Part name Washer tank Bolt, sems Band
Q'ty 1 4 1
Condition of part (Parts list No.) Packed together with cab Packed together with cab Packed together with cab
Precautions 1. When fixing the washer hose, take care not to flatten it.
Q'ty
Other remarks
63
Connection of cab piping
0360
Connection of cab piping
Z (View from below cab)
Path hoses through notches.

Brake accumulator
A
View Z (View from below cab)
A
Section A-A
1. 2. 3. 4. 5. 6
Remove the underside cover of the cab floor. Remove the plugs from each part. Connect the 7 hoses. Pass 5 hoses through the notches of rubber (3). Install the following parts. Clean the parts stained with oil.
(1) (2) (3) (4) (5) (6) Part No. 561-89-86241 561-89-86251 561-89-86232 424-54-14220 561-89-86262 01024-81025 Part name Bracket Plate Rubber Washer Bracket Bolt, sems Q'ty 1 1 1 2 2 10 Condition of part (Parts list No.) Packed separately (HD785-7-360) Packed separately (HD785-7-360) Packed separately (HD785-7-360) Packed separately (HD785-7-360) Packed separately (HD785-7-360) Packed separately (HD785-7-360)
Precautions
Q'ty
Other remarks
64
Connection of cab wiring
0370
Procedure for connecting wiring harness

CN LP2: Left platform wiring harness junction
CN LP1: Left platform wiring harness junction CN J06: Wiring harness junction in cab CN J05: Wiring harness junction in cab CN J03: Wiring harness junction in cab CN J02: Wiring harness junction in cab
CN J01: Wiring harness junction in cab
CN PMLA: PLM and side lamp wiring harness junction
(1) (2) (3) (4) (5) (6) (7) (9) (10) (11) (12)
Part No. 04434-52711 01024-81020 08193-21012 01024-81016 23S-62-25850 6152-51-5520 01024-81070 04434-52110 07095-20420 561-61-65530 561-61-65540
Part name Clip Bolt, sems Clip Bolt, sems Clip Spacer Bolt, sems Clip Cushion Clip Insulator
Q'ty 3 4 1 1 1 1 1 1 1 1 1
1. Connect the wiring harness in the cab. 2. Install the cab undercover removed in the previous step. 3. Fix the bracket installed in the previous step.
Q'ty
Other remarks
65
0375
Connection of cab wiring (ASR/ABS specification: If equipped)

Procedure for connecting wiring harness
CN LP2: Left platform wiring harness junction CN J04: Wiring harness junction in cab CN LP1: Left platform wiring harness junction
CN J06: Wiring harness junction in cab CN J05: Wiring harness junction in cab CN J03: Wiring harness junction in cab CN J02: Wiring harness junction in cab CN J01: Wiring harness junction in cab CN PMLA: PLM and side lamp wiring harness junction

Fix upper wiring harness : : Fix lower wiring harness
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16)
Part No. 04434-52711 01024-81020 08193-21012 01024-81016 23S-62-25850 6152-51-5520 04434-52110 01024-81070 04434-52511 07095-20420 561-61-65530 561-61-65540 195-979-5190 04434-53411 07095-20625 01024-81075
Part name Clip Bolt, sems Clip Bolt, sems Clip Spacer Clip Bolt, sems Clip Cushion Clip Insulator Collar Clip Cushion Bolt, sems
Q'ty 3 3 4 4 1 1 1 1 1 1 1 1 1 1 1 1
Condition of part (Parts list No.) Packed separately (HD785-7-375) Packed separately (HD785-7-375) Packed separately (HD785-7-375) Packed separately (HD785-7-375) Packed separately (HD785-7-375) Packed separately (HD785-7-375) Packed separately (HD785-7-375) Packed separately (HD785-7-375) Packed separately (HD785-7-375) Packed separately (HD785-7-375) Packed separately (HD785-7-375) Packed separately (HD785-7-375) Packed separately (HD785-7-375) Packed separately (HD785-7-375) Packed separately (HD785-7-375) Packed separately (HD785-7-375)
1. Connect the wiring harness in the cab. 2. Install the cab undercover removed in the previous step. 3. Fix the bracket installed in the previous step.
Q'ty
Other remarks
66
0376
Connection of engine prelubrication harness to cab (If equipped: Engine prelubrication specification)
Connection of engine prelubrication harness to cab 1. Fix the engine prelubrication harness to the cab and connect it to the harness on the cab side.
View X Connect: Cab relay connector PRE4
View Z
Section B-B
: Tighten together at 3 places.
Section A-A
View Y: Underside of cab
(1) (2) (3) (4) (5)
Part No. 6131-22-3750 04434-51210 198-06-53510 01024-81045 04434-50810 Precautions
Part name Boss Clip Cushion Bolt, sems Clip
Q'ty 1 1 1 1 3
Condition of part (Parts list No.) Packed separately (HD785-7-376) Packed separately (HD785-7-376) Packed separately (HD785-7-376) Packed separately (HD785-7-376) Packed separately (HD785-7-376) Necessary tools Name Necessary equipment Name Q'ty
Q'ty
Other remarks
67
0377
Connection and fixing of engine compartment lamp wiring harness (if equipped)
Connection and fixing of engine compartment lamp wiring harness

Pass wiring harness into cab.
Mark a: 4 places (Tighten with clip)
View Z: Cab seen from below
CAB
Remove cover in cab.
Section A-A
1. Lay the engine compartment lamp wiring harness from the machine to under the cab and fix it with clips (1). 2. Pass the engine compartment wiring harness into the cab. Remove the cover in the cab and connect the wiring harness to connector (SPARE4). 3. Install the cover in the cab again.
Connect: SPARE4
Inside of cab seen from front
(1)
Part No. 04434-50610 Precautions
Part name Clip
Q'ty 4
Condition of part (Parts list No.) Packed separately (HD785-7-377) Necessary tools Name Necessary equipment Name Q'ty
Q'ty
Other remarks
68
0378
Connection of auto grease harness to cab (If equipped: Auto grease specification)
Connection of auto grease harness to cab 1. Fix the auto grease harness to the cab and connect it to the harness on the cab side.
For other specifications, remove mounting bolt and install with it.
Section A-A
Connect: Harness on cab side
View Y
View Z
(1) (2) (3)
Part No. 04434-51210 01024-81020 561-95-83210 Precautions
Part name Clip Bolt, sems Bracket
Q'ty 1 2 1
Condition of part (Parts list No.) Packed separately (HD785-7-378) Packed separately (HD785-7-378) Packed separately (HD785-7-378) Necessary tools Name Necessary equipment Name Q'ty
Q'ty
Other remarks
69
0379
Connection of engine stop harness to cab (If equipped: Engine emergency stop specification)
Connection of engine stop harness to cab 1. Fix the engine stop harness to the cab and connect it to the harness on the cab side.
Install together with main harness clip mounting bolt.
View Y
Install together with cab under harness clip mounting bolt.
: 8 places
Section B-B
Install together with cab under harness clip mounting bolt.
Section A-A
Section C-C
Remove used for standard and install with it.
Section D-D : 2 places Install together with main harness clip mounting bolt.
Connect View X View Z
(1) (2) (3) (4) (5)
Part No. 04434-50610 04434-51210 198-06-53510 01024-81020 08193-21012 Precautions
Part name Clip Clip Cushion Bolt, sems Clip
Q'ty 8 1 1 2 1
Condition of part (Parts list No.) Packed separately (HD785-7-379) Packed separately (HD785-7-379) Packed separately (HD785-7-379) Packed separately (HD785-7-379) Packed separately (HD785-7-379) Necessary tools Name Q'ty Necessary equipment Name Q'ty
Other remarks
70
Installation and fixing of steering hoses
0380
Installation and fixing of steering hoses 1. Remove the cover from the front support. Install the 5 hoses to the steering valve. When installing the hoses, match the Nos. printed on them to the following figure.
Port P: "2" Port LS
Port RT: "5" Port R: "1" Port LT: "4"
View Z
(1) (2) (3) (4) (5) Part No. 02766-00423 561-61-82320 561-61-82350 561-61-82310 561-61-82340 Part name Hose Hose Hose Hose Hose Q'ty 1 1 1 1 1 Condition of part (Parts list No.) Packed separately (HD785-7-380) Packed separately (HD785-7-380) Packed separately (HD785-7-380) Packed separately (HD785-7-380) Packed separately (HD785-7-380)
Port R Port P Port LT Port RT Port LS
Port R: "1" Port P: "2" Port LS Port LT: "4" Port RT: "5"
2. Fix the 5 steering hoses to the front support. 3. Connect the hoses to the steering tubes of the frame. 4. Clean the parts stained with oil.
Q'ty 6 3 6 3 6 Condition of part (Parts list No.) Packed separately (HD785-7-380) Packed separately (HD785-7-380) Packed separately (HD785-7-380) Packed separately (HD785-7-380) Packed separately (HD785-7-380) Necessary tools Name Necessary equipment Name Q'ty
(6) (7) (8) (9) (10)
Part No. 561-61-64510 561-61-64540 561-61-64530 561-61-64520 01024-81290 Precautions
Part name Clamp Plate Spacer Plate Bolt sems
Q'ty
Other remarks
71
Fixing of air conditioner drain hose
0385
Fixing of air conditioner drain hose
1. Remove the cab undercover. 2. Remove wiring harness clamping bolts (2) of the front support LH. 3. Install the air conditioner drain hose to the wiring harness clamping position of the front support LH with clip (1) and bolts (2) removed in step 1. 4. Remove bolts (5) installed in field assembly procedure No. 0380. 5. Install the 2 air conditioner drain hoses together with clips (3) and (4) and bolts (5) removed in step 3.
Part No. 04434-51510 01024-81016 04435-51510 04435-51810 01024-81290 Precautions Part name Clip Bolt, sems Clip Clip Bolt, sems Q'ty 2 2 1 1 2 Condition of part (Parts list No.) Packed in cab Installed to front support LH Packed in cab Packed in cab Installed in No. 0380 Necessary tools Name Necessary equipment Name Q'ty
(1) (2) (3) (4) (5)
Q'ty
Other remarks
72
Installation of steering hose cover
0390
Installation of steering hose cover
1. Install the cover over the steering piping of the left front support
(1) (2) (3) (4)
Part No. 561-54-81490 01024-81220 561-54-81580 01024-81220
Part name Cover Bolt, sems Cover Bolt, sems
Q'ty 1 4 1 4
Condition of part (Parts list No.) Packed separately (HD785-7-390) Packed separately (HD785-7-390) Packed separately (HD785-7-390) Packed separately (HD785-7-390)
Precautions
Q'ty
Other remarks
73
Connection of air conditioner and heater hoses
0395
Connection of air conditioner and heater hoses
1. Connect the 4 hoses to the cab piping. 2. Fix hose (d) going to the engine and hose (c) coming from the engine with clamps (1).
(1) (2) Part No. 09479-02400 01024-81020 Precautions Part name Clamp Bolt, sems Q'ty 2 1 Condition of part (Parts list No.) Installed to hose Packed separately (HD785-7-395) Necessary tools Name Necessary equipment Name Q'ty
Q'ty
Other remarks
74
Connection of cab floor wiring
0400
Connection of cab floor wiring 1. Remove the cover in the cab floor.
Inside of cab floor
X
2. Connect the wiring coming from the following figure (View Z) inside the cab floor. * Each wiring harness is printed with a connector No. Take care not to connect them wrongly.
CN HM-21B Exhaust temperature sensor connector (RF) CN HM-21A Exhaust temperature sensor connector (LF)
CN HM-21D Exhaust temperature sensor connector (RR))
CN HM-21C Exhaust temperature sensor connector (LR)
View X
View Z
CN HM-22A
Connection
CN HM-23A
CN HM-22C
CN HM-23C
Inside of cab floor
CN HM-22B
CN HM-23B
CN HM-22D
CN HM-23D
(1)
Part No. 561-97-82250
Part name Wiring harness
Q'ty 1
Condition of parts Installed to frame
Precautions
Q'ty
Other remarks
75
Fixing of ASR/ABS wiring harness (If equipped)
0405
Fixing of ASR/ABS wiring harness 1. Fix ASR/ABS wiring harness (1) to the cab with clip (1) and bolt (2). 2. Fix the connector with clip (3) and bolts (2). (CN J11)
CAB
Fixing: CN J11
View X
CN ABSER: Ground
View Z
Part No. 04434-51910 01024-81016 08193-21012 Precautions Part name Clip Bolt, sems Clip Q'ty 1 2 1 Condition of part (Parts list No.) Packed separately (HD785-7-405) Packed separately (HD785-7-405) Packed separately (HD785-7-405) Necessary tools Name Necessary equipment Name Q'ty
(1) (2) (3)
Q'ty
Other remarks
76
0406
Connection and fixing of ABS wiring harness (If equipped)
Connection and fixing of ABS wiring harness 1. Connect and fix the wiring harness with the installed clip and bolt.
ABS front box
View Z
Wheel speed sensor wiring harness ABS/ASR wiring harness Fixing Connection and fixing: CN J11 Fixing
Z
View X
Section A-A
Precautions
Q'ty
Other remarks
77
Installation of cover under cab
0410
Installation of cover under cab
FWD A A
Z
View Z
Directed to inside of cover
Directed to inside of cover
Section A-A
Section B-B
Installed position of (5), (6) and (7)
View Z
1. Install seals (3) and (4) to cover (1). 2. Install the cover under the cab. 3. Fix the 2 hoses with clamps (5), cushions (6) and bolt (7).
Part No. 561-54-82141 01024-81020 569-54-82260 569-54-82290 07094-30620 07095-00628 01024-81270 Part name Cover Bolt, sems Seal Seal Clamp Cushion Bolt, sems Q'ty 1 9 1 1 2 2 1 Condition of part (Parts list No.) Packed separately (HD785-7-410) Packed separately (HD785-7-410) Packed separately (HD785-7-410) Packed separately (HD785-7-410) Packed separately (HD785-7-410) Packed separately (HD785-7-410) Packed separately (HD785-7-410)
(1) (2) (3) (4) (5) (6) (7)
Precautions
Q'ty
Other remarks
78
Wiring of front glass with heater wire (If equipped)
0415
Installation of cab undercover
a: 3 places
FWD
Z
: 2 places (1 place: See view X)
CN BR-4 Connection : 2 places
: 3 places
View Z
View X
(Battery)
Connection: Secondary side (BR04)
1. Using clips (1) and bolts (2), connect the glass heater wiring harness coming from the cab. 2. Remove the bolts marked with a (3 places) and fix wiring harness with clips (1), collars (4) and bolts (5). (Discard the removed bolts.) 3. Open the battery box cover and connect the glass heater wiring harness to the battery relay. (View X) 4. Fix the wiring harness with bands (3) and (6).
Part No. 04434-50610 01024-81016 08034-20823 22D-62-18450 01024-81055 08034-20519 Precautions Part name Clip Bolt, sems Band Collar Bolt, sems Band Q'ty 6 3 2 3 3 2 Condition of part (Parts list No.) Packed separately (HD785-7-415) Packed separately (HD785-7-415) Packed separately (HD785-7-415) Packed separately (HD785-7-415) Packed separately (HD785-7-415) Packed separately (HD785-7-415) Necessary tools Name Q'ty Necessary equipment Name Q'ty
(1) (2) (3) (4) (5) (6)
Other remarks
79
Installation of cab seal
0420
Installation of cab seal
1. Stick seal (1) to the clearance between the cab and radiator guard. (1) Degrease, clean and dry the seal sticking surface. (2) Thinly apply adhesive (LT-1A) to the seal sticking surface and sticking surface on the right side of the cab. Dry the surfaces coated with the adhesive for 3 - 5 minutes and then stick the seal.
Part No. 561-54-61290 Part name Seal Q'ty 1 Condition of part (Parts list No.) Packed separately (HD785-7-420)
(1)
Precautions
Q'ty
Other remarks
80
0430
Installation of ambient temperature sensor wiring harness
Installation of ambient temperature sensor wiring harness
Connection: CN FL06
Front support (Left)

Ambient temperature sensor wiring harness
1. Fix the wiring harness under the cab with clips (2) and bolts (3). 2. Fix the connector with clip (1) and bolts (3) and connect CN FL06. * Bolts (3) are those used in Assembly procedure No. 0480, however. Use them to fix the cab step, too.
(1) (2) (3)
Part No. 08193-21012 04434-50612 01024-81230
Part name Clip Clip Bolt, sems
Q'ty 1 2 3
Condition of part (Parts list No.) Packed separately (HD785-7-430) Packed in cab Bolt (2) used in No. 0480
Precautions
Q'ty
Other remarks Sales code: 6HF55K (VHMS + PLM + ORB, overseas)
81
Installation of undercab wiring harness connector
0440
Installation of undercab wiring harness connector
Front support (Left)
1. Fix the wiring harness under the cab with clip (2) and bolts (3). 2. Fix the wiring harness with clip (1) and bolts (3) and connect connector (4) to its end. * Bolts (3) are those used in Assembly procedure No. 0480, however. Use them to fix the cab step, too.
(1) (2) (3) (4)
Part No. 08193-21012 04434-50612 01024-81225 08192-23830
Part name Clip Clip Bolt, sems Connector
Q'ty 1 2 3 1
Condition of part (Parts list No.) Packed separately (HD785-7-440) Packed in cab Bolt (2) used in No. 0480 Packed separately (HD785-7-440)
Precautions
Q'ty
Other remarks
82
0445
Connection and fixing of rear view camera wiring harness (if equipped)
Connection and fixing of rear view camera wiring harness

Camera cable
Wiring harness rail
2-stage connection 1) Tighten the connector with the fingers. 2) Using 2 17mm spanner wrench, rotate the outer ring 180 degrees. Tighten to about 245 Nm {25 kgm} securely.
View X
Connect
View Y
Pass through backup lamp mounting hole and fix together with junction connector. Section A-A Section B-B Section C-C
Mark a: 9 places Mark u: 11 places
View Z
(1) (2) (3) (4)
Part No. 120-54-42430 04434-50610 01024-81050 08034-20823
Part name Spacer Clip Bolt, sems Band
Q'ty 9 9 9 11
Condition of part (Parts list No.) Installed temporarily to machine Installed temporarily to machine Installed temporarily to machine Packed separately (HD785-7-445)
1. Pull the camera cable out of the cab. (See view Z.) 2. Remove the wire harness rail cover and fix the camera cable with clips (2) installed temporarily. 3. Connect the rear view camera and camera cable and fix the wire harness with bands (4).
Precautions Necessary tools Name 17mm spanner wrench Q'ty 1 Necessary equipment Name Q'ty
Other remarks
83
Installation of R.H platform assembly
0450
Installation of R.H platform assembly
3 : 319 608 Nm {32.5 62 kgm} Target : 460 Nm {47 kgm}
1. Remove bolts (2) installed temporarily. 2. Sling the right platform and install it with bolts (2) and (3). Install caps (5).
(1) (2) (3) (4) (5) Part No. 561-54-80602 01024-81235 01010-82045 01643-32060 09415-05016 Part name R.H platform assembly Bolt Bolt Washer Cap Q'ty 1 8 2 2 2 Condition of part (Parts list No.) Packed separately (HD785-7-450) Temporarily installed to machine body Packed separately (HD785-7-450) Packed separately (HD785-7-450) Packed separately (HD785-7-450)
Installation of R.H platform mirror 1. Install the mirror and underview mirror to the handrail. (See view Z) 2. Adjust the angle of the mirror.
: 59 -- 74 Nm {6 -- 7.5 kgm}
: 59 -- 74 Nm {6 -- 7.5 kgm}
View Z
(1) (2) (3) (4) (6) (7) (8) (9) (10) (11)
Part No. 561-54-80900 07283-33442 01643-31032 01597-01009 07283-32236 07283-52232 01597-01009 01643-31032 23W-P86-2890 561-54-81871 Precautions
Part name Mirror & rail assembly Clip Washer Nut Clip Seat Nut Washer Mirror Stay
Q'ty 2 4 8 8 2 2 4 4 1 1
Condition of part (Parts list No.) Packed separately (HD785-7-450) Packed separately (HD785-7-450) Packed separately (HD785-7-450) Packed separately (HD785-7-450) Packed separately (HD785-7-450) Packed separately (HD785-7-450) Packed separately (HD785-7-450) Packed separately (HD785-7-450) Packed separately (HD785-7-450) Packed separately (HD785-7-450) Necessary equipment Q'ty Name Q'ty 1 Crane (25 ton) 1
Necessary tools Name Tighten the mounting bolts of rear support No. 0280 perNylon sling manently. (250 mm wide 5 m) (2) 3: 824 1,030 Nm {84 105} kgm (5) 3: 343 427 Nm {35 43.5} kgm
Other remarks
84
Installation of right fender
0470
Set glossy side toward front of machine.
1. Install the right fender. 2. Install the guard to the right fender.
Remove guard mounting plate and bolts installed to fender assembly. Install the guard with the removed plate and bolts. 3 : 29.4 49.0 Nm {3 5 kgm}
(1) (2) (3)
Part No. X251043130 01024-81230 561-54-87420
Part name Fender R.H Bolt sems Guard
Q'ty 1 6 1
Condition of part (Parts list No.) Packed separately (HD785-7-470) Packed separately (HD785-7-470) Packed separately (HD785-7-470)
Precautions Install guard (3) with its glossy side toward the front of the machine.
Q'ty
Other remarks
85
0472
Installation of right fender (If equipped: Body heating-less muffler specification)
: 6 places
Remove the plate and bolts for the guard installed to the fender assembly temporarily. Install the right fender with the removed plate and bolts. Tightening torque: 29.4 - 49.0 Nm {3 - 5 kgm} Install the fender with the glossy side toward front of machine.
(1) (2) (3) (4)
Part No. X251039700 01024-81225 01024-81225 561-54-87420
Part name Fender R, H Bolt, sems Bolt, sems Guard
Q'ty 1 6 2 1
Condition of part (Parts list No.) Packed separately (HD785-7-472) Installed to fender Packed separately (HD785-7-472) Packed separately (HD785-7-472)
Precautions
Q'ty
Other remarks
86
0475
Installation of fuel tank quick charge-less hose (If equipped)
Installation of fuel tank quick charge-less hose

Right fender
View X
Fuel tank
Fire prevention cover View Z * To be installed to fire prevention cover. : 3 places
Detail of part P
1. Fix bracket (1) to the fire prevention cover with bolts (2) installed to the fire prevention cover. (2 places) 2. Fix the hose going to the fuel tank breather to the bracket with clips (4) and bolts (5). (2 places) 3. Install cover (3) to the fire prevention cover with bolts (6). 4. Fix the hose going to the fuel tank breather to cover (3) with clip (4) and bolt (5). (1 place)
(1) (2) (3) (4) (5) (6) (7) Part No. 561-04-81530 01024-81020 561-04-81540 04434-51210 01024-81020 01024-81040 01024-81016 Precautions Part name Bracket Bolt, sems Cover Clip Bolt, sems Bolt, sems Bolt, sems Q'ty 2 4 1 5 3 2 2 Condition of parts Packed separately (HD785-7-475) Packed separately (HD785-7-475) Packed separately (HD785-7-475) Packed separately (HD785-7-475) Packed separately (HD785-7-475) Packed separately (HD785-7-475) Packed separately (HD785-7-475) Necessary tools Name Q'ty Necessary equipment Name Q'ty
Other remarks
87
0476
Installation of fuel tank quick chargeless hose: Muffler specification (If equipped: muffler specification)
Installation of fuel tank quick chargeless hose
Rear support
Right fender
View X
Fuel tank
View Y
* To be installed to rear support. L-plate
Detail of part Q
View Z
View P
Bolt
Bolt
1. Remove the L-plate and 2 bolts. (See view P.) 2. Install cover (1) and the hose going together to the fuel tank breather to rear support (1) with clips (2) and bolts (3). (See views Y and Q.) 3. Fix the hose going to the fuel tank breather with clips (7) and bolts (8). (3 places. See views X and Z.) 4. Install cover (4) with bolts (5) and (6). (See view Y.)
(1) (2) (3) (4) (5) (6) (7) (8) Part No. 561-04-81550 04434-51212 01024-81260 561-04-81560 01024-81045 01024-81035 04434-51210 01024-81016 Precautions Part name Cover Clip Bolt, sems Cover Bolt, sems Bolt, sems Clip Bolt, sems Q'ty 1 2 2 1 1 1 3 3 Condition of part (Parts list No.) Packed separately (HD785-7-476) Packed separately (HD785-7-476) Packed separately (HD785-7-476) Packed separately (HD785-7-476) Packed separately (HD785-7-476) Packed separately (HD785-7-476) Packed separately (HD785-7-476) Packed separately (HD785-7-476) Necessary tools Name Q'ty Necessary equipment Name Q'ty
Other remarks
88
Installation of cab step
0480
Only machine equipped with radio
Detailed assembly of (7), (8) and (9)
CAB
Scrape paint off ground part for radio antenna (Scrape paint off on left platform side, too).
Peel off masking tape.
Installation of front cab step 1. Install the step assembly to the front side of the cab.
(1) (2) Part No. 561-54-80103 01024-81230 Part name Front cab step assembly Bolt Q'ty 1 12 Condition of part (Parts list No.) Packed separately (HD785-7-480) Packed separately (HD785-7-480)
Installation of side cab step 1. Install the step assembly to the front side of the cab.
(3) (4) (5) (6) (7) (8) (9) Part No. 561-54-80203 01024-81225 01024-81230 01024-81250 01024-81245 01643-31232 01580-11210 Precautions Part name Side cab step assembly Bolt Bolt Bolt Bolt Washer Nut Q'ty 1 8 2 2 1 1 1 Condition of parts Packed separately (HD785-7-480) Packed separately (HD785-7-480) Packed separately (HD785-7-480) Packed separately (HD785-7-480) Packed separately (HD785-7-480) Packed separately (HD785-7-480) Packed separately (HD785-7-480) Necessary equipment Q'ty Name Q'ty 1 Crane (25 ton) 1
Necessary tools Name Nylon sling (250 mm wide 5 m)
Other remarks
89
Assembly of diagonal ladder (if equipped)
0481
Assembly of diagonal ladder 1. Install the handrail to the platform. * When installing clamp (9), see "Fig. 1".
Fig. 1
Up
Set edge side up.
Set rear side down. Photo of clamp (9)
Weight: 125 kg
Weight: 45 kg
(1) (2) (5) (6) (7) (8) (9) (10) (11) Part No. 561-89-85810 561-89-85850 561-89-85831 561-89-85861 561-89-85821 561-89-85870 561-54-61910 01643-31645 01010-81635
Weight: 75 kg
Part name Step Guard Step Guard Step Guard Clamp Washer Bolt Q'ty 1 1 1 1 1 1 8 16 16 Condition of part (Parts list No.) Packed separately (HD785-7-481) Packed separately (HD785-7-481) Packed separately (HD785-7-481) Packed separately (HD785-7-481) Packed separately (HD785-7-481) Packed separately (HD785-7-481) Packed separately (HD785-7-481) Packed separately (HD785-7-481) Packed separately (HD785-7-481)
Precautions
Q'ty
Other remarks
90
0482
Installation of cab step: Diagonal ladder specification (if equipped)
Installation of cab step 1. Install the step assembly to the left side of the cab.
Only machine equipped with radio EU specification
Remove paint from radio antenna ground part (Remove paint from ground part on left platform side, too). Remove masking tape.
(1) (2)
Part No. 561-54-80203 01024-81225
Part name Side cab step assembly Bolt
Q'ty 1 8
Installation of cab step 1. Install the step assembly to the front side of the cab.
(3) (4) (5) (6) (7) (8) (9) (10)
Part No. Part name 561-89-80100 Step assembly 01024-81230 Bolt, sems 01024-81250 Bolt, sems 01024-81245 Bolt, sems 01643-31232 Washer 01580-11210 Nut X251271380 Front cab step sub A., kal X251271400 Side cab step sub A., kal Precautions
Q'ty Condition of part (Parts list No.) 1 Packed separately (HD785-7-481) 14 Packed separately (HD785-7-482) 2 Packed separately (HD785-7-482) 1 Packed separately (HD785-7-482) 1 Packed separately (HD785-7-482) 1 Packed separately (HD785-7-482) 1 Packed separately (HD785-7-487) 1 Packed separately (HD785-7-489) Necessary tools Necessary equipment Name Q'ty Name Q'ty Nylon sling 1 Crane (25t) 1 (250 mm wide * 5 m)
Other remarks Sales code: 6HB55 or 5AC11
91
Installation of diagonal ladder 1 (if equipped)
0483
Installation of diagonal ladder 1 1. Install the step assembly to the front side of the cab. 2. Install the rod.
Tightening torque (10):490 608 Nm {50 62 kgm}
*2 places
Section A-A
Part name Step assembly Bolt Plate Plate Cushion Bushing Washer Nut Nut Nut Rod
*2 places Other than rod (11)

Q'ty 1 2 2 8 8 4 6 2 2 4 1
Section B-B
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
Part No. 561-89-8583A 01011-82015 566-54-21931 566-54-21920 566-54-12212 566-54-21910 01643-32060 01580-02016 01597-02016 01583-12012 561-89-6A970 Precautions
Condition of part (Parts list No.) See field assembly procedure No. 0481. Packed separately (HD785-7-483) Packed separately (HD785-7-483) Packed separately (HD785-7-483) Packed separately (HD785-7-483) Packed separately (HD785-7-483) Packed separately (HD785-7-483) Packed separately (HD785-7-483) Packed separately (HD785-7-483) Packed separately (HD785-7-483) Packed separately (HD785-7-483) Necessary equipment Q'ty Name Q'ty 1 Crane (25t) 1
Necessary tools Name Nylon sling (250 mm wide * 5 m)
Other remarks Sales code: 6HB55 or 5AC11
92
0484
Installation of diagonal ladder 2 1. Install the step assembly to the front side of the cab.
* 2 places
Detail of part A
(1) (2) (3) (4) (5)
Part No. 561-89-8581A 01024-81230 01024-81245 01643-31232 01580-11210
Part name Step assembly Bolt, sems Bolt, sems Washer Nut
Q'ty 1 6 2 2 2
Condition of part (Parts list No.) See field assembly procedure No. 0481. Packed separately (HD785-7-484) Packed separately (HD785-7-484) Packed separately (HD785-7-484) Packed separately (HD785-7-484)
Precautions
Necessary equipment Q'ty Name Q'ty 1 Crane (25t) 1
Other remarks
93
0485
Installation of diagonal ladder 3 1. Install the step assembly to the front side of the cab.
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) Part No. 561-89-8582A 01024-81230 01011-82015 566-54-21931 566-54-21920 566-54-12212 566-54-21910 0643-32060 01580-12016 09415-03614 Part name Step assembly Bolt, sems Bolt Plate Plate Cushion Bushing Washer Nut Cap Q'ty 1 6 2 2 4 4 2 2 2 2 Condition of part (Parts list No.) See field assembly procedure No. 0481. Installed temporarily to machine Packed separately (HD785-7-485) Packed separately (HD785-7-485) Packed separately (HD785-7-485) Packed separately (HD785-7-485) Packed separately (HD785-7-485) Packed separately (HD785-7-485) Packed separately (HD785-7-485) Packed separately (HD785-7-485)
* 2 places
Section A-A
Installation of step 1. Install the step assembly to the front side of the cab.
(11) (12) Part No. 561-54-6A151 01024-81235 Precautions Part name Step Bolt, sems Q'ty 1 4 Condition of part (Parts list No.) Packed separately (HD785-7-485) Packed separately (HD785-7-485) Necessary equipment Q'ty Name Q'ty 1 Crane (25t) 1
Other remarks
94
Installation of diagonal ladder (EU specification)
0486
Installation of diagonal ladder 1. Install the handrails to the ladder and platform. * When installing clamp (7), see "Fig. 1".
Fig. 1
Up
Set edged end up
Set round end down Clamp figure
Weight: 125 kg
mark: 8 place
Weight: 45 kg
Weight: 75 kg
(1) (2) (3) (4) (5) (6) (7) (8) (9)
Part No. 561-89-85810 561-89-85850 561-89-85831 561-89-85861 561-89-86820 561-89-86870 561-54-61910 01643-31645 01010-81635 Precautions
Part name Step Guard Step Guard Step Guard Clamp Washer Bolt
Q'ty 1 1 1 1 1 1 8 16 16
Condition of part (Parts list No.) Packed separately (HD785-7-487) Packed separately (HD785-7-487) Packed separately (HD785-7-487) Packed separately (HD785-7-487) Packed separately (HD785-7-487) Packed separately (HD785-7-487) Packed separately (HD785-7-487) Packed separately (HD785-7-487) Packed separately (HD785-7-487) Q'ty Necessary equipment Name Q'ty
Other remarks Sales code: 5AC11
95
Installation of diagonal ladder-2 (EU specification)
0487
Installation of ladder-2 1. Install the step assembly to the front side of the cab.
* 2 places
Detail A
(1) (2) (3) (4) (5)
Part No. 561-89-8581A 01024-81230 01024-81245 01643-31232 01580-11210
Part name Step assembly Bolt, sems Bolt, sems Washer Nut
Q'ty 1 6 2 2 2
Condition of part (Parts list No.) See Field assembly manual No. 0486. Packed separately (HD785-7-484) Packed separately (HD785-7-484) Packed separately (HD785-7-484) Packed separately (HD785-7-484)
Precautions
Necessary tools Name Nylon sling (250 mm wide x 5 m)
Necessary equipment Q'ty Name Q'ty 1 Crane (25t) 1
96
Installation of diagonal ladder-3 (EU specification)
0488
Installation of ladder-3 1. Install the step assembly to the front side of the cab.
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) Part No. 561-89-8682A 01024-81230 01011-82015 566-54-21931 566-54-21920 566-54-12212 566-54-21910 01643-32060 01580-12016 09415-03614 Part name Step assembly Bolt, sems Bolt Plate Plate Cushion Bushing Washer Nut Cap Q'ty 1 6 2 2 4 4 2 2 2 2 Condition of part (Parts list No.) See Field assembly manual No. 0486. Temporarily Installed to machine Packed separately (HD785-7-488) Packed separately (HD785-7-488) Packed separately (HD785-7-488) Packed separately (HD785-7-488) Packed separately (HD785-7-488) Packed separately (HD785-7-488) Packed separately (HD785-7-488) Packed separately (HD785-7-488)
* 2 places
Section A-A
Installation of step 1. Install the step to the step assembly on the front side of the cab.
(11) (12) Part No. 561-54-88200 01024-81235 Precautions Part name Step Bolt, sems Q'ty 1 4 Condition of part (Parts list No.) Packed separately (HD785-7-488) Packed separately (HD785-7-488) Necessary equipment Q'ty Name Q'ty 1 Crane (25t) 1
Necessary tools Name Nylon sling (250 mm wide x 5 m)
97
Installation of L.H underview mirror (If equipped)
0490
Installation of L.H underview mirror
3:
59 -- 74 Nm {6 -- 7.5 kgm}
1. Install the underview mirror to the cab step. 2. Adjust the angle of the mirror.
(2) (3) (4) (5) (7) (8) Part No. 07283-32236 07283-52232 01597-01009 01643-31032 23W-P86-2890 561-54-81871 Part name Clip Seat Nut Washer Mirror Stay Q'ty 2 2 4 4 1 1 Condition of part (Parts list No.) Packed separately (HD785-7-490) Packed separately (HD785-7-490) Packed separately (HD785-7-490) Packed separately (HD785-7-490) Packed separately (HD785-7-490) Packed separately (HD785-7-490)
Precautions
Q'ty
Other remarks
98
Installation of fire extinguisher (If equipped)
0500
Installation of fire extinguisher (If equipped)
1. Remove the temporarily installed bolts and install fire extinguisher (1) with bolts (2).
(1) (2) Part No. 09495-00000 01435-00616 Part name Extinguisher Bolt Q'ty 1 4 Condition of part (Parts list No.) Packed separately (HD785-7-500) Packed separately (HD785-7-500)
Precautions
Q'ty
Other remarks Sales code: 6ZZ01
99
Installing radio antenna and fixing its cable
0510
Perform this work only when the radio is installed.
View Z
Bind connector and cable
L.H.platform assembly
Conection
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
Part No. 561-54-87480 01225-40412 01023-10414 07270-51514 04434-51910 01435-01016 08037-11825 561-54-86941 01435-01016 08037-01008 08210-00610
Part name Antenna assembly Screw Screw Tube Clip Bolt Grommet Cover Bolt Grommet Spairal tube
Q'ty 1 1 1 1 6 6 1 1 2 1 1
1. Install antenna (1) to the handrail installed to the L.H platform assembly as shown in the above figure. 2. Connect the antenna cable coming from the cab to the cable coming from the antenna. 3. Fix the cable with the other parts as shown in the above figure.
Precautions Necessary tools Name Q'ty Necessary equipment Name Q'ty
Other remarks
100
Installation of L.H fender
0520
Installation of L.H fender
Installed to
Set glossy side toward front of machine.
(1) (2) (3)
Part No. X251042740 01024-81230 561-54-87410
Part name Fender L.H Bolt sems Guard
Q'ty 1 6 1
1. Install the left fender. 2. Remove the bolts and plate installed temporarily to the left fender. 3. Install the guard with the bolts and plate removed in 2. (Install the guard with its glossy side toward the front of the machine.) 4. Tighten the guard mounting bolts to 29.4 49.0 Nm {3 5 kgm}.
Precautions
Q'ty
Other remarks
101
Installation of left side mudguard
0530
Installation of left side mudguard
View from inside of cab
3 : 29.4 -- 49.0 Nm {3 -- 5 kgm} r: 3 places
a: 6 places
View Z
Part No. 561-54-86670 01024-D1025 561-54-86820 01024-D1220 569-54-81571 01024-D1030 417-43-16210 283-54-11470 Precautions Part name Bracket Bolt, sems Bracket Bolt, sems Guard Bolt, sems Washer Plate Q'ty 1 2 1 3 1 6 2 2 Condition of part (Parts list No.) Packed separately (HD785-7-530) Packed separately (HD785-7-530) Packed separately (HD785-7-530) Packed separately (HD785-7-530) Packed separately (HD785-7-530) Packed separately (HD785-7-530) Packed separately (HD785-7-530) Packed separately (HD785-7-530) Necessary tools Name Necessary equipment Name Q'ty
(1) (2) (3) (4) (5) (6) (7) (8)
1. Install the left side mudguard.

Q'ty
Other remarks
102
Installation of grille guard
0540
Installation of grille guard
(1)
Part No. 561-54-81763
Part name Guard
Q'ty 1
Condition of part (Parts list No.) Packed separately (HD785-7-540)
1. Remove the bolts installed temporarily to the grille. 2. Sling and move the guard over the grille. 3. Install the guard with the removed bolts.
Precautions
Q'ty
Other remarks
103
Installation of left payload lamp (If equipped)
0550
Installation of left payload lamp 1. Install the payload lamp wiring harness to the rear of the cab. 2. Fix the wiring harness to the bottom of the cab. 3. Connect the payload lamp wiring harness to the frame wiring harness 4. If the side lamp is not installed, bind and fix the wiring harness with band (13).
Cab seen from rear
View Z Fix together with main wiring harness.

Connection: CN.PMLA
Cab seen from below
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (12) (13)
Part No. 561-86-80100 569-86-87321 01024-81020 421-62-23710 421-62-18550 175-54-34170 01010-81235 561-86-87522 04434-50810 04434-51010 01024-81016 08034-20834 Precautions
Part name PLM lamp sub assembly L.H Bracket Bolt, sems Cushion Cushion Washer Bolt Wiring harness Clip Clip Bolt, sems Band
Q'ty 1 1 3 4 4 4 4 1 5 1 4 1
Condition of part (Parts list No.) Packed separately (HD785-7-550) Packed separately (HD785-7-550) Packed separately (HD785-7-550) Packed separately (HD785-7-550) Packed separately (HD785-7-550) Packed separately (HD785-7-550) Packed separately (HD785-7-550) Packed separately (HD785-7-550) Packed separately (HD785-7-550) Packed separately (HD785-7-550) Packed separately (HD785-7-550) Packed separately (HD785-7-550) Q'ty Necessary equipment Name Q'ty
Other remarks
104
Installation of left side lamp (If equipped)
0555
Installation of left side lamp 1. Install side lamp wiring harness (1) to the rear of the cab. 2. Fix the wiring harness to the rear and underside of the cab. 3. Connect the wiring harness to the main wiring harness. (Connection: PMLA)
Fix together with main wiring harness.
Connection: CN. PMLA
Bottom view
(1) (2) (3)
Part No. 561-85-81211 04434-50810 01024-81016
Part name Wiring harness Clip Bolt, sems
Q'ty 1 5 3
Precautions
Q'ty
Other remarks Sales code: 5AC11 (EC Regulations)
105
Installation of right payload lamp (If equipped)
0560
Installation of right payload lamp 1. Install the payload lamp wiring harness to the right platform. 2. Remove the bolts marked with a on the right platform (3 places) and fix the wiring harness with them. Fix the other parts of the wiring harness, too. 3. Connect the payload lamp wiring harness to the frame wiring harness 4. If the side lamp is not installed, bind and fix the wiring harness with band (10).
Red Orange Green
View Y
Right platform seen from rear
3 : 59 -- 74 Nm
{6 -- 7.5 kgm} Connection: CN.PMRA
Right platform see from above
View Z
Q'ty 1 4 4 4 4 1 2 7 1 1 1 3 2 4 4 Condition of part (Parts list No.) Packed separately (HD785-7-560) Packed separately (HD785-7-560) Packed separately (HD785-7-560) Packed separately (HD785-7-560) Packed separately (HD785-7-560) Packed separately (HD785-7-560) Packed separately (HD785-7-560) Packed separately (HD785-7-560) Packed separately (HD785-7-560) Packed separately (HD785-7-560) Packed separately (HD785-7-560) Packed separately (HD785-7-560) Packed separately (HD785-7-560) Packed separately (HD785-7-560) Packed separately (HD785-7-560) Q'ty Necessary equipment Name Q'ty
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15)
Part No. 561-86-80201 421-62-23710 421-62-18550 175-54-34170 01010-81235 561-86-87531 01024-81016 04434-50810 08193-21012 08034-20834 561-54-86541 01024-81025 07283-33442 01643-31032 01597-01009 Precautions
Part name PLM lamp sub assembly R.H Cushion Cushion Washer Bolt Wiring harness Bolt, sems Clip Clip Band Cover Bolt, sems Clip Washer Nut
Other remarks
106
Installation of right side lamp (If equipped)
0565
Installation of right side lamp 1. Connect side lamp wiring harness (1). (Connection: PMRA) 2. Fix wiring harness (1) with clip (3) and bolt (2). 3. Fix cover (6) and wiring harness (1) together with clip (3) and bolt (4). 4. Fix cover (6) and guard with clip (7), washer (8) and nut (9).
Right platform
3 : 59 -- 74 Nm {6 -- 7 kgm}
Connection: CN-PMRA
(1) (2) (3) (4) (5) (6) (7) (8) (9)
Part No. 561-85-81220 01024-81016 04434-50810 01024-81025 08193-21012 561-54-86541 07283-33442 01643-31032 01597-01009
Part name Wiring harness Bolt, sems Clip Bolt, sems Clip Cover Clip Washer Nut
Q'ty 1 1 4 3 1 1 2 4 4
Condition of part (Parts list No.) Packed separately (HD785-7-565) Packed separately (HD785-7-565) Packed separately (HD785-7-565) Packed separately (HD785-7-565) Packed separately (HD785-7-565) Packed separately (HD785-7-565) Packed separately (HD785-7-565) Packed separately (HD785-7-565) Packed separately (HD785-7-565)
Precautions
Q'ty
107
0570
Installation of left fender side lamp wiring harness (If equipped)
Installation of left fender side lamp wiring harness 1. Remove the cover installed to the fender temporarily. 2. Remove the lamp cover and connect the wiring harness. (Side lamp wiring harness: CN. SLL) 3. Fix the side lamp wiring harness with the clips and bolts installed to the fender temporarily. 4. Install the cover removed in steps 1 and 2 again.
Fix with clips and bolts installed temporarily.
Connection: SLL
Precautions
Q'ty
108
0580
Installation of right fender side lamp wiring harness (If equipped)
Z
(1) (2) (3) (4) (5) (6) Part No. 04434-50810 01024-81016 561-85-81170 01024-81020 561-85-81180 01024-81035 Part name Clip Bolt, sems Cover Bolt, sems Cover Bolt, sems Q'ty 2 2 1 2 1 2 Condition of part (Parts list No.) Packed separately (HD785-7-580) Packed separately (HD785-7-580) Installed temporarily to right fender Installed temporarily to right fender Packed separately (HD785-7-580) Packed separately (HD785-7-580)
1. Remove the cover installed to the fender temporarily. 2. Remove the lamp cover and connect the wiring harness. (Side lamp wiring harness: CN. SLR) 3. Fix the side lamp wiring harness with the clips and bolts installed to the fender temporarily and clips (1) and bolts (2). 4. Install cover (5) with bolts (6). 5. Install the covers removed in steps 1 and 2 again.
View Z
Connection: SLR
Reinstallation of cover
Q'ty
109
0581
Installation of right fender side lamp wiring harness (If equipped: Body heating-less muffler, exhaust gas selector box muffler specification)
Z
(1) (2) (3) (4) (5) Part No. 561-84-81250 561-84-84250 04434-50810 01024-81016 01024-81045 Part name Cover Cover Clip Bolt, sems Bolt, sems Q'ty 1 4 4 2 4 Condition of part (Parts list No.) Packed separately (HD785-7-581) Packed separately (HD785-7-581) Packed separately (HD785-7-581) Packed separately (HD785-7-581) Packed separately (HD785-7-581)
1. Remove the cover, clips and bolts installed to the fender temporarily. 2. Remove the lamp cover and connect the wiring harness. (Side lamp wiring harness: CN. SLR) 3. Pass clips 3 through the side lamp wiring harness. Fix the wiring harness with the clips and bolts removed in step 1. 4. Install cover (1) and clips together with bolts (5). 5. Install cover (2) with bolts (5). 6. Install the cover removed in steps 1 again together with the clips.
Connection: SLR
View Z
Reinstallation of cover
View Z
Precautions
Q'ty
Other remarks
110
Installation of KOMTRAX (If equipped)
0590
Installation of KOMTRAX
3 : 59 -- 74 Nm {6 -- 7 kgm}
3 : 59 -- 74 Nm {6 -- 7 kgm} Apply LT-2 to threaded part.
Right handrail
= 5 places
Cable supplied with cab (561-97-62250)
Detail of assembly of antenna
3 : 59 -- 74 Nm {6 -- 7 kgm}
Right platform
Detail of fixing of pole (2 places)
View Z
1. Install the KOMTRAX antenna as shown above.
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) Part No. 561-97-82141 01010-81635 01643-31645 8A13-10-2100 561-97-62250 561-97-62150 07283-33442 07283-36155 01597-01009 01643-31032 04434-50610 01024-81016 Precautions LT-2 Part name Pole Bolt Washer Antenna. sat Antenna cable Plate Clip Clip Nut Washer Clip Bolt, sems Q'ty 1 2 2 1 1 2 4 2 12 12 5 5 Condition of part (Parts list No.) Packed separately (HD785-7-590) Packed separately (HD785-7-590) Packed separately (HD785-7-590) Packed separately (HD785-7-590) Packed separately (HD785-7-590) Packed separately (HD785-7-590) Packed separately (HD785-7-590) Packed separately (HD785-7-590) Packed separately (HD785-7-590) Packed separately (HD785-7-590) Packed separately (HD785-7-590) Packed separately (HD785-7-590) Necessary tools Name Q'ty 1 Necessary equipment Name Q'ty
Other remarks
111
Fixing of ORBCOMM antenna (If equipped)
0595
Fixing of ORBCOMM antenna
= 20 places
View Z
View Y
= 7 places
= 2 places
= 4 places
View X
Bind excessive part of antenna cable together with electrical intake air heater wiring harness.
1. Fix the wiring harnesses with clips (1) in the order of the above numbers. Fix them together at places where bolts (2) are not used. Fix Nos. 6 12 with spacers (5) and bolts (6) and (7). 2. After fixing the wiring harness, bind it with bands (3) and (4). 3. Bind the excessive part of the antenna cable together with electrical intake air heater wiring harness between Nos. 19 and 20.
(1) (2) (3) (4) (5) (6) (7) Part No. 04434-50610 01024-81016 08034-20823 08034-20519 175-79-83760 01024-81045 01024-81040 Precautions Part name Clip Bolt, sems Band Band Spacer Bolt, sems Bolt, sems Q'ty 20 4 1 3 8 7 1 Condition of part (Parts list No.) Packed separately (HD785-7-595) Packed separately (HD785-7-595) Packed separately (HD785-7-595) Packed separately (HD785-7-595) Packed separately (HD785-7-595) Packed separately (HD785-7-595) Packed separately (HD785-7-595) Necessary tools Name Q'ty Necessary equipment Name Q'ty
Other remarks
112
0597
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 - 1 1. Fix the harness and hose going to the auto grease pump with the parts installed temporarily to the right platform.
View Y
(When ORBCOMM antenna is installed) (When payload meter and ORBCOMM antenna are installed) (When ORBCOMM antenna is installed)
(When payload meter and ORBCOMM antenna are installed)
(When payload meter is installed)
Section CA-CA Section BM-BM : 5 places

(1) (2) (3) (4) (5) (6) (7)
Part No. 04434-51210 01024-81075 154-06-34790 01024-81095 175-79-83760 04434-52712 07095-20420 Precautions
Part name Clip Bolt, sems Spacer Bolt, sems Spacer Clip Cushion
Q'ty 6 6 6 6 6 5 5
Condition of part (Parts list No.) Installed to right platform Installed to right platform Installed to right platform Installed to right platform Installed to right platform Installed to right platform Installed to right platform Necessary tools Name Q'ty 1 Necessary equipment Name Q'ty
LT-2 Other remarks
113
0598
Connection and fixing of harness and hose going to auto grease pump - 2 (If equipped: Auto grease specification)
Connection and fixing of harness and hose going to auto grease pump - 2 1. Fix the harness and hose going to the auto grease pump with the parts installed temporarily to the right platform. 2. Connect the auto grease hose to the pump.
View WW
Connect
View Y
(When payload meter and ORBCOMM antenna are installed)
(When ORBCOMM antenna is installed)
Connect:
GREASE PUMP A CONNECTOR
Connect:
PRESSURE SWITCH CONNECTOR
Section CD-CD Section CC-CC

Section CB-CB
(1) (2) (3) (4) (5) (6) (7) (8) (9)
Part No. 04434-51210 01024-81075 154-06-34790 01024-81085 561-46-43390 04434-52712 07095-20420 01024-81016 02896-21012 Precautions
Part name Clip Bolt, sems Spacer Bolt, sems Spacer Clip Cushion Bolt, sems O-ring
Q'ty 2 1 1 1 1 1 1 1 1
Condition of part (Parts list No.) Installed to right platform Installed to right platform Installed to right platform Installed to right platform Installed to right platform Installed to right platform Installed to right platform Installed to right platform Packed separately (HD785-7-598) Necessary tools Name Q'ty Necessary equipment Name Q'ty
Other remarks
114
Removal of hoist cylinder fixing bracket
0600
Removal of hoist cylinder fixing bracket
Hoist cylinder fixing jig Hoist cylinder
Right side of machine
Hoist cylinder
Hoist cylinder fixing jig
Left side of machine
1. Remove the right and left hoist cylinder fixing jigs and secure them with lever blocks. 2. Discard the jigs removed in step 1 above.
Precautions
Necessary tools Name Torque wrench
Q'ty 1
Other remarks
115
Connection of hoist cylinder piping
0610
Connection of hoist cylinder piping 1. Remove hoist cylinder mounting bolts A and B and remove the parts marked with A. Since the parts marked with A are not used any more, discard them.
Hoist cylinder
A
Reused
B
(1) (2) (3) (4) (5) Part No. 07372-21035 07000-F3038 01024-80845 07000-F3030 01643-51032
Reused
Part name Bolt O-ring Bolt O-ring Washer
Q'ty 8 2 8 2 8
Condition of part (Parts list No.) Packed separately (HD785-7-610) Packed separately (HD785-7-610) Packed separately (HD785-7-610) Packed separately (HD785-7-610) Packed separately (HD785-7-610)
2. Using bolt (1) and washer (5) instead of bolt (A) and using bolt (3) instead of bolt B, reconnect the hose. When reconnecting the hose, use O-rings (2) and (4) supplied loose.
Precautions 1. When installing the piping, take care that O-ring will not be caught. 2. If the engine is started after this process is completed, the cylinder is extended automatically. Necessary tools Name Necessary equipment Name Q'ty
Q'ty
Other remarks
116
Welding of body
0620
Welding of body
*) For details of welding of body, see the separate manual.
(1)
Part No. 561-74-81102
Part name Body U., assembly
Q'ty 1
Precautions
Necessary tools Name Port power (300 mm for 10 ton) Hydraulic jack (10 ton) Hydraulic jack (5 ton)
Necessary equipment Q'ty Name Q'ty 1 Cranes (50 ton, 25 ton) Each one 1 1
Other remarks
117
Sticking of body decal
0630
Sticking of body decal
Left side of body
Right side of body

1. Stick the decals to the body.
(1) (2) (3) Part No. 561-93-81320 561-93-81310 561-93-81360 Part name Mark Mark Mark Q'ty 2 1 1 Condition of part (Parts list No.) Packed separately (HD785-7-630) Packed separately (HD785-7-630) Packed separately (HD785-7-630)
Precautions 1. Eliminate blisters and fit each decal perfectly. 2. Remove all the oil and dust from the surfaces to stick the decals. 3. Stick the decal before installing the body.
Q'ty
Other remarks
118
Supply of oil
0640
Supply of oil *) Referring to No. 0010, check the types of oil and supply proper oil. *) Before starting the engine, be sure to check the oil level in the brake oil tank. If the level is low, add new oil.
1. Before starting the engine, add oil through the filler tube of the transmission case to the H level and then add oil through the oil filler of the brake oil tank to the top (36 liters). 2. After starting the engine, run the engine at low idle and add oil until the oil pressure gauge indicates the maximum. 3. Bleed air from the brake system. Then, run the engine at low idle and adjust the oil level again. (Do not use the oil discharged during the air bleeding operation.) For details, see the Operation and Maintenance Manual. Retightening of hose clamps *) After starting the engine, retighten the clamps of the low-pressure hoses.
Precautions
Q'ty
Other remarks
119
Slinging of body
0650
Slinging of body
Body sling pin (ATH-785-006) Shackle BC40 for 10 ton
Chain sling (ATH-465-039) or 28 wire
Inserting direction of body sling pin (ATH-785-006): Insert from outside of body.
1. Set the body sling pins from outside of the body side plate (4 pieces to holes of body). 2. Set the shackles and sling. 3. Check the center and sling the body.
Precautions
Q'ty
Necessary equipment Name Q'ty Sling (ATH-465-039) 1 Sling (ATH-785-006) 4 Pin (BC40) 4 Crane (50 ton) 1
Other remarks
120
Installation of hinge pin
0660
Installation of hinge pin
A A
3:
245 -- 309 Nm {25 -- 31.5 kgm}
Clearance: Max. 1 mm Clearance: Max. 1 mm
Section A-A
(1) (2) (3) (4) (5) (6) (7) (8) Part No. 568-74-12650 568-74-11421 568-74-12660 568-74-12670 561-74-61740 01010-81635 01643-31645 421-70-11280 Part name Shim t = 6.0 Shim t = 2.3 Shim t = 1.0 Shim t = 4.5 Pin Bolt Washer Washer Q'ty 2 8 8 2 2 2 2 2 Condition of part (Parts list No.) Packed separately (HD785-7-660) Packed separately (HD785-7-660) Packed separately (HD785-7-660) Packed separately (HD785-7-660) Packed separately (HD785-7-660) Packed separately (HD785-7-660) Packed separately (HD785-7-660) Packed separately (HD785-7-660)
1. Operate the crane to set the pin holes of the frame to those of the body. 2. Insert shims to even the clearance and reduced to 1 mm or less and then insert pins (5). 3. Fix the pins with the lock bolts.
Precautions Necessary tools Name Q'ty Torque wrench (2800QL) 1 Necessary equipment Name Q'ty
Other remarks
121
Connecting hoist cylinder
0670
Connecting hoist cylinder
Hoist cylinder
:157 -- 196 Nm {16 -- 20 kgm}
Main frame
(1) (2) (3)
Part No. 561-52-61211 01010-81430 569-40-61710
Part name Pin Bolt Washer
Q'ty 2 2 2
1. 2. 3. 4.
Match the hoist cylinder rod hole to the pin hole of the body mounting part. Insert pin (1) and fix it. Tighten set bolts (2) and (3). Install plug (4).
Precautions
Q'ty
Other remarks
122
Hoist cylinder grease piping
0680
Hoist cylinder grease piping
Install fitting (7) outward.
(1) (2) (3) (4) (5) (6) (7)
Part No. 421-09-12540 423-09-12110 561-52-82610 01024-80816 04434-50608 07042-20108 07020-00000
Part name Elbow Connector Tube Bolt, sems Clip Plug Fitting
Q'ty 2 2 2 2 2 2 2
Condition of part (Parts list No.) Packed separately (HD785-7-680) Packed separately (HD785-7-680) Packed separately (HD785-7-680) Packed separately (HD785-7-680) Packed separately (HD785-7-680) Packed separately (HD785-7-680) Packed separately (HD785-7-680)
1. Install the grease tubes to the hoist cylinder. (Install the right and left tubes similarly.) 2. Supply grease.
Precautions
Q'ty
Other remarks
123
0685
Fixing of auto grease piping to body (If equipped: Auto grease specification)
Fixing of auto grease piping to body 1.Fix the auto grease piping to the body.
: 9 places
View X
Section A-A
Section B-B
Detail of part P
(1) (2) (3) (4)
Part No. 561-95-83250 04434-51010 01024-81020 01024-81016 Precautions
Part name Bracket Clip Bolt, sems Bolt, sems
Q'ty 1 11 3 9
Condition of part (Parts list No.) Packed separately (HD785-7-685) Packed separately (HD785-7-685) Packed separately (HD785-7-685) Packed separately (HD785-7-685) Necessary tools Name Q'ty Necessary equipment Name Q'ty
Other remarks
124
Installation of field welding protection cover
0700
Installation of field welding protection cover
Part welded in field
1. Install the protection cover around each "part welded in field" shown in the above figure.
Precautions
Necessary tools Name Fireproof cloth (1 m 10 m)
Q'ty 1
Other remarks
125
Installation of body mount
0710
Installation of body mount 1. Install the body mount. 2. For the adjustment procedure, see the following section. 3 : (8) (12) 245 309 Nm {24.9 31.5 kgm}
Welded to frame For welding procedure, see C-0130. Welded to frame For welding procedure, see C-0130.
(1) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15)
Part No. 561-74-61531 561-83-69540 561-83-69550 561-83-69560 561-83-69570 561-74-61511 01010-81645 01643-31645 561-74-61521 561-74-61540 01010-81660 01643-31645 561-46-8A890 561-46-8A870 Precautions
Part name Shim t = 1.0 Shim t = 1.0 Shim t = 1.0 Shim t = 1.0 Shim t = 1.0 Pad Bolt Washer Pad Shim t = 1.0 Bolt Washer Bracket (LH) Bracket (RH)
Q'ty 70 8 8 8 8 8 32 32 2 18 8 8 1 1
Condition of part (Parts list No.) Packed separately (HD785-7-710) Packed separately (HD785-7-710) Packed separately (HD785-7-710) Packed separately (HD785-7-710) Packed separately (HD785-7-710) Packed separately (HD785-7-710) Packed separately (HD785-7-710) Packed separately (HD785-7-710) Packed separately (HD785-7-710) Packed separately (HD785-7-710) Packed separately (HD785-7-710) Packed separately (HD785-7-710) Packed separately (HD785-7-710) Packed separately (HD785-7-710) Necessary tools Name Necessary equipment Name Q'ty
After welding in the field, touch up the welded parts.
Q'ty
Other remarks
126
Procedure for adjusting body mount shim
0720
Procedure for adjusting body mount shim
1. Procedure for adjusting shim for body mount Adjust the shim according to the following procedure. (1) Bottom mounts (Rubber mounts of body bottom plate) 1. Insert a spacer 43 mm thick (dimension marked with a) in the body end. 2. Measure distance b between the center of the body mount and the frame top (8 places on both sides). 3. Insert (b1 - 35), (b2 - 35), (b3 - 35) and (b4 - 35) pieces of shims (561-74-61531) in the points of b1, b2, b3 and b4 respectively. Omit the figures after the decimal fractions. 4. Install the bottom mounts and remove the spacers. 5. Lower the body and check that all of the 8 bottom mounts are in contact with the frame top. If not, adjust the shims. 6. Finish adjustment of the bottom mounts. * Before installing the frame temporarily, remove the paint from the grounding surface. (2) Front mounts (Rubber mounts of body front plate) 1. After the above adjustment of the bottom mounts, place and tack-weld brackets 561-468A890 and 561-46-8A870 on the frame so that the clearance between the body and bracket will be 57 mm. (See Fig. 1) 2. Raise the body and weld the brackets permanently. 3. Insert 7 shims 561-74-61540 7 mm in total and install rubber pad 561-74-61521. 4. Lower the body and check that the total thickness of the rubber pad is 50 mm. If it is not 50 mm, set it to 50 mm by adjusting the shim. 5. Finish adjustment of the front mounts. 2. After the body is assembled, the discrepancy between the protector and cab must be 59 30 mm. If the discrepancy is not 59 30 mm, adjust the shim of hinge pin (561-7461740) (See A-A).
Fig. 1
127
Field welding of exhaust tube
0730
Field welding of exhaust tube
1. 2. Make the hook (part P) and weld it as shown in the figure. After finishing the work, cut the welded hook with gas and finish the cut surface smoothly with a grinder and the paint it yellow.
Must be aligned.
Section A-A
Procedure for assembling body exhaust inlet portion 1. Carry out the following work after adjusting the body mount. 2. Install spring (581-02-31360) and seal (582-02-11210) between tube (561-02-81170) and flange (561-02-61150) and then lock nut (0158011411) to dimension A shown in the figure. (4 places) 3. Fix the tube and flange with the jigs so that the distance between them will be the dimension show in the figure (188). 4. While the parts are fixed as explained in 2 and (3), insert plate (582-0211230) in the tube and insert them in the body exhaust inlet portion. 5. Align tube (561-02-81210) with flange (561-02-61150) at the flange mating face and then weld the plate and tube (561-02-81170). (Runout must be 3 mm or less.) 6. After steps 2 - 5 above, remove the jigs used in step 3. 7. Tighten the bolts according to KES 04.123.1.
(1) (2)
Part No. 561-74-80100 582-02-11230 Precautions
Part name Exhaust box, sub assembly Plate
Q'ty 1 1
Condition of part (Parts list No.) Packed separately (HD785-7-730) Packed separately (HD785-7-730) Q'ty Necessary equipment Name Q'ty Spacer (ATH-465-027) 3
Runout must be 3 mm or less. Carry out the above work after adjusting the body mount shim.
Other remarks
128
Assembly of body heater cover
0740
Assembly of body heater cover
3:
54 123 Nm
{5.5 12.5 kgm}

1. Install the heater cover to the body.
Part No. 561-74-81470 01024-81220 Part name Cover Bolt, sems Q'ty 1 6 Condition of part (Parts list No.) Packed separately (HD785-7-740) Packed separately (HD785-7-740)
(1) (2)
Precautions
Q'ty
Other remarks
129
Installation of poke ejector
0770
Installation of poke ejector
Weight: 40.4 kg
Bend end of pin. View from inside
(1) (2) (3)
Part No. 561-74-81620 581-74-11360 04050-18055
Part name Bar Pin Pin
Q'ty 2 2 2
1. Install the poke ejector to the body.
Precautions
Q'ty
Other remarks
130
Installation of poke ejector storage pin
0780
Installation of body lock pin
(1) (2)
Part No. 04205-11650 04052-11664
Part name Pin Pin
Q'ty 2 2
1. Install the poke ejector storage pin to the body.
Precautions
Q'ty
Other remarks
131
Installation of body mudguard
0790
Installation of body mudguard 1. Install the mudguard to the body.
Caution for installing guard
is curved, install it with * Since guard toward the rear of the machine.
3:
29.4 -- 49.0 Nm {3.0 -- 5.0 kgm}
3:
29.4 -- 49.0 Nm {3.0 -- 5.0 kgm}
Bolt between support and body
3:
29.4 -- 49.0 Nm
{3.0 -- 5.0 kgm} Guard fixing bolt
Set glossy side toward rear of machine.
Set glossy side toward rear of machine.
(1) (2) (3) (4) (5) (6) (7) (8)
Part No. 561-74-61631 561-74-61641 01010-81225 01643-31232 561-74-61661 561-74-61651 01010-81230 01643-31232 Precautions
Part name Support (L) Support (R) Bolt Washer Guard Plate Bolt Washer
Q'ty 1 1 14 14 2 2 16 16
Condition of part (Parts list No.) Packed separately (HD785-7-790) Packed separately (HD785-7-790) Packed separately (HD785-7-790) Packed separately (HD785-7-790) Packed separately (HD785-7-790) Packed separately (HD785-7-790) Packed separately (HD785-7-790) Packed separately (HD785-7-790) Necessary tools Name Q'ty Necessary equipment Name Q'ty
Other remarks
132
Installation of body lock pin
0800
Installation of body lock pin 1. Store the hoist stopper pin in the axle housing.
View from rear of frame
(1)
Part No. 561-86-68141
Part name Pin
Q'ty 2
Precautions
Q'ty
Other remarks
133
Installation of transmission underguard
0810
Installation of transmission underguard 1. Install the transmission underguard.
A A
Thickness 1 Thickness 1
Section A-A
(Weight: 120 kg)
View Z
(1) (2) (3) (4) (5) (6)
Part No. 561-54-86201 561-54-66250 01010-82080 01580-12016 01643-32060 01010-82055
Part name Guard sub assembly Collar Bolt Nut Washer Bolt
Q'ty 1 2 2 2 6 2
Precautions
Q'ty
Other remarks
134
Installation of front handle
0830
Installation of front handle 1. Install the handle to the front axle cooling piping. (Install to the right and left similarly.)
3:
59 -- 74 Nm
{6.0 -- 7.5 kgm}
Front axle on right side of frame
Front axle on left side of frame
(1) (2) (3) (4) (5)
Part No. 561-54-86811 07283-34949 07283-34346 01597-01009 01643-31032 Precautions
Part name Grip Clip Clip Nut Washer
Q'ty 2 2 2 8 8
Condition of part (Parts list No.) Packed separately (HD785-7-830) Packed separately (HD785-7-830) Packed separately (HD785-7-830) Packed separately (HD785-7-830) Packed separately (HD785-7-830) Necessary tools Name Necessary equipment Name Q'ty
Q'ty
Other remarks
135
Connection of dump sensor
0850
Connection of dump sensor
(1) (2) (3)
Part No. 01010-81035 566-40-11560 04245-4102A
Part name Bolt Washer Rod assembly
Q'ty 1 2 1
1. 2. 3. 4.
Install the rod. Check that the distance between the rod end centers is 484 mm (If not, adjust). Fix the dump sensor to the body with bolt (1). Adjust the dump sensor according to "Procedure for adjusting dump sensor" on the next page.
Precautions
Q'ty
Other remarks
136
Procedure for adjusting dump sensor
0860
Procedure for adjusting dump sensor Note) Be sure to perform the following adjustment after adjusting the shim of the body mount. 1. Seat the dump body. 2. Check that the difference between the centers of the lever hole and potentiometer hole (Positioning hole marked with a: 5) is below 1 mm. Caution) If the misalignment is larger than 1 mm, adjust it to 1 mm or less. If the adjustment dimension of the rod is reduced to 480 mm or less at this time, the potentiometer may be broken. Accordingly, never reduce it so. 3. Check the value of the "Body position" on the real-time monitor in the cab. Standard value of "Body position" when dump body is seated: 0.46 0.54 V Procedure for using real-time monitor (1). Press the "t" and "<" switches simultaneously to set the machine monitor in the service mode and input the ID. ID No.: 6491 (2). Select the real-time monitor. (Change the item with the ">" and "<" switches and select it with the "U" switch.) (3). Select the retarder controller. (Select the item with the ">" and "<" switches.) (4). Check the value of Item No. 34602: "Body position". If the value of the "Body position" is out of the standard range, adjust the rod length to set the value in the standard range. To increase the value, increase the rod length. To decrease the value, decrease the rod length. Caution) If the adjustment dimension of the rod is reduced to 480 mm or less at this time, the potentiometer may be broken. Accordingly, never reduce it so. 4. Check that the value of the "Body position" is in the standard range and tighten the rod permanently.
NUT
Angle sensor
BOLT
484
Lever
REAR Frame
a
Precautions Never reduce the rod length below 480 mm. If it is reduced below 480 mm, the potentiometer may be broken. Necessary tools Name Necessary equipment Name Q'ty
Q'ty
Other remarks
137
Calibrating dump control
0870
Calibrating dump control
REAR Frame
a Before starting the calibration, run the engine until the hydraulic oil temperature reaches 80 90 C. (Check with the real-time monitor.) 1. Lower the dump body to the stroke end and keep the control lever in the "Float" position for 5 seconds. a Check that the body pilot lamp is turned OFF. 2. Raise the dump body to the stroke end and keep the control lever in the "Raise" position for 5 seconds while running the engine at low idle. 3. Lower the body and then raise it while running the engine at high idle. Then, while running the engine at low idle, set the lever in the "Lower" position. When the body starts lowering, set the lever in the "Float" position and lower the body to the seat. Repeat this operation 5 10 times. a Move the body to the stroke end by the raising operation and floating operation. 4. While running the engine at high idle, raise the body and then set the lever in the "Lower" position. When the body starts lowering, set the lever in the "Float" position and lower the body to the seat. Repeat this operation 5 10 times. a Move the body to the stroke end by the raising operation and floating operation.
Q'ty
Other remarks
138
Adjustment of optical axis of light
0880
Adjustment of optical axis of light 1. Remove the 4 bolts at the light bracket bottom and set the bracket as shown below. 2. Remove cap (09415-03614). 3. Loosen nut (A) and adjust the light lens face perpendicular to the ground. 4. Return the light, cap and bolts to the original state.
Fig. 1
Precautions
Q'ty
Other remarks
139
Bleeding air from brake
0900
Bleeding air from brake * Bleed air from the rear hood box, rear brake and front brake in order. <Procedure for bleeding air from rear hood box> 1. Inside of rear hood box: 1 place
2. Rear brake: 7 places Left wheel brake: Right wheel brake:
2 places 2 places
Parking brake Foot brake retarder brake
* Common to right and left
Rear brake slack adjuster: 2 places Parking brake differential top block: 1 place
3. Front brake: 6 places Left wheel brake: Right wheel brake: Front brake slack adjuster:
Foot brake Retarder brake Parking brake
2 places 2 places 2 places
* Common to right and left
1. Remove the rear hood box cover. 2. Start the engine and check that the oil levels in the transmission case and brake oil sub tank are in the specified range and the brake oil pressure caution lamp is turned OFF. 3. Remove the cap of bleeder screw (1) on the block and insert the air hose. Prepare a container filled with oil and put the other end of the air hose in the oil by 50 mm. 4. Turn the parking brake switch OFF, loosen bleeder screw (1) about 3/4 turns and wait until the bubbles do not come out of the air hose any more. 5. After bleeding air, tighten bleeder screw (1) securely and put the cap. <Procedure for bleeding air from rear brake> 1. Start the engine and check that the oil levels in the transmission case and brake oil sub tank are in the specified range and the brake oil pressure caution lamp is turned OFF. 2. Remove the cap of bleeder screw (2) of the slack adjuster and insert the air hose. Prepare a container filled with oil and put the other end of the air hose in the oil by 50 mm. 3. Press the brake pedal, loosen bleeder screw (2) about 3/4 turns and keep pressing the brake pedal until the bubbles do not come out of the air hose any more. 4. Pull the retarder control lever, loosen bleeder screw (2) about 3/ 4 turns and keep pulling the retarder control lever until the bubbles do not come out of the air hose any more. 5. Turn the parking brake switch OFF, loosen bleeder screw (2) about 3/4 turns and wait until the bubbles do not come out of the air hose any more. 6. After bleeding air, tighten bleeder screw (2) securely and put the cap. 7. Bleed air from the wheel brake by loosening and tightening bleeder screw (3) similarly to steps 2, 3, 4 and 6. 8. Bleed air from the wheel brake by loosening and tightening bleeder screw (4) similarly to steps 2, 5 and 6. 9. After finishing the above procedure, work on the opposite side similarly. 10. Referring to steps 2 6, bleed air from block (5) above the parking brake differential. <Procedure for bleeding air from front brake> 1. Start the engine and check that the oil levels in the transmission case and brake oil sub tank are in the specified range and the brake oil pressure caution lamp is turned OFF and the front brake OFF switch is in the OFF position. 2. Remove the cap of bleeder screw (6) of the slack adjuster and insert the air hose. Prepare a container filled with oil and put the other end of the air hose in the oil by 50 mm. 3. Press the brake pedal, loosen bleeder screw (6) about 3/4 turns and keep pressing the brake pedal until the bubbles do not come out of the air hose any more. 4. Pull the retarder control lever, loosen bleeder screw (6) about 3/ 4 turns and keep pulling the retarder control lever until the bubbles do not come out of the air hose any more. 5. Turn the parking brake switch OFF, loosen bleeder screw (6) about 3/4 turns and wait until the bubbles do not come out of the air hose any more. 6. After bleeding air, tighten bleeder screw (6) securely and put the cap. 7. Bleed air from the wheel brake by loosening and tightening bleeder screw (7) similarly to steps 2, 3, 4 and 6. 8. Bleed air from the wheel brake by loosening and tightening bleeder screw (8) similarly to steps 2, 5 and 6. 9. After finishing the above procedure, work on the opposite side similarly. * Bleed air from all of the 14 bleeding points. * After bleeding air, add oil to the transmission case and brake sub tank.
Necessary tools Name 1. When bleeding air, stop the machine on a level Air hose (6 1 m) place and lock the wheels with chocks. 2. When bleeding air, raise the oil temperature to above 40 C so that the air will be bled easily.
Precautions
Q'ty 1
Other remarks
140
0901
Bleeding air from brake of ASR specification (ASR specification: If equipped)
Bleeding air from brake of ASR specification

<Procedure for bleeding air from brake of ASR specification> 1. Start the engine. 2. Check that the transmission case and brake sub-tank are filled with oil and the brake oil pressure caution lamp is turned OFF. Turn the ASR switch ON, remove the cover from the rear of the operator's seat, and connect connector "TEST". (The valve opens and oil pressure is applied to the ASR circuit.) Referring to No. 0900 "Bleeding air from brake", bleed air from the rear brake. After bleeding air from the brake, disconnect connector "TEST". Install the cover removed in step 3. After bleeding air, refill the traffic accident and brake subtank with oil.
3.
Remove cover from rear of operator's seat.
4. 5. 6.
Connector "TEST"
View Z
Necessary tools Name 1. When bleeding air, stop the machine on a flat place Air hose (6 1 m) and set chocks under the wheels. 2. Bleed air while the oil temperature is above 40 C so that air will be bled well.
Precautions
Q'ty 1
Other remarks
141
0905
Bleeding air from ABS circuit (ABS specification: If equipped)
Bleeding air from ABS circuit * Bleed air from air bleeding points (a), (c), (b), (d), (c) and (d) in order. 1. Inside of ABS front box: 2 places <Procedure for bleeding air from ABS circuit>
1. 2. 3. 4. 5.
Air bleeding point (a)
6.
Air bleeding point (b)
7. 8.
2. Inside of rear hood box: 2 places
9. 10.
Air bleeding point (c)
11. 12. 13.
14.
Air bleeding point (d)
15. 16. 17.
Rear hood box
18. 19.
Remove the rear hood box cover. Remove the ABS front box cover. Start the engine and fill the brake sub-tank with oil. Turn the ABS switch ON. (The valve opens and oil pressure is applied to the ABS circuit). Air bleeding point (a): Remove the cap of bleeder screw (1) in the ABS front box and insert the air hose. Prepare a container filled with oil and put the other end of the air hose in the oil by 50 mm. Press the brake pedal, loosen bleeder screw (1) about 3/ 4 turns, and wait until bubbles do not come out of the air hose any more. Pull the retarder control lever, loosen bleeder screw (1) about 3/4 turns, and wait until bubbles do not come out of the air hose any more. After bleeding air, tighten bleeder screw (1) securely and put the cap. Air bleeding point (c): Bleed air through bleeder screw (3) in the rear hood box according to steps 5 8. Air bleeding point (b): Bleed air through bleeder screw (2) in the ABS front box according to steps 5 8. Air bleeding point (d): Bleed air through bleeder screw (4) in the rear hood box according to steps 5 8. Turn the ABS switch OFF. Air bleeding point (c): Remove the cap of bleeder screw (3) in the rear hood box and insert the air hose. Prepare a container filled with oil and put the other end of the air hose in the oil by 50 mm. Press the brake pedal, loosen bleeder screw (3) about 3/ 4 turns, and wait until bubbles do not come out of the air hose any more. Pull the retarder control lever, loosen bleeder screw (3) about 3/4 turns, and wait until bubbles do not come out of the air hose any more. After bleeding air, tighten bleeder screw (3) securely and put the cap. Air bleeding point (d): Bleed air through bleeder screw (4) in the rear hood box according to steps 13 16. Install the rear hood box cover. Install the ABS front box cover.
* *
ABS front box
Bleed air from all of the 4 bleeding points. After bleeding air, refill the transmission case and brake sub tank with oil.
Machine seen from above
Necessary tools Name 1. When bleeding air, stop the machine on a flat place Air hose (6 1 m) and set chocks under the wheels. 2. Bleed air while the oil temperature is above 40 C so that air will be bled well.
Precautions
Q'ty 1
Other remarks
142
Adjusting suspension
0910
Adjusting suspension
Nitrogen gas filter valve
Air bleeder valve
Air bleeder
Nitrogen gas cylindrer Suspension gas filler unit (7926-10-1000) Dimension 247 10 mm
Location of air bleeder valve of front suspension
Dimension
Section of rear suspension Dimension 199 10 mm
Front
Section of front suspension
Rear
1. 2. 3. 4. 5. 6. 7. 8.
Loosen the air bleeder valves of the right and left front suspensions to bleed all air. (Check that air does not come out any more (only oil flows out), and then tighten the valves again. (Tightening torque: 39.2 49 Nm {4 5 kgm})) Check that the valves are closed and install the suspension gas filler unit to the suspension cylinders. Connect the hoses of the suspension gas filler unit to the nitrogen gas filler valves. (Since there are 2 hoses, connect them to the right and left suspension cylinders so that pressure will be applied to both cylinders evenly.) Open the valve of the suspension gas filler unit gradually. When the suspension cylinders rise to the specified level shown above, close the valve. (Supply the gas to the front side according to the decal and to the rear side so that the dimensions in the figure will be obtained.) Remove the hoses from the nitrogen gas filler valves and move the chassis forward and in reverse to fit the suspension cylinders, and then stop without applying the brake. (Finally, stop the truck without applying the brake to prevent an uneven load caused by braking.) Apply the parking brake and check the length of the suspension cylinders. If the length of the suspension cylinders is out of the standard range, repeat steps 3 7. (Usually, adjustment is completed by repeating those steps 3 4 times.) Precautions Necessary tools Name Q'ty Suspension gas filler unit 1 (7926-10-1000) Necessary equipment Name Q'ty
1. Bleed air from the cylinders. Quantity of oil to be supplied = 16.5 l (Reference) 2. Fill both suspension cylinders simultaneously. 3. Do not extract the suspension cylinders to the stroke end. 4. After moving the truck forward and in reverse, stop it without applying the brake. 5. Do not steer the truck before finishing this adjustment. (If it is steered, the piping may be broken.)
Other remarks
Dimension
143
Charging air conditioner with refrigerant
0920
Charging air conditioner with refrigerant
Connection of gas charge
Receiver sight glass
1. Connect the air conditioner refrigerant charge. 2. Charge the air conditioner with the specified quantity of the refrigerant. Air conditioner refrigerant: R134a Quantity: 900 50 g Point While running the engine at low idle, charge the air conditioner with refrigerant. Adjust the quantity of the refrigerant by checking the receiver sight glass.
(1)
Part No. 20Y-979-3310 Precautions
Part name Drum
Q'ty 5
Condition of part (Parts list No.) Packed separately (HD785-7-920) Necessary tools Name Necessary equipment Name Q'ty
Q'ty
Other remarks
144
Fitting of floating seal
0930
Fitting of floating seal 1. Prepare for travel.
To fit the floating seal in the rear axle, install oil receivers as shown in the above figure. (Install similar oil receivers to the front axle, too.) 2. Check of travel After preparing for travel, drive the machine for several km. Reference: HD785-5 Travel distance (Rough standard) 500 m 500 m 1000 m 1000 m 1000 m 1500 m 1500 m
Gear speed F1 F2 F3 F4 F5 F6 F7
After driving the machine, visually check that little oil has been drained.
Precautions Necessary tools Name Q'ty Drained oil receiving con- 1 tainer Necessary equipment Name Q'ty
Other remarks
145
Painting
0950
Painting
Welded parts of exhaust pipe (Heat-resistant silver paint)
Welded parts body
Welded part of body mount
Paint (Sent from factory for trucks in Japan) Undercoat paint RETAN GP primer : 4 kg RETAN GP hardener : 0.8 kg RETAN GP thinner : 4 l Heat-resistant silver paint : Spray can Black gray paint : Spray can 1. Paint each welded part and scratch with the specified paint. 2. Mix the base and hardener of the paint well at the ratio of "5:1, thinning rate: 10 30%" before using. 3. If there is a scratch on the chassis, touch up it with the above paint.
Precautions Necessary tools Name Cup gun set (W87-20R2S) Brush Paint sander (914B) Paint sand paper (#80) Paint sand paper (#180) Necessary equipment Name Q'ty
Topcoat paint SR3000 natural yellow: 16 kg SR3000 hardener : 15 kg Urethane thinner 205 : 17 l
Q'ty 1 1 1 100 10
Other remarks
146
Touchup
0960
Touchup * The paint may be removed from the parts on which slings were installed or which were machined or bruised. Touch up those parts. Touch up each part with paint of the color around it. (See 5-2. Touchup paint list.) (Always touch up parts (1) (3) shown below. Touch up the other parts if the paint is removed from them.) (1) Machined part of tire (2) Hoist cylinder clamp (3) Bruised part of pin
Precautions * Work on both sides similarly.
Necessary tools Name Q'ty (See 5-2. Touchup paint list)
Other remarks
147
Sticking of front axle decal
1000
Front axle-RH
Front axle-LH
Sticking of front axle decal 1. Stick the decals to the front axle. (Stick to the cover side. Front axle RH is on the front side and front axle LH is on the rear side.)
General overseas countries and Indonesia
USA and Puerto Rico
Japan
Cover
View Y
(3) (4) (5)
Part No. 09659-A0881 09659-33000 09659-A0880
Part name Plate Plate Plate
Q'ty 2 2 2
Precautions 1. Note that different front axle decals ((3) (5)) are used for different destinations. (Necessary quantity: 2 pieces/machine)
Q'ty
Other remarks
Sales code:(3) 2ZZ02 (General overseas countries), 2ZZ39 (Indonesia) (4) 2ZZ03: (USA and Puerto Rico) (5) 2ZZ01: (Japan)
148
1020-1
Operating procedure of prelubrication system (If equipped: Engine prelubrication specification)
Operating procedure of prelubrication system A. In normal state 1. Turn "ON" the starting switch in the cab. (See Fig. 1.) 2. Check the state of the prelubrication indicator on the left side of the starting switch. State of prelubrication indicator Blinking : Engine needs to be prelubricated. Lighting : Engine is being prelubricated. OFF : Prelubrication is finished (Engine can be started). 3. Start the engine according to the state of the prelubrication indictor. 3-a) Prelubrication indicator is blinking Step 1. Turn the starting switch to the "START" position and wait until the prelubrication indicator stops blinking and lights up and then release the starting switch. (The released starting switch returns automatically to the "ON" position.) Step 2. Prelubrication is finished in 10 60 seconds. (If the engine temperature is low (the coolant temperature is -5 C or below), the preheater operates automatically after prelubrication is finished. Check the state of preheat lamp.) (See Fig. 3.) Preheat lamp ON : Engine is being preheated. OFF : Preheating is finished. Step 3. Check the prelubrication indicator. If the indicator is blinking, wait for 60 seconds and then repeat steps 1 3 (up to 3 times). If the indicator is turned OFF, turn the starting switch to the "START" position to start the engine. 3-b) Prelubrication indicator is turned OFF. Turn the starting switch to the "START" position to start the engine. B. Procedure for connecting emergency start connector (when prelubricator is broken and engine cannot be started) 1. There are 2 each of the 3-pole connectors tagged with "PRE1" and "PRE2" around the prelubrication controller under the passenger seat, and the connectors of the same tags are connected to each other. 2. To start the engine without performing prelubrication, disconnect the 2 couples of the connectors and connect "PRE1 (male)" to "PRE2 (female)" and connect "PRE1 (female)" to "PRE2 (male)". (See Fig. 4.) 3. Turn the starting switch to the "START" position, and the engine skips prelubrication and starts. If prelubrication is skipped while the engine is cold, when the starting switch is turned to the "ON" position, the preheater operates. (The preheat lamp does not light, however.)
149
1020-2
Operating procedure of prelubrication system (If equipped: Engine prelubrication specification)
Operating procedure of prelubrication system
STARTING SWITCH
CONNECTOR FOR EMERGENCY PURELUBE SET ON RELAY
ENGINE CONTROLLER PREHEAT SIGNAL PRE1 (FEMALE) (BATTERY) PREHEAT RELAY PRE1 (MALE) PURELUBE OIL PRESSURE SWITCH
PRE2 (MALE) TO DRIVE RELAY
PRE2 (FEMALE)
PURELUBE CONTROLLER
STARTER RELAY
ENGINE START AUTHORIZE RELAY
CONNECTOR FOR EMERGENCY
PURELUBE START AUTHORIZE RELAY
PURELUBE PUMP PRE1 (FEMALE) PRE1 (MALE) PRE2 PRE2 (MALE) (FEMALE)
PURELUBE RELAY
CONNECTING EMERGENCY START CONNECTOR
Fig. 4
CHECK VALVE
PRESSURE HOSE
PRELUBE PUMP
ENGINE
OIL FILTER SUCTION HOSE
150
Installation of chocks (If equipped)
1100
Installation of chocks
1. Install the bracket to the front of the frame. 2. Install the chocks
Part No. 569-98-63110 569-95-46820 01010-81625 01643-31645 Part name Bracket Stopper (Tire) Bolt Washer Q'ty 1 2 4 4 Condition of parts Loose-supply item (Separately packed) Loose-supply item (Separately packed) Loose-supply item (Separately packed) Loose-supply item (Separately packed)
(1) (2) (3) (4)
Precautions
Q'ty
Other remarks
151
Installation of radiator curtain (If equipped)
1200
Installation of radiator curtain 1. Remove the installed snaps (2) and washers (3). 2. Install curtain (1) with the snaps (2) and washers (3) removed in step 1.
A A
Point marked with : 22 places
Point marked with : 22 places
Section A-A
(1) (2) (3)
Part No. 561-84-81810 409-03-19130 01602-20720
Part name Curtain Snap Washer
Q'ty 1 22 22
Condition of part (Parts list No.) Packed separately (HD785-7-1200) Installed to machine Installed to machine
Precautions
Q'ty
Other remarks
152
1300
Installation and connection of beacon lamp (If equipped: Yellow beacon lamp specification)
Tighten together with beacon lamp mounting nut. Connect: PR04B (Ground) Connect: PR04 (Beacon lamp)
Installation and connection of beacon lamp
Section B-B
1. Remove the nut of beacon lamp (1) and install it to bracket (2). Section A-A 2. Install cover (4) to the beacon lamp with bolts (5). 3. Install the beacon lamp to the right platform with bolts (3). 4. Fix the beacon harness coming out of the right front support with clips (6). 1 place: Tighten with beacon lamp mounting nut. 1 place: Fix with bolt (10). 5. Connect the beacon harness coming out of the right front support. CN PR04 : Beacon lamp CN PR04B : Ground ... Install with bolt (7), washer (8) and nut (9). * If the ground connecting part is stained or painted, remove all the stain or paint.
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) Part No. 08154-12400 561-85-81340 01024-81020 569-85-88570 01024-81025 04434-50810 01024-80825 01643-30823 01580-10806 01024-81016 Precautions Part name Lamp, beacon Bracket Bolt, sems Cover Bolt, sems Clip Bolt, sems Washer Nut Bolt, sems Q'ty 1 1 4 1 2 2 1 1 1 1
Detail of part P
View Z
Condition of parts Packed separately (HD785-7-1300) Packed separately (HD785-7-1300) Packed separately (HD785-7-1300) Packed separately (HD785-7-1300) Packed separately (HD785-7-1300) Packed separately (HD785-7-1300) Packed separately (HD785-7-1300) Packed separately (HD785-7-1300) Packed separately (HD785-7-1300) Packed separately (HD785-7-1300) Necessary tools Name Q'ty Necessary equipment Name Q'ty
Other remarks
153
T-0010
Bleeding air from fuel circuit 1 (If equipped: Extra low-grade fuel specification)
Bleeding air from fuel circuit * Bleed air in the following cases. When the fuel filter has been replaced When fuel has run out When the engine is started for the first time after modification of the piping or replacement of the supply pump -- Before bleeding air: Warning - Before starting the engine, check that there are no persons around the machine. The machine may start suddenly and may injure a person. When using the electric priming pump, do not loosen the air bleeding plug of the fuel circuit. While the electric priming pump is operating, pressure is applied to the fuel circuit. If the air bleeding plug is loosened at this time, fuel may spout out. Air bleeding procedure 1. Set the starting key in the OFF position and stop the engine. 2. Check that the fuel valve of the fuel tank is open.
3. Open the shut valves on the sides of the engine. There are 2 shut valves on the right and left sides. Open both of them.
4. Set the electric priming pump switch to the ON position, and the lamp blinks and the electric priming pump starts.
Precautions
Q'ty
Other remarks
154
T-0020
Bleeding air from fuel circuit 2 (If equipped: Extra low-grade fuel specification)
Supplementary explanation The electric priming pump switch has a built-in timer, which starts and stops the pump automatically. The electric priming pump stops while the lamp is blinking. This does not indicate a trouble, however. If the switch is set to the OFF position while the lamp is lighting, the electric priming pump stops.
OFF
5. After the set time (approx. 7 minutes), the lamp goes off automatically and the electric priming pump stops. 6. When the engine has stopped because of running up of fuel or when the fuel hose, fuel tube, etc. has been replaced, after the supply pump stops (the lamp goes off), set the electric priming pump switch to the ON position again. 7. When the lamp has gone off, air bleeding is finished. 8. Close the shut valves on the sides of the engine.
Set to ON position.
9. Start the engine. If the engine does not start, try again according to the following procedure. 1) Check that the shut valve (Step 2) is open. 2) Set the electric priming pump switch (Step 4) to the ON position. 3) Start the engine while the electric priming pump is operating. If the engine still does not start, wait for about 2 minutes and then repeat steps 2) and 3). 4) After the engine starts, run it for about 5 minutes to bleed all air from the fuel circuit. Important Do not operate the starting motor for more than 20 continuous seconds. If you have failed start the engine, wait for about 2 minutes and then try again.
Q'ty
Other remarks
155
Setting of machine monitor
T-0030
Note) The machine monitor is set when the machine is delivered. Set it again only when it needs to be set differently. After assembling the machine to a degree that the starting switch can be turned ON, execute the procedures securely in order from 2. (How to set machine monitor in service mode) to No. T-0070 (Saving change of option selection), even if there is an error. If the procedures are finished to No. T-0070 (Saving change of option selection) and the model and options are entered, each controller performs troubleshooting normally. If there is any error, repair it.
Monitor panel selector switches
Symbols in drawings
1. Operation method of machine monitor When initializing the sensor or setting options, set the machine monitor in the service mode. 2. How to set machine monitor in service mode Operating method Turn ON the starting switch of the machine and then turn ON the machine monitor. While the character display of the machine monitor is displaying the normal service meter screen or warning screen, hold down machine monitor mode selector switch 1 (t) and machine monitor mode switch 2 (<) simultaneously for 5 seconds, and the screen changes to the service ID input screen. 3. Inputting method of ID (1) Press the </> switch, and the number at the cursor increase/decreases. Select the specified number and press the U switch. (2) Perform the operation of (1) for the 4 places, and the screen changes to the electrical equipment system fault history screen.
(3) If a wrong number is input, press the t switch to return the cursor to the left end place and input the correct number from the left end place. (4) If the t switch is pressed while the cursor is at the left end place, the screen changes to the normal service meter screen or warning screen. (5) If no switch is pressed for 60 seconds in the ID input mode, the screen changes to the normal service meter screen or warning screen. The ID to set the machine monitor in the service mode is "6491". Remarks: If the starting switch is turned OFF while the machine monitor is in the service mode, the normal service meter screen or warning screen appears when the starting switch is turned ON next time.
Other remarks
156
Selection of machine model
T-0040
1. Selection of machine model While the machine model selection screen is displayed in the service mode, press the U switch to change the selection of the machine model. q If machine model selection is executed, the setting of options is reset. Accordingly, execute machine model selection first after the machine monitor is initialized. After executing machine model selection, execute optional component selection from the first step. q A change of machine model selection becomes effective when the starting switch is turned ON after the change is made and the starting switch is turned OFF and each controller on the machine is turned off perfectly (about 15 seconds later).
Symbols in drawings
Note) After setting a new machine model, be sure to turn the starting switch OFF and wait for 15 seconds. After setting a new machine model, be sure to set the optional component again.
Machine model selection function screen
The currently selected machine model is displayed in the place of ?????. If HD785-7 is selected, "HD785" is displayed.
2. Change of machine model Press the U switch, and the screen changes to the setting screen. * Only when the U switch is held down for 5 seconds, the screen changes to the machine model selection change screen.
Machine model selection function screen
The currently selected machine model is displayed in the place of ?????. If HD785-7 is selected, "HD785" is displayed.
Enter Cancel Machine model selection change screen
Each time the > switch is pressed, the item changes from the smallest item No. to the largest item No. After the largest item No., the smallest No. is displayed. Each time the < switch is pressed, the item changes from the largest item No. to the smallest item No. After the smallest No., the largest No. is displayed. (1) Set the machine model selection change screen to "HD785" with the </> switch. (2) Press the U switch to enter the machine model, and the screen returns to the model selection function screen. (3) If the t switch is pressed, change of machine model selection stops and the screen returns to the machine model selection function screen. (4) Check that the machine model selection change screen is set to "HD785". 3. Saving of machine model change When the machine model selection has been changed, turn the starting switch OFF to stop the operation of the controllers perfectly (Wait for about 15 seconds after turning starting switch OFF). When the starting switch is turned ON next time, the new machine model selection becomes effective. Accordingly, after executing machine model selection, be sure to turn the starting switch OFF, wait for at least 15 seconds, and turn starting switch ON again.
Other remarks
157
Selection of optional component
T-0050
1. Selection of optional component While the optional component selection screen is displayed in the service mode, hold down the U switch for at least 5 seconds to execute optional component selection. Check installation of the optional components of the related machine and set it correctly. q A change of machine model selection becomes effective when the starting switch is turned ON after the change is made and the starting switch is turned OFF and each controller on the machine is turned off perfectly (about 15 seconds later). Note) After setting a new machine model, be sure to turn the starting switch OFF and wait for 15 seconds. q Before setting optional components, check that model selection has been executed.
Item Sales Default Contents of selection No. code Exhaust brake 1 Not added (NO ADD) If exhaust brake is added, select ADD. 6HC23 ARSC 2 Added (ADD) If ARSC is added, select ADD. ASR 3 Not added (NO ADD) If ASR is added, select ADD. 6HF66 ABS 4 Not added (NO ADD) If ABS is added, select ADD. 6HC22 Auto suspension 4 Added (ADD) If auto suspension is added, select ADD. 2HE02 VHMS/PLM 7 VHMS/PLM Select no VHMS [NON], 6HF55X only VHMS [VHMS] or 6HF55 VHMS + built-in PLM [+VHMS]. 6HF55D EG mode selection ENG MODE 9 E1 Select engine mode (E1/E2/E3). Set E1 normally. Body-up caution BODY UP CAU 10 Not added (NO ADD) If body-up caution function is added, select ADD. Dump counter DUMP COUNT 11 Not added (NO ADD) If dump counter function is added, select ADD. Tire size correction TIRE SIZE 12 0% Set speed correction quantity by tire size. HD785-7(27.00R49aa) : 0% HD785-7(31/90R49 E4) : -1% Pitch angle sensor INCLINOMET. 13 Added (ADD) If pitch angle sensor (machine lateral inclina6HB72 tion sensor) is added, select ADD. Front brake cut F BRAKE CUT 14 Added (ADD) If front brake cut function is added, select ADD. Unit selection SPEED(UNIT) 15 MPH Selectable only when machine monitor of non (MPH or km/h) SI specification is installed. Select unit of travel speed (MPH or km/h). Parking brake interlock PARKING I.L. 16 Not added (NO ADD) If parking brake interlock function is added, select ADD. Maintenance sensor SENSOR 19 Not added (NO ADD) If maintenance sensor is added, select ADD. Item Display in English EXH BRAKE ARSC ASR ABS AUTO SUS VHMS/PLM
Symbols in drawings
Precautions
Q'ty
Other remarks
158
Selection of option
T-0060
1. Selection of option Press the U switch, and the screen changes to the setting screen. * Only when the U switch is held down for 5 seconds, the screen changes to the option selection screen. If the screen changes, the right and left differential lock selection screens are displayed. Note) Be sure to start option setting from item No. 1 and set item No. 1 according to the following procedure. When exhaust brake is not installed
Symbols in drawings
q Check installation of the optional components of the related machine and set the items in order according to the above table. For the setting method, see No. 1340.1. See No. 1340.2 for correction of the tire size and see No. 1340.3 for selection of the unit, however.
Precautions
Q'ty
Other remarks
159
T-0070
Option setting/no-setting selection screen - Saving of change of option selection

1. Option setting/no-setting selection screen (1) If each optional component is not selected, the option no-setting screen is displayed. ("NO ADD" is displayed at the left bottom.) (2) If each optional component is selected, option setting screen is displayed. ("ADD" is displayed at the left bottom.) (3) ADD/NO ADD of each optional component can be changed with the U switch. Each time the ? switch is pressed, ADD or NO ADD is replaced with the other. (4) On each optional component selection change screen, the next optional on the other hand is selected with the </> switch. (5) If the t switch is pressed, each optional component selection change screen returns to the option selection screen.
Symbols in drawings
2. Tire size correction setting screen
3. Unit selection (Only monitor panel of non-SI specification)
4. Saving of change of option selection When the option selection has been changed, turn the starting switch OFF to stop the operation of the controllers perfectly (Wait for about 15 seconds after turning starting switch OFF). When the starting switch is turned ON next time, the new option selection becomes effective. Note) After executing option selection, be sure to turn the starting switch OFF, wait for at least 15 seconds, and turn starting switch ON again.
Other remarks
160
T-0080
OFF setting of corrosion resistor with maintenance monitor

OFF setting of corrosion resistor with maintenance monitor Turn the corrosion resistor maintenance function OFF for a machine which is not equipped with the corrosion resistor. While the maintenance monitor screen is displayed in the service mode, press the U switch to select the maintenance function. If the U switch is pressed, the screen changes to the "Maintenance item No. 1" screen.
Symbols in drawings
Maintenance monitor (1st layer)
Maintenance item selection Select a corrosion resistor item with the </> switch.
When the corrosion resistor item is displayed, press the U switch, and the screen changes to the interval time change screen. Press the > switch to change the screen to the timer stop screen.
On the screen of selection of each item timer stop/each item effective, press the U switch, and the YES/ NO screen is displayed. Move the cursor with the < switch to YES and press the t switch.
To return to the normal screen, press the t switch 3 times.

Other remarks
161
Adjustment of body positioner sensor
T-0090
Adjustment of body positioner sensor When the body positioner rod has been disconnected and connected or the body positioner has been removed and installed, test and adjust the body positioner according to the following procedure. 1. Testing sensor input voltage 1) Change the display of the machine monitor to the monitoring function of service mode 1 and display the body positioner sensor input voltage. q Monitoring item Code No. 34603: BODY POSITION
Symbols in drawings
2) Start the engine. 3) Move the dump lever to the "lower stroke end" and "raise stroke end" and check the monitoring voltage at each stroke end. q Lower stroke end: 0.46 0.54 V q Raise stroke end: 4.00 4.70 V 2. Adjusting link length If the monitoring voltage is out of the normal range, adjust the link length according to the following procedure. 1) Loosen locknut ((1)). 2) Remove mounting bolt ((2)). 3) Rotate rod end ((3)) to adjust the link length. q The input voltage changes as follows. * If the link length is increased, the input voltage is decreased. * If the link length is decreased, the input voltage is increased. q Change of voltage per turn of rod end: Approx. 0.04 V 4) Install mounting bolt ((2)). 5) Tighten locknut ((1)). 6) Check that the input voltage is normal according to the procedure described above. 3. Calibration of system 1) Run the engine and increase the hydraulic oil temperature to 80 90 C. 2) Set the dump body to the "lower stroke end" and continue "lower relief" for at least 5 seconds at this position. q Check that the body pilot lamp is turned OFF. 3) Set the dump body to the "raise stroke end" and continue "raise relief" for at least 5 seconds at this position. 4) While running the engine at low idle, raise and float the dump body 10 times. q Move the body to the stroke end by the raising operation and floating operation. 5) While running the engine at high idle, raise and float the dump body 10 times. q Move the body to the stroke end by the raising operation and floating operation.
Other remarks
162
Deletion of electrical system fault history (1)
T-0100
1. Deletion of electrical system fault history While the electrical system fault history screen is displayed in the service mode, press the U switch to select an electrical system fault history item.
If 0 is displayed in the place of **, there is not an electrical system fault history and deleting operation is not necessary. If the U switch is pressed under this condition, the screen changes to the following screen.
Symbols in drawings
1-1. Deletion of fault history when there is only that history (1) Press the U switch to select an electrical system fault history, and the screen changes to the following screen.
(2) Press the U switch, and the screen changes to the history delete screen.
(3) Move the cursor with the </> switch to YES and press the t switch, and the history is deleted. (4) If the fault history is deleted, the screen changes to the fault history screen. Check that the number of fault history is "0".
Precautions
Q'ty
Other remarks
163
Deletion of electrical system fault history (2)
T-0110
1-2. Deletion of multiple fault histories (1) Press the U switch to select an electrical system fault history, and the screen changes to the following screen.
Symbols in drawings
(2) Press the U switch and select the item screen of all electrical system fault history delete screen.
(3) Press the </> switch, and the screen changes to the all electrical system fault history delete screen.
(4) Move the cursor with the </> switch to YES and press the t switch, and all the histories are deleted. (5) If the fault history is deleted, the screen changes to the fault history screen. Check that the number of fault history is "0".
Precautions
Q'ty
Other remarks
164
Preparation of welding body
C-0010
1. Select a place for work. Select a place for work, secure an area of 169 m2 (13 m 13 m) on the floor or ground. The grdient of the floor or groung must not exeed 0.05 m in 10 m. 2. Arrange the welder, generator, and tools. 3. Lift off the body (in the normal position). Place the body on proper wood blocks.
4. Remove the right half body and protector stored in the split body. Cut off the angle bar and plate used to fix the right half body and protector with gas. At this time, sling the right half body and protector with a crane to prevent them from falling after the angle bar and plate are cut. Remove the protector first, and then remove the right half body. After lowering the right half body, cut the 2 brackets (56186-68112) tack-welded to its inside with gas. 5. Remove the paint from the parts to be welded. Remove the paint from the range of 15 mm through along the fitting line of the body. Burn the paint with a gas burner or scrape it with a grinder.
561-86-68112
15
15
6. Reverse the split body. It can be reversed easily with the following. (1) Hanging shaft (ATH-785-006) (2) Eagle clamp: For 5 ton, 2 pieces
Precautions
Q'ty
Other remarks
165
Assembly of split body (1/2)
C-0020
1. Install the stand on ground, as shown in right figure. 2. Set the right side of the split body on the stand. 600 600 16t Stand
7,400 5,200
3. Set the left side of the split body on the stand so that the clearance will be even.
4. Fix the set body with the bolts. (1) Tighten the set right and left half bodies temporarily with the bolts. (For the necessary parts, see the following table.)
Part No. 01011-82010 01643-32060 01580-12016 581-74-11630 Part name Bolt Washer Nut Tube Q'ty 5 5 5 5 Condition of part (Parts list No.) Packed separately (HD785-7-C020) Packed separately (HD785-7-C020) Packed separately (HD785-7-C020) Packed separately (HD785-7-C020)
(1) (2) (3) (4)
(2) Pass the alignment shaft (89.3) through the hinge bracket at the bottom (See the photo at right) and check the heights and positions of the right and left half bodies. Alignment shaft (89.3)
Precautions
Q'ty
Other remarks
166
Assembly of split body (2/2)
C-0030
(3) Tighten the bolts.
(4) Check that you can move the alignment shaft with the fingers. If the split parts are off largely from each other, adjust them with a hydraulic cylinder or a wedge. When adjusting, check that the clamping bolts are loosened.
Adjustment with wedge

Precautions
Adjustment with hydraulic cylinder

Necessary tools Name Necessary equipment Name Q'ty
Q'ty
Other remarks
167
Tack welding body
C-0040
1. Tack-weld the body (outside and inside). (1) Tack-weld to a degree of 6 100 500 . Tack-weld the corners and ends of weld lines. Note) Limit the root gap at the joint of the front and bottom large plates to 3 mm (Direction on drawing: 2 mm). (2) After tack-welding, check that you can move the alignment pint with your fingers. (3) Remove the bolts, washers, nuts, and tube. 2. Position and tack-weld 2 brackets (561-86-68112) removed in C-0010 above to the following dimensions.
542
Front side
561-86-68112 561-86-68112 598 561-74-68112
Precautions
Q'ty
Other remarks
168
Welding body (1/2)
C-0050
1. Weld the front plate. (Refer the C-0070 and C-0080 for welding instruction.) Apply arc welding to the front plate in vertical position. Observe the welding condition shown in Table 1 of C-0060. 2. Weld the bottom plate on the level. (Refer the C-0070 and C-0080 for welding instruction.) Put a stand under the rear part of the bottom plate to keep the bottom plate on the level.
Stand GL
Bead
20 30 mm Note) Perform back step welding at each joint of beads and at each start of welding. Note) Weld the inside of the channels of the large plates, too.
3. Position and weld 1 plate (561-83-69411), 1 plate (561-83-69440), 2 plates (561-83-69450), 4 plates (561-83-69462), 2 plates (561-83-69521) and 1 plate (561-83-89490) to the channel steel. (For the installing positions and welding instructions, see C-0070.)
(1) (2) (3) (4) (5) (6) (7)
Part No. 561-83-69411 561-83-69450 561-83-69440 561-83-69462 561-83-89490 561-83-69481 561-83-69521
Part name Plate Plate Plate Plate Plate Plate Plate
Q'ty 1 2 1 4 1 1 2
Condition of part (Parts list No.) Packed separately (HD785-7-C050) Packed separately (HD785-7-C050) Packed separately (HD785-7-C050) Packed separately (HD785-7-C050) Packed separately (HD785-7-C050) Packed separately (HD785-7-C050) Packed separately (HD785-7-C050) Necessary tools Name Q'ty Necessary equipment Name Q'ty
Precautions
Other remarks
169
Welding body (2/2)
C-0060
4. After finishing the welding work, remove the spatters and finish the beads with a grinder. Table 1
Welding position Welding rod CO2 gas arc welding Flat (F) JIS Z3312YGW11 or equivalent AWS ER70S-G and equivalent 1.2, 1.6 Welding current (A) 320 350, 380 420 Preheating/Postheating Unnecessary Gas shielding rate (l/min) 25 35 Arc welding Remarks Flat, vertical (V) (1) Do not apply CO2 gas welding when wind velocity is higher than 2 JIS Z3212D5816 3 (m/sec). or equivalent AWS E8016-G and (2) Remove moisture, dust, and paint from surfaces to be welded. equivalent (3) Drying time of arc welding rod 4.0, 5.0 1] Temperature: 150 200C 130 160, 220 260 2] Time: 120 minutes Unnecessary
Precautions
Q'ty
Other remarks
170
Welding body instruction (1/2)
C-0070
Welding instructions are shown in Procedure for welding body (2/2) (C-0080)
Weld cross rib (inside of channel), too.
Weld cross rib (inside of channel), too.
Precautions
Q'ty
Other remarks
171
C-0080
Precautions
Q'ty
Other remarks
172
Turn over the body
C-0090
1. Remove the stands (8 pieces) for transportation installed to the bottom plate.
Stand for transportation
2.
Reverse the body (1) Prepare a 50-ton crane and a 20-ton crane. (Set the crane trucks as near the body as possible.) (2) Insert the lifting pins (ATH-785-006) from inside of the body into the body and install 2-pieces chains (ATH465-040) with shackles. (2 places each on right and left sides, 4 pieces in total) (3) Taking care of the center of gravity, wind in the 50-ton and 25-ton cranes simultaneously. (Secure the space for reversing the body.) (4) Taking care of the center of gravity, wind in the 50-ton crane and wind out the 25-ton crane to lay the body on its side. (5) Keep holding up the body with the 50-ton crane, remove the sling from the 25-ton crane, move the 25-ton crane to the opposite side and install the sling to the 25-ton crane. (6) Taking care of the center of gravity, wind in the 25-ton crane and wind out the 50-ton crane. (7) After the body becomes horizontal, wind out both cranes simultaneously to lower the body to the ground and then remove the slings. At this time, put wooden blocks under the front and rear of the bottom plate.
(1)
(2)
(3)(4)
(4)
(5)
(6)
(7)
(7)
Table 1
Next, weld the inside of the bottom plate. Connect the welding ground cable to the body securely. Apply CO2 gas shielded arc welding as standard. If it is difficult to apply CO2 gas shielded arc welding, apply arc welding.
CO2 gas arc welding Flat (F) JIS Z3312YGW11 or equivalent AWS ER70S-G and equivalent 1.2, 1.6 320 350, 380 420 Unnecessary 25 35 Arc welding Remarks Flat, vertical (V) (1) Do not apply CO2 gas welding when wind velocity is higher JIS Z3212D5816 than 2 3 (m/sec). or equivalent AWS E8016-G and equivalent (2) Remove moisture, dust, and paint from surfaces to be 4.0, 5.0 welded. 130 160, 220 260 (3) Drying time of arc welding rod Unnecessary 1] Temperature: 150 200C 2] Time: 120 minutes
Welding position Welding rod
Welding current (A) Preheating/Postheating Gas shielding rate (l/min)
Precautions
Q'ty
Other remarks
173
Welding body protector (1/2)
C-0100
1. Weld the protector. (1) Place the protector on the tops of the side plate and front plate with a crane. Capacity of crane: Min. 2 tons Lift of crane: Min. 7 m Breaking strength of wire rope, chain, chain block: Min. 2 tons (2) When positioning the protector, set the protector plate parallel to body side plate. (3) Cut the front and side plates of the protector with gas so that the top of the body side plate and will be in parallel with the top of the protector. Note: Since the protector and front plate are distorted by welding as shown below, the front and side plates of the protector must be cut with gas so that the clearance will be minimized at the time of welding. (Reduce the clearance to below 3 mm.) (4) After positioning, tack-weld the front panel of the protector. If any plate is used to secure the protector, remove it with a gas cutting device or a grinder.
Welding position Welding rod
CO2 gas arc welding Flat (F) JIS Z3312YGW11 or equivalent AWS ER70S-G and equivalent 1.2, 1.6 Welding current (A) 320 350, 380 420 Preheating/Postheating Unnecessary Gas shielding rate (l/min) 25 35 Precautions
Arc welding Remarks Flat, vertical (V) (1) Do not apply CO2 gas welding when wind velocity is higher than 2 JIS Z3212D5816 3 (m/sec). or equivalent AWS E8016-G and (2) Remove moisture, dust, and paint from surfaces to be welded. equivalent (3) Drying time of arc welding rod 4.0, 5.0 1] Temperature: 150 200C 130 160, 220 260 2] Time: 120 minutes Unnecessary Necessary tools Name Q'ty Necessary equipment Name Q'ty
Other remarks
174
Welding body protector (2/2)
C-0110
1. Weld the protector. Welding order: Weld the side plate first. Welding symbol: Follow welding instruction drawing below. Welding condition: Follow welding condition table below. Perform welding according to KES04.343, General, 2nd Grade. 2. Tack-weld the right and left triangular plates (Section C-C shown below) and then weld them permanently.
View X
Apply CO2 gas shielded arc welding as standard. If it is difficult to apply, however, apply arc welding.
CO2 gas arc welding Flat (F) JIS Z3312YGW11 or equivalent AWS ER70S-G and equivalent 1.2, 1.6 Welding current (A) 320 350, 380 420 Preheating/Postheating Unnecessary Gas shielding rate (l/min) 25 35 Welding position Welding rod Precautions Arc welding Remarks Flat, vertical (V) (1) Do not apply CO2 gas welding when wind velocity is higher than 2 JIS Z3212D5816 3 (m/sec). or equivalent AWS E8016-G and (2) Remove moisture, dust, and paint from surfaces to be welded. equivalent (3) Drying time of arc welding rod 4.0, 5.0 1] Temperature: 150 200C 130 160, 220 260 2] Time: 120 minutes Unnecessary Necessary tools Name Q'ty Necessary equipment Name Q'ty
Other remarks
175
Finishing and painting welded parts of body
C-0120
1. Finishing Remove the spatters and finish the beads with a grinder. Cut the hanging plate welded to the top of the body with gas and finish the marks of weld with a grinder. 2. Check the welded parts for defects. (1) Crack of weld bead (visual check) (2) Undercut, overlap, and spatter (3) Leg length of weld for shortage (Insufficient leg length is not permitted.) 3. After cooling, paint the welded parts. (1) Mix the base and hardener of the paint well at the ratio of 5:1 as specified. (2) After painting, clean the paint spray gun with paint thinner before the paint is hardened. Put on mask, goggles, gloves, etc. to protect yourself from paint mist. [Undercoat paint] RETAN GP primer RETAN GP hardener RETAN GP thinner [Top coat paint] NAX MIGHTYLAC G II KB natural yellow NAX MIGHTYLAC G II KB hardener NAX MIGHTYLAC G II KB thinner
Precautions
Q'ty
Other remarks
176
Welding front body mount bracket
C-0130
Weld the front body mount bracket. 1. Install the body to the frame and adjust its dumping posture. (For the method of installing the body, see Assembly Manual No. 0650 0730.) 2. Adjust the distance between the body and frame with shims in advance. (See Assembly Manual No. 0720.) 3. Position the front body and mount bracket properly and weld them. For the welding condition, see Table 1. Place bracket (561-46-8A870) on the right of the frame (rear support) and place bracket (561-468A890) on the left and then measure the clearance between the body and bracket at 4 places. If the clearance is 57 mm or less, cut the lower part of the bracket (hatched part). (See the following figure.) 4. Position the front body mount bracket properly and weld it.
Zo
A
If less than 57 mm, cut hatched part.
Left figure shows 561-46-8A890 (LH), which is symmetrically identical to 561-46-8A870 (RH).
View Z Table 1
CO2 gas arc welding Flat (F) JIS Z3312YGW11 or equivalent AWS ER70S-G and equivalent 1.2, 1.6 Welding current (A) 320 350, 380 420 Preheating/Postheating Unnecessary Gas shielding rate (l/min) 25 35 Welding position Welding rod Precautions
Detail of A
Arc welding Remarks Flat, vertical (V) (1) Do not apply CO2 gas welding when wind velocity is higher than 2 JIS Z3212D5816 3 (m/sec). or equivalent AWS E8016-G and (2) Remove moisture, dust, and paint from surfaces to be welded. equivalent (3) Drying time of arc welding rod 4.0, 5.0 1] Temperature: 150 200C 130 160, 220 260 2] Time: 120 minutes Unnecessary Necessary tools Name Necessary equipment Name Q'ty
Q'ty
Other remarks
177
1/8
Report No.
Field assembly inspection report

After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance and quality. Model-Type Machine Serial No. User Unit No. Engine Model Engine Serial No.
HD785-7
Service Meter Reading Date of Inspection
SAA12V140E-3B
Attachment 1 Location of Machine at Inspection Manufacture 2
Distributor's Name
Model
Serial No.
Customer's Name
Address:
Signature:
Delivery Report No. attached
Date: Inspector's Comments:
Inspector's Name: Title Signature:
KOMATSU USE ONLY
C. Sheet Receiving Date : By Remark: :
Check sheets filling instructions: 1. Use following indexes for entry of judgement
T..... Normal T..... Abnormal

2. Enter actually measured values in parenthese, [ Notes: ].
T ..... Correction made on abnormal point T..... Not applied
(1) Criteria are based on the standards when the machine is shipped out of the factory.
SUBMITTANCE OF THIS REPORT (AND CHECK SHEETS) TO KOMATSU IS ONE OF THE CONDITIONS OF WARRANTY VALIDATION, COPY FOR KOMATSU SHALL BE FORWARDED TO THE KOMATSU REGIONAL OFFICE TOGETHER WITH THE COPY OF DELIVERY SERVICE REPORT.
Printed in Japan
2/8
Maintenance Remarks
No.
Inspection item
Judgment procedure and standards
Check
Record the serial Nos. of the component parts. 1 2 3 Cab assembly No. Front axle Nos. Rear axle No. Enter the No. (No. ) * No. is stamped on floor (near left door bottom). Enter the Nos. (Left: ) (Right: * No. is stamped on front suspension cylinder. )
Enter the No. (No. ) * Nameplate of No. is installed to differential case.
Check the oil and water levels. (Check before starting engine.) 4 5 6 7 8 9 Engine oil level (Check with engine stopped) Hydraulic oil level Transmission oil level (1) Brake oil level Coolant level Battery fluid level Level must be between (H) and (H-10 mm). (Check with oil level gauge.) Level must be within inspection window range. Level must be above (L) of gauge (engine stop position). Level must be in range of brake oil tank gauge. The level must be above the midpoint between Full and Low of the sub-tank. The fluid level must be 10 12 mm above the plates. The fluid level must be above 2/3 of the tank.
10 Windshield washer fluid level Turn switch ON. 11 Function of horn 12 Function of back buzzer
Sound must be proper in volume and must not have beat noise. (Sensory check) Sound must be proper in volume and must not have beat noise. (Sensory check) When wiper switch is turned to [LO] or [HI], wiper must operate. (Wiping speed must change between LO and HI.) When wiper switch is turned to [INT], wiper must operate intermittently.
13 Function of windshield wiper
Wiping range must be proper. (Wiper must not project from glass.) When wiper switch is turned to [OFF], wiper must stop at stopping position automatically. (Wiper must stop at proper position.) When windshield washer switch is turned to [ON], washing fluid must be splashed over glass and wiper must operate. (Washing fluid must be splashed over proper position.)
14 Safety function (1) 15 Safety function (2)
When key switch is turned to START position while transmission shift lever is not in N, engine must not start. When the parking brake switch is ON and the transmission shift lever is not in N, the centralized warning lamps and alarm buzzer must be turned ON.
Start the engine. (Before starting the engine, check the safety around the truck. Measure each item after warm-up operation.) 16 Abnormal noise from engine Safety function (3) 17 * Check with engine started and parking brake turned off. No abnormal noise must be generated. (Sensory check) When dump lever is set to any position other than FLOAT and transmission lever is set to any position other than N position, centralized warning lamp must light up and centralized alarm buzzer must sound.
3/8
No.
Inspection item
Judgment procedure and standards
Check
Mainte- Remarks nance
Safety function (4) While dump lever is not in FLOAT position, transmission shifts to 18 * Check after starting engine and D L but does not shift to R. turning parking brake OFF. Safety function (5) 19 * Check with engine started and parking brake turned off. 20 Function of engine cooling water temperature gauge Function of torque converter oil 21 temperature gauge When body is not seated and transmission lever is shifted to D L, "only 2nd speed must be selected at D and only 1st speed must be selected at 5 to L" As cooling water temperature rises while engine is running, bar meter must move toward High side. As oil temperature rises while engine is running, bar meter must move toward High side.
Function of brake oil temperature 22 gauge of retarder, bar meter must When brake oil temperature rises because of operation of retarder, bar meter must move toward High side. move toward High side. 23 Measure with parking brake ON, accelerator pedal OFF, and AISS switch ON. Standard: 625 675 rpm Low idle speed, Measured value: ( ) rpm Measure with parking brake ON and body seated (float caution lamp OFF) in power mode. Standard: 2,200 2,300 rpm High idle speed, Measured value: ( ) rpm Engine speed at torque converter stall - Measured value: ( rpm) Power mode standard: 1,735 100 rpm Engine speed at torque converter stall - Measured value: ( rpm) Economy mode standard: 1,635 100 rpm Standard value: Max. 3.5 sec, Measured value: ( HD785: LiL o Hi 0.95 (LiL o 2,100 rpm) Standard value: Max. 6.0 sec, Measured value: ( HD785: LiL o Hi 0.95 (LiL o 1,700 rpm) ) sec
Engine speed * Engine coolant temperature: In green range * Engine oil temperature: 70 80 C 24 * Torque converter oil temperature: 70 80 C * If method of measuring engine speed is unknown, see Shop 25 manual, Testing and adjusting, Measuring engine speed. 26 27 Engine acceleration time (LiL o Hi), in power mode 28 Engine acceleration time (LiL o Stall), in power mode
) sec
29
When AISS switch is turned ON, low idling speed of engine must be set to LiL (650 rpm). * Regardless of engine water temperature and operation of brake. Function of AISS While AISS switch is turned OFF, if engine water temperature is below 50 C, low idling speed of engine must be kept at LiH (945 rpm). While AISS switch is turned OFF, if engine water temperature is above 50 C, low idling speed of engine must be kept at LiL (650 rpm). If parking brake and retarder brake are both turned OFF at this time, low idling speed of engine must be set to LiH (1,000 rpm). When truck is steered to end, engine must not stop at low idling speed. Engine oil pressure caution lamp must not light up. Exhaust gas color must be proper during sharp acceleration (Li o Hi). (Sensory check.) Exhaust gas must not leak from exhaust pipe joint, exhaust shutter, etc.
30
31
32 Low idling regulation 33 Exhaust gas color 34 Exhaust gas leakage Check the lamps. 35 Function of clearance lamps 36 Check of head lamp Check of high beam (Function of dimmer switch)
When the lamp switch is turned ON (1st/2nd stage), both front lamps and 3 rear lamps (right, center, and left) must light up. When the lamp switch is turned ON (2nd stage), the head lamps (1 lamp on each side) must light up. When the head lamp is turned ON and the dimmer switch is operated, the number of the lamps must change between 2 and 4. (The lighting direction must change.) When the turn signal lever is operated, the front and rear turn signal lamps in the turning direction must flash. When the hazard switch is turned ON, both turn signal lamps and pilot (arrow) lamp in the cab must flash.
37
38 Function of turn signal lamps 39 Function of hazard lamp
4/8
No.
Inspection item
Judgment procedure and standards When the transmission shift lever is in R, the backup lamp must light up. When the brake pedal is pressed, the 3 red brake lamps (Right, center, and left) must light up. When the retarder lever is pulled, the 2 red brake lamps (Right and left) must light up. The center brake lamp must not light up at this time. When the lamp switch is turned ON and the brake is used, the brightness of the brake lamp must change (increase). When emergency brake is pressed while parking brake is ON, brake lamp must not light. When the switch is turned ON. Must light up when cab door is open. Lamp must light up when switch is turned ON (Right and left sides).
Check
40 Function of backup lamp 41 42 Function of brake lamp 43 44 Function of emergency brake 45 Function of room lamp 46 Function of working lamp
Lamp must light up when switch is turned ON (Right and left 47 Function of fog lamp (If equipped) sides). Drive and check truck. (Before checking the following items, check the safety around the truck.) 48 Abnormal noise from transmission No abnormal noise must be generated. (Sensory check) No abnormal noise must be generated. (Sensory check) When engine speed is set to high idling in N-range, truck must not start. While machine is traveling, control of steering wheel is not lost. When shift lever is set to D with brake turned ON (rear brake pilot lamp turned ON), gear speed must not change from F2. (1) When lockup operates and brake is turned ON (rear brake pilot lamp lights up), exhaust brake must operate (regardless of operation of exhaust brake switch). (2) When lockup operates and accelerator pedal is turned OFF, exhaust brake must operate (only when exhaust brake switch is ON). When (1) or (2) occurs, exhaust brake pilot lamp must light up.
49 Abnormal noise from differential 50 Dragging of power train 51 Straight travel of truck 52 Braking mode function 53 Function of exhaust brake 54 (If equipped) 55
56 Heating of front brake discs (Both After truck travels inside yard, check by touching with hand that sides) front brake discs are not heated. Heating of rear axles (Both sides) After driving in yard, check by feeling that axle housing and final 57 brake drive cover are normal. 58 Drainage through floating seal (All width) After machine travels in yard, oil of abnormal quantity must not be drained through seal. * Check with drain plug removed. (Reference: After 60-minute travel, oil must not be drained more than 100 cc from each side.)
Check the brake. (Before checking, confirm the safety around the machine.) 59 Uneven working of service brake When machine is stopped suddenly with service brake, it does not turn and control of steering wheel is not lost. When retarder brake is applied sharply, truck must not turn and 60 Uneven working of retarder brake steering wheel must not turn by itself. *** Method of checking No. 27 30 (start limit value) *** (1) Operate the brakes to be checked (Release other brakes). (2) Set the transmission shift lever in the D range. (3) Press the accelerator pedal gradually and read the engine speed when the machine starts. (4) If the machine does not start when the engine speed reaches the torque converter stall speed in the D range (F2), return to (2) and set the transmission shift lever in the 6 range (F1), and then check. [Precautions] 1. When operating the transmission shift lever, set the engine speed to low idle. 2. Check the oil temperature gauge frequently and take care that the torque converter oil will not be overheated.
5/8
No.
Inspection item
Judgment procedure and standards When the engine is stalled at F2 (above 1,610 rpm), the truck must not start. Enter start limit value. Measured value (F : rpm) When the engine is stalled at F2 (above 1,570 rpm), the truck must not start. Enter start limit value. Measured value (F : rpm) When the engine is stalled at F2 (above 1,200 rpm), the truck must not start. Enter start limit value. Measured value (F : rpm) When emergency brake (left pedal) is pressed, service brake and parking brake must operate. (Check that pilot lamp lights.) When emergency brake (left pedal) is pressed, central warning lamp and caution buzzer must operate. Enter the start limit. Measured value (F : rpm)
Check
61 Function of parking brake
62 Function of service brake
63 Function of retarder brake
64 65 Function of emergency brake 66 Check steering function. 67 Abnormal noise and vibration in steering operation 68 Smooth steering operation 69 Steering effort (When empty)
No abnormal noise must be generated. (Sensory check) There must be no hitch and operating effort must not change. (Sensory check) Steering effort must not be heavy. (Sensory check) Standard: Max. 29 N {3 kg} Standard: Max. 150 mm With engine stopped, measure peripheral length of steering wheel. Measured value: ( ) mm Standard: 3.1 3.8 turns Measured value: Left ( ) turns, Right ( ) turns
70 Play of steering wheel Lock-to-lock turns of steering wheel
71 72
Steering speed (Lock-to-lock time) 73
(1) Standard: Max. 4.0 sec (Engine speed: 650 rpm) Turning to left ( ) sec, Turning to right ( ) sec (2) Standard: Max. 3.6 sec (Engine speed: Constant speed above 1,500 rpm) Turning to left ( ) sec, Turning to right ( ) sec When key switch is ON and parking brake is OFF, emergency steering system must operate (for at least 24 seconds). * Do not operate emergency steering pump for more than 90 seconds continuously. Steering effort must not be heavy. (Sensory check) Reference: Max. 29 N {3 kg} Standard: Max. 12.0 sec (With battery charged fully) Turning to left ( ) sec, Turning to right ( ) sec
Automatic emergency steering 74 function
75 Emergency steering effort Emergency steering speed 76 (Oil temperature: 80 C Atmospheric temperature: 25 C)
Check the functions of the work equipment. [Note] Before checking, correctly carryout Assembling and adjusting dump sensor, "Field assembly manual". If the work equipment is operated without carrying out correctly, the original performance is not obtained. In the worst case, the dump sensor potentiometer and linkage (rod) may be broken. 77 Check of potentiometer voltage * Check with real-time monitor. 78 Check of function of body operation caution lamp Potentiometer voltage at lowering end (when body is seated) Measured value: ( )V Standard value: 0.46 0.54 V (Target: 0.50 V) Potentiometer voltage at raising end (stroke end) Measured value: ( )V Standard value: 4.00 4.70 V When the dump lever is not in FLOAT or when the body is not seated, the body operation caution lamp must light up. The operating effort must be proper and dump lever must not be hitched. Check by sensory evaluation. When dump body is seated, unpleasant shock must not be made. (Sensory check)
79
80 Operating effort of dump lever 81 Shock made when dump body is lower to end
6/8
No. 82
Inspection item
Judgment procedure and standards Operate lever to RAISE position and check that it does not return to HOLD when released.
Check
Function of body positioner 83 84 Alignment of dump body on right 85 and left 86 Body lifting speed (Oil tempera87 ture: 80 C) Body lowering speed (Lever at 88 FLOAT, Oil temperature: 50 70 C) 89 Hydraulic drift of dump body
Operate lever to RAISE position to raise dump body and check that it automatically returns to HOLD at a point 50 100 mm before end of hoist cylinder stroke. When dump body is raised fully, it must not sway to right or left. When dump body is lower fully, it must come in contact with mount evenly. (Contact area must be at least 80 %.) When dump body is lower fully, it must come in contact with vibration stopper evenly. Engine speed: 2,000rpm Measured value: ( ) sec, Standard: 13.0 1.5 sec Engine speed: Low idling speed Measured value: ( ) sec, Standard: 14.0 1.5 sec Hydraulic drift in 5 minutes must be 85 mm or less. (From point where cylinder No. 2 is extended by 100 mm) Measured value: (Left: ) mm, (Right: ) mm
Stop the truck on level ground and measure. 90 Transmission oil level (2) (Low idle level) Level must be between (H) (intermediate point between H L) of gauge (on low idle side). * Warm up machine before checking.
The length must be in dimension A. Dimension A: Length of suspension cylinder 247 (Center of label) 10 mm 91 (Front) Measured value: * Measure with dump body empty. Left ( mm), Right ( mm) The length must be in dimension A. Dimension A: 199 10 mm Measured value: Left ( mm), Length of suspension cylinder Right ( mm) 92 (Rear) Dimension A: From rod head * Measure with dump body empty. shoulder of suspension cylinder to top of flange 93 94 Check of automatic suspension control function (Optional) 95 Measure with dump body empty. (1): When the dump lever is set to any position other than FLOAT, display must change from [Soft] to [Hard]. (2): When the service brake or emergency brake is turned ON, the display must change from [Soft] to [Medium]. (3): The display must show [Soft] in all cases other than (1) and (2) above. Operations of cylinder link installed to front axle must be same as display in cab. * Cylinder link position: "Soft o Upper", "Hard o Middle", "Medium o Lower"
96
Inspect each part. 97 Function of body lock pin The safety pin must be inserted without obstruction in the right and left stopper holes.
98 Storage function of body lock pin The safety pin must be removed from, installed to, and locked at the storage position securely. 99 Installation of drive shaft (Engine o Torque converter) 100 Installation of drive shaft (Transmission o Differential) 101 Engine mount All mounting bolts must be free from looseness and abnormal play. All mounting bolts must be free from looseness and abnormal play. Mounting bolts must be free from looseness.
7/8
No.
Inspection item
Judgment procedure and standards Mounting bolts must be free from looseness. Mounting bolts must be free from looseness. Mounting bolts must be free from looseness. Mounting bolts must be free from looseness. No oil and water leakage. No oil leakage. No leakage.
Check
102 Transmission mount 103 Operator's cab mount 104 Rear support 105 Hydraulic tank 107 Inspection around engine 108 Inspection around transmission 109 Fuel leakage from fuel system
110 Oil leakage from hydraulic oil sys- No leakage. tem (tank, cylinder, pump, piping) 111 112 Oil leakage from transmission system Oil leakage from torque converter system No leakage. No leakage. No leakage. No leakage.
Oil leakage from differential and 113 final drive system 114 Oil leakage from brake system
115 Oil leakage from steering system No leakage. 116 Oil leakage from suspension (Both sides, front) 117 Oil leakage from suspension (Both sides, rear) 118 Car radio antenna (Front of cab) 119 Rear view mirror, undermirrors (Both sides) No leakage. No leakage. Antenna must be free from harmful flaw. Must not be loosened. When belt is pushed with thumb (approx. 59 N {6 kg}), its deflection must be 7 10 mm. Belt must be free from flaw and twist.
120 Tension of fan belt
Deflection of air conditioner com- When belt is pushed with thumb (approx. 59 N {6 kg}), its deflec121 pressor belt tion must be 10 15 mm. Belt must be free from flaw and twist. 122 Installation of battery 123 Tightness of battery terminals 124 Rubber caps of battery terminals and positive cable (+) 125 126 127 Function of air conditioner 128 129 Double nuts for installation of battery must be tightened. Terminals must not move when swing with hand. Must be installed securely. (1) Airflow must be changed to 4 levels with blower switch. (2) When air conditioner switch is turned ON after blower switch is turned ON, cab must be cooled and dried. (3) When temperature control switch is set to green side, cold air must come out. When former is set to red side, hot air must be come out. (4) Fresh air or circulating air must be selected with fresh/circulating air selector switch. (5) Air outlet must be set to "Vent", "Vent & foot", "Foot", "Defrost & Foot", or "Defrost" with air outlet selector switch.
8/8
No. 130
Inspection item
Judgment procedure and standards (1) Front left: Retighten. (2) Front right: Retighten. (3) Rear left: Retighten. (4) Rear right: Retighten. Standard: Shown at left Measured value: Front left ( Front right ( Standard: Shown at left Measured value: Rear left inside ( Rear right inside ( Standard: Shown at left Measured value: Rear left outside ( Rear right outside( MPa), MPa) MPa), MPa) MPa), MPa)
Check
Tightness of tire hub nuts 131 Tightening torque: 1,519 1,617 Nm {154.8 164.8 kgm} (Target: 1,568 Nm {159.8 kgm}) 132 * When nothing is applied to the threads. 133 134 Tire inflation pressure 135 (When dump body is empty) 27.00-R49: 0.686 0.715 MPa 31/90R49 E4 (OP): 0.686 MPa 136 137 Flaw of tires
The tires must be free from flaw and tear. Check the all 6 tires.
Check the external appearance after painting (touching up) in the field. 138 Steering cylinders (Both sides) 139 Hoist cylinders (Both sides) The plated surfaces must be free from rust, harmful flaw, spatter, paint, etc. The plated surfaces must be free from rust, harmful flaw, spatter, paint, etc.
Suspension cylinders (Both sides, The plated surfaces must be free from rust, harmful flaw, spatter, 140 front) paint, etc. 141 Suspension cylinders (Both sides, The plated surfaces must be free from rust, harmful flaw, spatter, rear) paint, etc. Glass must be free from flaw, paint, etc.
142 Appearance of cab glass
HD785-7
DUMP TRUCK
Form No.GEN00058-07
2009 KOMATSU All Rights Reserved Printed In Japan 07-09

Field Assembly HD787!7!7001 Up

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Field Assembly HD787!7!7001 Up

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GEN00058-07

Field Assembly Instruction

Appendix Field assembly inspection report

1. Outline of division (Only main components)

3. Front axle assembly

4. Rear axle and tire assembly

5. Front tire and wheel assembly

2. Dimensions of main components

Drawing of bare machine on trailer

3,800 1,680 530 6,200 11,980

G.L. 3,000 2,780

Reference Specifications of completed truck

3. Layout of work space

Tire and wheel assembly

Rear axle assembly and tire assembly

Light units keeping place

Compressor parts and tools keeping place

4-1. Rough schedule of assembly and welding

Installing front axle Installing tires

4 ton * Fork length: Approx. 2 m Number of workers 2

Contents of welding work

Unloading Removal of stands and fixing parts

Positioning and fixing split body Welding back side

Crane 245 kN {25 ton} Number of workers 3 245 kN {25 ton}

4-2. Rough schedule of assembly and welding

Rough contents of assem- Installing support bly work Installing cab

Piping and wiring

Crane 490 kN {50 ton} 490 kN {50 ton}

Contents of welding work

Positioning and fixing split body Welding back side

Crane 245 kN {25 ton} Number of workers 3

4-3. Rough schedule of assembly and welding

Rough contents of assem- Installing platform bly work Painting

Supply of oil and coolant Starting engine

Contents of welding work

Welding inside of body

Crane 245 kN {25 ton} Number of workers 3

4-4. Rough schedule of assembly and welding

Contents of welding work

4-5. Rough schedule of assembly and welding

Installing exterior parts Rough contents of assemPainting bly work

Maintenance, adjustment Inspection

Crane 245 kN {25 ton} (98 kN {10 ton}) Number of workers 2

Contents of welding work

List of touch-up coating on body for overseas specifications

5-3. Tools and consumables

Body lifting pin

Body lifting pin AHT-785-006

Sketches of special tools

Body assembly lifting tool

Body assembly lifting tool ATH-465-039

Chassis lifting tool

Chassis lifting tool ATH-465-040

Dump body lifting tool

Split dump body lifting tool ATH-465-041

Universal lifting tool

Universal lifting tool ATH-465-042

Front axle installation guide

Front axle installation guide ATH-785-078

Assembly process No.

Oil, grease, and coolant

a For details of the notes (e.g., Note. 1, Note.2

) in the table, see the Operation and Maintenance Manual.