Komatsu HD785-5 Dump Truck Field Assembly Instruction Manual SN 4001 and up - PDF DOWNLOAD

GEN00027-03

Field Assembly Instruction

DUMP TRUCK

HD785 -5 SERIAL NUMBERS

4001

and up

CONTENTS FRONT AXLE, F/T, CHASSIS, HD785-5 (COMMON TO ALL SPECIFICATIONS) ........................................... 3 TIRE ASSEMBLY (INCLUDING TIRES), REAR AXLE, HD785-5 ...................................................................... 4 R.H. PLATFORM, CABIN, HD785-5................................................................................................................... 5 BODY ASSEMBLY (INCLUDING BODY), HD785-5 .......................................................................................... 6 LIST OF JIGS, TOOLS, AND CONSUMABLES FOR FIELD ASSEMBLING (1/3) ........................................... 7 LIST OF JIGS, TOOLS, AND CONSUMABLES FOR FIELD ASSEMBLING (2/3) ........................................... 8 LIST OF JIGS, TOOLS, AND CONSUMABLES FOR FIELD ASSEMBLING (3/3) ........................................... 9 LIST OF TOUTH-UP COATING ON BODY FOR OVERSEAS SPECIFICATIONS............................................. 9 SKETCHES OF SPECIAL TOOLS .................................................................................................................... 10 MAN-HOURS, WORKERS NEEDED FOR LOCAL ASSEMBLY ..................................................................... 14 ASSEMBLING PROCEDURES ON SITE ......................................................................................................... 16 1. Lifting and mounting rear axle assembly ............................................................................................ 16 2. Lifting chassis assembly ....................................................................................................................... 18 3. Transferring chassis assembly onto rear axle assembly .................................................................... 20 4. Connecting rods to rear axle suspension ............................................................................................ 22 5. Placing mount for front side ................................................................................................................. 24 6. Connecting rear axle and parking brake line ....................................................................................... 25 7. Lifting front axle assembly .................................................................................................................... 26 8. Assembling front axle ........................................................................................................................... 28 9. Connecting tie rod of steering cylinder ................................................................................................ 30 10. Connecting front axle hoses ................................................................................................................. 32 11. Installing steps on A-shaped arm and bumper ................................................................................... 34 12. Installing front tire ................................................................................................................................. 36 13. Installing propeller shaft ....................................................................................................................... 38 14. Installing fuel tank (1/2) ........................................................................................................................ 40 15. Installing fuel tank (2/2) ........................................................................................................................ 42 16. Installing left- and right-hand stays of frame ...................................................................................... 44 17. Installing left-and right-hand fenders ................................................................................................... 46 18. Installing front supports ........................................................................................................................ 48 19. Installation of front support (-40 °C specification for POLYUS) ......................................................... 50 20. Installation of front support (Diagonal ladder + Large-capacity air cleaner specification) .............. 52 21. Installation of air cleaner assembly indicator hoses (Large-capacity air cleaner specification) ..... 54 22. Installation of right front support air cleaner assembly (Large-capacity air cleaner specification).... 56 23. Connecting steering oil line .................................................................................................................. 58 24. Connection of air cleaner piping (Large-capacity air cleaner specification) ..................................... 60 25. Removing engine hood ......................................................................................................................... 62 26. Installing right-hand platform handrail ................................................................................................ 63 27. Installing right-hand platform ............................................................................................................... 64 28. Fixing of air cleaner piping (Large-capacity air cleaner specification) .............................................. 66 29. Wiring along right-hand platform side................................................................................................. 68 30. Wiring in battery box ............................................................................................................................. 70 31. Installation of diagonal ladder (1/3) (Diagonal ladder + Large-capacity air cleaner specification) ..... 72 32. Installation of diagonal ladder (2/3) (Diagonal ladder + Large-capacity air cleaner specification) ..... 74 33. Installation of diagonal ladder (3/3) (Diagonal ladder + Large-capacity air cleaner specification) ..... 76 34. Replacing side bracket of cabin ............................................................................................................ 78 35. Installing handrail of cabin .................................................................................................................... 79 36. Installing cabin ....................................................................................................................................... 80 37. Connecting steering column ................................................................................................................. 82 38. Clamping drain hose of air conditioner ............................................................................................... 84 39. Installing rops and payload lamp ......................................................................................................... 85 40. Connecting dump control...................................................................................................................... 86 41. Installing air intake (1/2) ....................................................................................................................... 88 42. Installing air intake (2/2) ....................................................................................................................... 89 43. Installing air intake (1/2) (Front air intake specification) .................................................................... 90 44. Installing exhaust pipe .......................................................................................................................... 91

1

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.

Drawing harness into inside of cabin ................................................................................................... 92 Connecting harnesses inside cabin (1/2) ............................................................................................. 93 Connecting harnesses inside cabin (2/2) ............................................................................................. 94 Connecting air conditioner hoses ......................................................................................................... 96 Installing washer tank ............................................................................................................................ 97 Installing and connecting air horn ........................................................................................................ 98 Wiring around cabin (1/2) ..................................................................................................................... 99 Wiring around cabin (2/2) .................................................................................................................... 100 Installation and connection of fuel filter (-40 °C specification for POLYUS) ................................... 102 Connecting right-hand front brake and radiator surge tank............................................................. 104 Wiring for head lamp ........................................................................................................................... 106 Connecting air charge line .................................................................................................................. 108 Air piping .............................................................................................................................................. 110 Connecting left-hand front brake ........................................................................................................ 112 Installing parts around hood ............................................................................................................... 113 Checking for oil and cooling water ..................................................................................................... 114 Filling gas into air conditioner ............................................................................................................ 115 Bleeding air from brake ....................................................................................................................... 116 Removing parts from host cylinder after transportation .................................................................. 118 Equipping machine body .................................................................................................................... 120 Installing grease tubes on hoist cylinder ........................................................................................... 122 Adjustment of body bottom mount.................................................................................................... 124 Adjustment of body positioner ........................................................................................................... 126 Welding by determining dimensions with actual parts (body front mount) ................................ 128 Welding by determining dimensions with actual parts (swing prevention of body) .................... 130 Welding by determining dimensions with actual parts (exhaust flange) ..................................... 131 Installing body seating switch ............................................................................................................ 132 Installing body accessories ................................................................................................................. 133 Painting ................................................................................................................................................. 134 Body stopper pin .................................................................................................................................. 136 Adjustment of suspension .................................................................................................................. 137 Smoothing of floating seal .................................................................................................................. 138

PROCEDURE FOR WELDING AND ASSEMBLING THREE SEPARATED BODY PARTS ........................... 139 WORK PROCEDURES FOR TURNING OVER THE BODY ........................................................................... 154 2900 mm TRANSPORTATION POSTURE (IF EQUIPPED)........................................................................... 157 APPENDIX FIELD ASSEMBLY INSPECTION REPORT

2

3

Chasis A’ssy

F. Axle Ass’y (R.H.)

F. Axle Ass’y (L.H.)

Fuel Tank Ass’y

01

02

03

Part name

01

No

561-04-6111

561-27-L0000

561-27-R0000

Part No.

1

1

1

A

A

A

Quantity/ Classifimachine cation 561-00-00000 1 A

Component

Note 1: Install fittings such as bolts, washers, nuts, retaining plates, and pins on their specified locations. Those fittings was used to mount separated package during transportation.

Note 2: Install or weld the components specified in the delivery instruction in place, except those specified to make package separate.

Front Axle, F/T, Chassis, HD785-5 (common to all specifications)

(Note) Two spill lines added for HD785-5.

For Japan...........without rack, with air cleaner Except Japan .....cleaner separated

Description

Remarks: A ... Single part of assembly L ... Single part of lot B ... Single part of bulk

4

R. Axle Ass’y

Tire Ass’y (L.H.)

02

Part name

01

No

561-30-X0000

561-22-60001

Part No.

Component

2

A

Quantity/ Classifimachine cation 1 A

Note 1: Install fittings such as bolts, washers, nuts, retaining plates, and pins on their specified locations. Those fittings was used to mount separated package during transportation.

Note 2: Install or weld the components specified in the delivery instruction in place, except those specified to make package separate.

Description

Remarks: A ... Single part of assembly L ... Single part of lot B ... Single part of bulk

(Note) Stopper pin bracket added for HD785-5.

Tire Assembly (including Tires), Rear Axle, HD785-5

5

R.H. Platform Ass’y 561-54-61411

02

1

A

Quantity/ Classifimachine cation 561-54-67003 1 A

Part No.

Cabin A’ssy

Part name

01

No

Component

Note 1: Install fittings such as bolts, washers, nuts, retaining plates, and pins on their specified locations. Those fittings was used to mount separated package during transportation.

Note 2: Install or weld the components specified in the delivery instruction in place, except those specified to make package separate.

R.H. Platform, Cabin, HD785-5

(Note) Standardization of pressure reducing valve for HD785-5

(Note) Improved cabin to make assembling easy for HD785-5

Description

Remarks: A ... Single part of assembly L ... Single part of lot B ... Single part of bulk

6

01

No

Body Ass’y

Part name

Part No.

Quantity/ Classifimachine cation 561-74-00000 1 A

Component

Note 1: Install fittings such as bolts, washers, nuts, retaining plates, and pins on their specified locations. Those fittings was used to mount separated package during transportation.

Note 2: Install or weld the components specified in the delivery instruction in place, except those specified to make package separate.

Body Assembly (Including Body), HD785-5

Description

Remarks: A ... Single part of assembly L ... Single part of lot B ... Single part of bulk

LIST OF JIGS, TOOLS, AND CONSUMABLES FOR FIELD ASSEMBLING (1/3) No.

Item

Specification

Q’ty

1 Truck crane

25 tons

1

2 Truck crane

45 tons

1

3 Forklift truck

2.5 tons

1

4 Gas cutting machine

No. A type Novac 112R

1

5 Torch

1220N2

1

6 Acetylene gas

1

For gas cutting machine For gas cutting machine

7 Oxygen gas

150kg/cm2

1

8 Grinder (round)

FG50L-1

1

9 Grindstone

SCW50 × 19 • 10

1

10 Grinder

LISG-7S

1

11 Grindstone

180d × 6 × 22

3

12 Dia. bar

CB7C105

1

13 Dia. bar blade

6GH

1

14 Semi-automatic welding machine

500A

3

15 Hand shield

GP-1S

3

16 Welding wire for semi-au- 1.2 mm tomatic welding machine

Remarks

For finishing

80kg

17 Chipper scaling hammer

FCM-20F

2

18 Port power

300 mm for 10 tons

1

For adjustment of dump body deviation

19 Hydraulic jack

10 tons

1

For dump body

20 Hydraulic jack

5 tons

1

For dump body

21 Pin for body hinge

WJ-H46-74001-023

1

22 Refractory cloth

1 m × 10 m

1

Protection when field welding

23 Spacer

ATH-465-027

3

Use when welding exhaust flange in field

24 Nitrogen gas injector

566-88-14003

1

2

25 Nitrogen gas bottle

150 kg/cm

1

Injection into suspension

26 Tire inflation gauge

No. 2252

1

27 Electric nut runner

For 200 kgm NR-30T

1

For tire tightening

28 Extension

ATH-785-014

1

For tire tightening

29 Cord reel

For 200V

1

For electric nut runner

30 Generator

220V

1

31 Grease pump gun

For 20kg can

1

32 Grease

GL-2

33 Footstool

Three steps

1

34 Footstool

Six steps

1

35 Blue sheet

5 m × 10 m

5

36 Square timber

300 mm square, 1 m long

16

5 kg

Protection for equipment

7

LIST OF JIGS, TOOLS, AND CONSUMABLES FOR FIELD ASSEMBLING (2/3) No.

Item

Specification

Q’ty 1

Remarks For oil injection

37 Oil jack

5L

38 Oil

Engine oil SAE10W

100l See Field Assembling Procedures.

39 Oil

Engine oil SAE30W

20l See Field Assembling Procedures.

2

40 Oil sump, washing can 41 Drained oil can

Empty drum can

5kg

42 Cloth 43 Diesel fuel

1

For refilling fuel

No. 2 for summer Special No. 3 for winter (ASTM D975 No. 2)

44 Antifreeze

5l

For adding in subtank (to change mixing ratio depending on local weather)

45 Air hose

6d × 1m

1

For air bleeding

46 Three-bond #1521

Tube of 100 gram

1

Use for windshield glass

3l

47 Washer liquid

1

48 Sanding machine for scaling-off coating

914B

49 Sandpaper

#80

100

50 Sandpaper

#180

10

51 Cup gun set

W87-20R2S

1

Use for coating

1

Use to repair coating.

52 Brush 53 Air compressor

Not less than 3.5 m3 or 7 kg/cm2

1

54 Air hose

With mouthpiece of d12

5

55 Impact wrench

UW-13SK

2

56 Impact wrench

KW-3800P

1

57 Impact wrench

UW-9SK

2

58 Extension for impact wrench 38S

150 mm long

1

59 Socket

1 inch × 41 mm

1

For tightening tire

60 Socket

1 inch × 36 mm

1

For tightening ROPS (option for overseas specification)

61 Socket

1 inch × 30 mm

1

For tightening support

62 Wrench

Width across flats: 36 mm

1

63 Wrench

Width across flats: 41 mm

1

64 Torque-wrench

1800QL

1

65 Torque-wrench

10000QLE

1

66 Torque-wrench, open type 24 × 1200SP

1

67 Torque-wrench, open type 36 × 2200SP

1

68 Torque-wrench, box type

Width across flats: 27 mm, 4200CL

1

69 Torque wrench, box type

Width across flats: 30 mm, 7000CL

1

70 Convex

5m

2

8

For impact grinder

For propeller shaft

LIST OF JIGS, TOOLS, AND CONSUMABLES FOR FIELD ASSEMBLING (3/3) No.

Item

Specification

71 Locktite

LT-2

Q’ty

Remarks

1

72 Vinyl tape

1

73 Standard tool (ISO specifi- 700SX cation)

2

74 Bar

1

1m

75 Shino

1

Use to bundle harnesses

For hole alignment

76 Sledgehammer

10 lb

1

77 Shackle

BD10 for 500 kg

4

78 Shackle

BC40 for 10 tons

4

For mounting body

79 Chain

ATH-465-042

1

Multi purpose

80 Nylon shoe ring

100 mm wide × 5 m

2

For mounting fuel tank

81 Nylon shoe ring

250 mm wide × 5 m

1

For mounting R.H. platform to cabin

82 Nylon shoe ring

60 mm wide × 3 m

2

For mounting support and small articles

83 Nylon shoe ring

100 mm wide × 12 m

1

For mounting front tires

84 Nylon shoe ring

30 mm wide × 2 m

3

For installing front axle

85 Nylon shoe ring

100 mm wide × 3 m

1

For installing front axle

86 Pin

d60 × 250 mm

2

For slinging chassis, rear side

87 Jig for slinging body

ATH-785-006

4

For mounting body

88 Lever block

3/4 tons, LB008

3

For installing front axle

89 Lever block

2 tons, LB020

1

For installing front axle

90 Wire

7m 28d

2

For slinging chassis

91 Wire

4m 28d

2

For mounting body

92 Wire

5m 28d

2

For installing body

1 2 1

For mounting body For slinging chassis For slinging separated body

The following items may be substituted for No. 90 to 92.

ATH-465-039 ATH-465-040 ATH-465-041

LIST OF TOUCH-UP COATING ON BODY FOR OVERSEAS SPECIFICATIONS No.

Part Name

Unit

Q’ty

1 Retane GP primer

4kg

1

2 Retane GO hardener

0.8kg

1

3 Retane GP thinner

16

1

4 AX Mightylacq G2KB type natural yellow

10kg

2

5 NAX Mightylacq G2KB type hardener

2kg

2

6 X Mightylacq G2 500 standard thinner

16kg

1

7 Acryliquid cloud gray

Spray can

1

8 Heat-resistance silver

Spray can

1

9

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

SS40

PART NAME

QTY

SPACER

3

ATH-465-027

Body assembly lifting tool

HEAT TREATMENT

—

PART NAME

QTY

Body assembly lifting tool

1

ATH-465-039

10

MATERIAL

—

Chassis lifting tool

HEAT TREATMENT

MATERIAL

—

—

PART NAME

QTY

Chassis lifting tool

2

ATH-465-040

Dump body lifting tool

HEAT TREATMENT

MATERIAL

—

—

PART NAME

QTY

?? dump body lifting tool

1

ATH-465-041

11

Universal lifting tool

HEAT TREATMENT

MATERIAL

—

—

PART NAME

QTY

Universal lifting tool

1

ATH-465-042

Body lifting pin

HEAT TREATMENT

MATERIAL

—

SS400

PART NAME

QTY

Body lifting pin

4

ATH-785-006

12

Chassis lifting tool

HEAT TREATMENT

MATERIAL

—

STKM13A

PART NAME

QTY

Shaft

1

WJ-H46-74001-023

No. 01 02

Parts Name BOLT SOCKET

Parts No. M33 × 170 P850ML

Material SCM435

HEAT TREATMENT 1124001600

MATERIAL

PART NAME Extension

QTY 1

ATH-785-014

13

Equipment

Man-power

HD465 series (day) with lock (field welding) HD785 series (day) lock (field welding) Assembly (per day) Welding (per day) Inspection (per day) Coating (per day)

3

1 1 1 1 3 2

0.5 0.5 1.5 1.5

0.5 0.5 0.5 0.5 1

1 1

1

25 tone crane

1

1

1 Working car with crane Semi-automatic welding machine Gas cutting machine Generator Compressor

3 1 1 1

1 6 2 9 1 7 2 10 3 Total shows max. man/day.

3 Total shows max. man/day.

1 2 2 3 1st day (when shipment received), 2nd day (when reversing), and when mounting body

1

2 1 1 1

Total

Remarks Coating

Maintenance

Inspection

Welding 3 5 3 5

45 ton crane (day)

Note:

14

1.5 1.5 2.5 2.5 3

Body mounting, connection of exhaust pipes

Assembly

MAN-HOURS, WORKERS NEEDED FOR LOCAL ASSEMBLY

1

1

2 1st day (when shipment received), 2nd day (when reversing) 1 Everyday 3 Total shows max. welding work days.

1 Total shows max. welding work days.

1 Total shows max. welding work days.

1 1 everyday

This schedule is made on the assumption that work day is not rainy (for welding and coating.)

If it is rainy, postpone the work.

ASSEMBLING PROCEDURES ON SITE 1. LIFTING AND MOUNTING REAR AXLE ASSEMBLY 1. Remove rod retaining bolts for pins 1 and 2 on upper face of differential case and then withdraw pins. Hook sling at pins. Then, install pins in place again with sling.

Æ Æ Æ

Rear axle: 9.5 tons for single body.

Tire assembly: 1.5 ton per each tire.

(Tire weight varies according to its specification.)

Rear axle assembly: approx. 16 tons Î Remember to remove spacers.

2. Lower rear axle on ground. Place chocks 3 and rectangular timbers to mount parking disc plate assembly. Î Select flat ground for assembling operation. Î Adjust stack height of rectangular timbers 4 so that axle is placed horizontally.

3. Remove sling.

16

Photo shows sling operation by simultaneously using two cranes.

17

2.

LIFTING CHASSIS ASSEMBLY

1. Use two cranes.

Æ

Chassis assembly: approx. 22 tons For movable crane: 45 tons for front side 25 tons for rear side

2. Hook sling at chassis and then sling up chassis assembly. Î Protect bumper on front side not to damage. Î Be careful not to interfere assembly with grease tubes on rear side.

18

Chassis assembly is slung.

Use hook located under frame on front side.

Use holes for body stopper pin on rear side.

19

3. TRANSFERRING CHASSIS ASSEMBLY ONTO REAR AXLE ASSEMBLY 1. Lift rod (upper rod) before installing upper side of differential.

2. Move chassis assembly onto rear axle assembly.

Upper rod lifted.

Chassis assembly is transferring onto rear axle.

20

4.

CONNECTING RODS TO REAR AXLE SUSPENSION

1. Connect rods A, B, and C in this order as shown in left-hand figure.

2. Align pin with hole, and temporally move rod. Î When alignment, be careful not to be caught your finger.

3. Place spacer in rubber portion on spherical bushing. Î Force spacer carefully,but not so strong as to deform spacer.

4. Again, align pins with holes. Î When driving pins with hammer, be careful not to damage grease fittings.

5. Place lock bolts and washers.

Tightening torque: 157 to 196 Nm {16 to 20 kgm}, desired value: 177 Nm {18 kgm}

½

6. Supply grease in related lubrication points.

22

23

5.

PLACING MOUNT FOR FRONT SIDE

1. Place rectangular timbers under vertical member up to 1 m in height. ÃŽ Stack timbers crosswise in parallel 2. Lower frame.

24

6.

CONNECTING REAR AXLE AND PARKING BRAKE LINE

1. Remove blind parts A from elbow of relay valve on parking brake line. Î For machine with two-way brake system, only one hose is provided.

2. Connect hose from rear axle.

Tightening torque: 29 to 69 Nm {3.0 to 7.0 kg}, desired value: 49 Nm {5.0 kgm}

½

3. Remove blind parts B from connector of brake chamber on brake chamber line.

4. Connect hose from rear axle Tightening torque: 108 to 167 Nm {11.0 to 17.0 kgm}, desired value: 137 Nm {14.0 kgm} Î Keep hoses from interfering with each other.

5. Place oil sump.

½

6. Remove blind parts C (total four on both sides) of cooling tube on rear axle.

7. Remove blind parts D (total two on upper and lower sides) of cooling tube on chassis side.

8. Connect two hoses on each left and right side respectively. Î Keep hoses uncrossed. Î Remember to mount spacer on lower right side. Î Keep hoses from interfering with each other.

9. Clean any greasy surfaces.

25

7.

LIFTING FRONT AXLE ASSEMBLY

1. Remove pins and spacers from portions A, B, and C on chassis side. ĂŽ Dimensions of pin vary on each portion.

Place pins near relevant locations to install pins in place with ease.

2. Lifting front axle as shown in photo. ĂŽ Adjust sling so that suspension cylinder becomes vertical against ground.

Hook slings at suspension cylinder assembly and hub stud portion.

26

27

8.

ASSEMBLING FRONT AXLE

1. While controlling crane and lever block, insert A-shaped arm into mounting portion on chassis and align pins with holes once. Then, lower A-shaped arm with lever block.

Caution: When making alignment, watch your fingers!

2. Insert 8 spacers previously removed into rubber cover on spherical bushing (four places on both sides) of A-shaped arm. Align pins with holes again using lever block. Î Check spacer for deviation. Î Check for O-ring on spherical bushing.

3. Set pins and install lock bolts.

Tightening torque: 157 to 196 Nm {16 to 20 kgm}, desired value: 177 Nm {18 kgm}

½

5. Remove sling from A-shaped arm.

6. Install upper portion of suspension in the same way as for A-shaped arm while controlling crane.

7. Supply grease in related lubrication points.

28

Left side

Right side

29

9. CONNECTING TIE ROD OF STEERING CYLINDER 1. Remove grease tube from portion over pins on front axle lever assembly. Remove pins and boots. ĂŽ When working on machine equipped with auto-suspension, remove air cylinder cover.

2. Control crane so that lever assembly becomes parallel to ground surface.

3. Place boots on upper and lower sides and align them with related pin holes. Insert pins into bushings. ĂŽ Check that O-ring locates in spherical bushing.

4. Install lock bolts and connect grease tubes again.

5. Supply grease into related lubrication points.

30

31

10. CONNECTING FRONT AXLE HOSES 1. Remove four blind parts (two on each side) from portion X (front brake hose).

When working on machine equipped with autosuspension, remove six blind parts (three on each side) on portion Y. for brake hose: ½ Tightening30torque to 69 Nm {3.0 to 7.0 kgm}, desired value 49 Nm {5.0 kgm} 2. Connect all hoses after making sure of each hose number. Î In figure, Symbols A, B, and C: port number Nos. 20, 21, and 22: hose number 3. Remove sling from axle.

4. Lock hub parallel to machine body.

32

33

11. INSTALLING STEPS ON A-SHAPED ARM AND BUMPER 1. Remove mounting bolts from A-shaped arm.

Install steps on A-shaped arm by using removed bolts. Î Install steps symmetrically on both sides.

2. Install steps in the same way as for A-shaped arm. Î Install steps symmetrically on both sides.

34

561-54 31690 (2)

35

12. INSTALLING FRONT TIRES 1. Remove the clamps and nuts from the hub. (8 places each on right and left sides) Î Remove the paint and foreign matter from the tapered part of the hub.

2. Match the air valve of the tire to the cut part of the hub and install the tire to the hub. Î Take care not to break the air valve.

3. Install the clamps and tighten the nuts lightly.

4. Tighten the clamps in the order shown in the photo. Î Tighten all the clamps evenly.

5. Measure the runout of the tire with a scribing block, etc. as shown in the figure. If the runout is 5 mm or larger, loosen the nuts and tighten them again to reduce the runout.

6. Tighten the nuts permanently.

Tightening torque: 1.961 – 2.452 Nm {200 – 250 kgm}, Target: 2.207 Nm {225 kgm} (When oil, etc. is not applied) Tightening torque: 1.520 – 1.912 Nm {155 – 195 kgm}, Target: 1.716 Nm {175 kgm} (When oil, etc. is applied)

½ ½

7. Remove the blocks under the chassis.

36

37

13. INSTALLING PROPELLER SHAFT 1. For machine equipped with propeller shaft guard, remove guard.

2. Remove 8 bolts, 510-20-12820, located rear axle and transmission side from coupling.

3. Face female portion of propeller shaft toward transmission and align female with faucet joint.

Fit propeller shaft into faucet joint portion with hammer. Î Make sure that coupling surface is free from dust and dirt. Î Do not connect faucet joint by tightening bolts.

4. After applying LT-2 to bolts removed in step 2, tighten bolts temporarily. Î Tighten bolts to not more than 157 Nm {16 kgm} 5. Tighten bolts properly.

Tightening torque: 157 to 196 Nm {16 to 20 kgm}, desired value: 177 Nm {18 kgm} (Always use torque wrench.)

½

6. Install propeller shaft again in place.

7. Supply grease.

38

39

14. INSTALLING FUEL TANK (1/2) 1. Remove nuts, washers, and spacers tightened temporarily to bolts on chassis side. Î Support hoist cylinder.

2. Align bolts with bolt holes on fuel tank and place nuts, washers, and spacers on bolts.

Then, tighten nuts.

Tightening torque: 490 to 608 Nm {50 to 62 kgm}, desired value 549 Nm {56 kgm}

½

3. After removing upper cover, remove blind parts. (3 places) 4. Clamp 3 hoses from chassis with attached clip marked Î(tm)and connect hoses to related ports.

Tightening torque: 20 to 30 Nm{2.0 to 3.0 kgm}, desired value 25 Nm {2.5 kgm} for spill hose 30 to 69 {3.0 to 7.0 kgm}, desired value 49 Nm {5.0 kgm} for overflow hose

½

5. Replace cover as before.

40

Return hose cover

41

15. INSTALLING FUEL TANK (2/2) 6. Remove under cover and remove blind parts on all connectors. (2 places) 7. Clamp 2 hoses on chassis with attached clips, marked ✩(tm), and connect hoses to related ports. Î After connecting hoses, open cock to supply fuel.

8. Install cover as before.

9. Clamp ground cable and connector of fuel gauge. Connect connector CN-61 and clamp it. Î Remove coating on surface to be soldered ground cable.

10. Install step with bolts attached on fuel tank.

42

43

16. INSTALLING LEFT- AND RIGHTHAND STAYS OF FRAME 1. Install left- and right-hand supports with bolts attached on chassis.

Tightening torque: 824 to 1030 Nm {84 to 105 kgm}, desired value 927 Nm {945 kgm}

½

44

45

17. INSTALLING LEFT- AND RIGHTHAND FENDERS 1. Sub-assemble upper and lower portions of right-hand fender.

2. Install left- and right-hand fenders on chassis supports.

3. Install mudguards on fender with plates attached on fender.

Tightening torque: 29 to 49 Nm {3.0 to 5.0 kgm}, desired value 39 Nm {4.0 kgm}

½

4. Clamp breather tube connected to upper face of fuel tank with clips on side face of right-hand fender, (except machines with quick-charge specifications).

46

Left side

Right side

47

18. INSTALLING FRONT SUPPORTS 1. Remove 10 bolts each on left and right sides attached on front support and 6 bolts each on left and right sides attached on chassis.

2. Mount temporarily left and right-hand front supports with bolts removed in step 1.

3. After adjusting with shims clearances between front and rear supports and between front supports, install front supports with bolts removed in step 1.

Tightening torque: 490 to 608 Nm {50 to 62 kgm}, desired value 549 Nm {56 kgm} for stay between rear and front supports 245 to 309 Nm {25 to 31.5 kgm}, desired value 279 Nm {28.5 kgm} for stay between front supports

½

4. Tighten bolts properly on chassis.

48

49

19. INSTALLATION OF FRONT SUPPORT (-40 °C SPECIFICATION FOR POLYUS) 1. Remove the 12 sets of bolt(3 and 5 ) and washer (4 and 6 ) attached to each of the right and left sides of the front support , 4 sets (q, w) installed to each of the right and left sides of the frame, and 6 sets of right stay mounting bolt and washer (e, r).

2. Install right stay 9 with e and r.

3. Install the front support temporarily.

4. Adjust the clearance at parts D and C with and tighten with q and w. Î If the holes are not aligned, loosen the stay mounting bolts, align the holes, adjust the shims, and tighten each part.

5. Adjust the clearance at parts Z1 and Z2 with 7 and 8 and tighten with 5 and 6.

6. Tighten front support and parts A and B of the frame with 3 and 4.

* 5 Bolt tightening torque : 245 – 308.7 Nm (25 – 31.5 kgm) 3, q, e Bolt tightening torque : 490 – 607.6 Nm (50 – 62 kgm)

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)

50

Part No. 561-54-6131A 561-54-6132A 01010-82050 01643-32060 01010-81655 01643-31645 561-54-61160 561-54-61170 561-84-6749A 561-54-61970 01010-82050 01643-32060 01010-82050 01643-32060

Part Name Front support L.H assembly Front support R.H assembly BOLT WASHER BOLT WASHER SHIM SHIM STAY SHIM BOLT WASHER BOLT WASHER

Q’ty 1 1 12 12 12 12 8 8 1 12 8 8 6 6

Condition Packed separately (H7-C-146) Packed separately (H7-C-146) Installed to frame Installed to frame Installed to right and left supports Installed to right and left supports Packed separately (H7-C-146) Packed separately (H7-C-146) Packed separately (H7-C-146) Packed separately (H7-C-146) Installed to right and left supports Installed to right and left supports Installed to frame Installed to frame

51

20. INSTALLATION OF FRONT SUPPORT (DIAGONAL LADDER + LARGE-CAPACITY AIR CLEANER SPECIFICATION) 1. Remove the 10 bolts each from the right and left sides of the front support and the 6 bolts each from the right and left sides of the frame mounting section.

2. Install the front support temporarily.

3. Adjust the clearances at parts D and C with 9 and tighten with 7 and 8. Î If the holes are not aligned, loosen the stay mounting bolts, align the holes, adjust the shim, and then tighten each part.

4. Adjust the clearances at parts Z1 and Z2 with - and q and tighten with 5 and 6.

5. Parts A and B

* 5 Bolt tightening torque : 245 – 308.7 Nm (25 – 31.5 kgm) 3, 7 Bolt tightening torque : 490 – 607.6 Nm (50 – 62 kgm)

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

52

Part No. 561-84-6981A 561-84-6831A 01010-82050 01643-32060 01010-81655 01643-31645 01010-82050 01643-32060 561-54-61970 561-54-61160 561-54-61170

Part Name Front support L.H assembly Front support R.H assembly BOLT WASHER BOLT WASHER BOLT WASHER SHIM SHIM SHIM

Q’ty 1 1 12 12 12 12 8 8 12 8 8

Condition Packed separately (H7-C-230) Packed separately (H7-C-230) Installed to frame Installed to frame Installed to right and left supports Installed to right and left supports Installed to right and left supports Installed to right and left supports Packed separately (H7-C-230) Packed separately (H7-C-230) Packed separately (H7-C-230)

53

21. INSTALLATION OF AIR CLEANER ASSEMBLY INDICATOR HOSES (LARGE-CAPACITY AIR CLEANER SPECIFICATION) 1. Remove the indicator hose from the right platform assembly.

2. Connect the removed hose to air cleaner assembly 1. Î Install the indicator hose to the air cleaner first. It cannot be installed in the following processes.

(1)

54

Part No. X251224820

Part Name Air cleaner assembly

Q’ty 1

Condition Packed separately (H7-C-240)

55

22. INSTALLATION OF RIGHT FRONT SUPPORT AIR CLEANER ASSEMBLY (LARGE-CAPACITY AIR CLEANER SPECIFICATION) 1. Remove 4 – - from the front support.

2. Using 2 and 3, install air cleaner assembly 1 to right front support.

3. Install fixing bracket 4 with 5 and 6.

4. Install mudguard q with removed 7 – -.

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

56

Part No. X251224820 01010-81635 01643-31645 561-84-68490 01010-81635 01643-31645 561-84-68320 01024-81230 561-84-68340 01024-81230 561-84-68331

Part Name Air cleaner assembly BOLT WASHER BRACKET BOLT WASHER BRACKET BOLT,SEMS PLATE BOLT,SEMS GUARD

Q’ty 1 16 16 1 3 3 1 5 1 5 1

Condition Packed separately (H7-C-240) Packed separately (H7-C-240) Packed separately (H7-C-240) Installed to right front support Installed to right front support Installed to right front support Installed to right front support Installed to right front support Installed to right front support Installed to right front support Packed separately (H7-C-240)

57

23. CONNECTING STEERING OIL LINE 1. Remove blind parts on hoses and tubes.

2. Connect hoses and tubes.

Tightening torque: 147 to 206 Nm {15.0 to 21.0 kgm}, desired value 177 Nm {18.0 kgm} for big hose 29 to 69 Nm {3.0 to 7.0 kgm}, desired value 49 Nm {5.0 kgm} for small hose

½

Rear side of left-hand front support

58

24. CONNECTION OF AIR CLEANER PIPING (LARGE-CAPACITY AIR CLEANER SPECIFICATION) 1. Connect the tubes to the air cleaner and fix it with the attached clamps. Î Remove the vinyl bags etc. used to prevent entry of dirt.

When connecting the tubes, take care of their insertion length.

2. Fix the tubes with the bands.

3. Connect the tubes to the engine and fix them with the attached clamps.

4. Connect the tubes by the hoses. * Hose clamp tightening torque : 8.8 ± 0.5 Nm (0.9 ± 0.05 kgm) Set the tightening portions of the clamps on the exactly opposite side to each other so that they can be tightened from the same direction.

If the hoses cannot be inserted easily, use neutral detergent. (Do not use adhesive.)

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)

60

Part No. 561-84-68120 561-84-68140 565-44-12310 01582-11008 01643-31032 568-02-22230 07289-00195 561-84-68131 561-84-68180 568-02-22230 07289-00195 07042-30108

Part Name TUBE TUBE BAND NUT WASHER HOSE CLAMP,HOSE TUBE TUBE HOSE CLAMP,HOSE PLUG

Q’ty 1 1 2 4 4 2 4 1 1 1 2 1

Condition Packed separately (H7-C-242) Packed separately (H7-C-242) Packed separately (H7-C-242) Packed separately (H7-C-242) Packed separately (H7-C-242) Packed separately (H7-C-242) Packed separately (H7-C-242) Packed separately (H7-C-242) Packed separately (H7-C-242) Packed separately (H7-C-242) Packed separately (H7-C-242) Packed separately (H7-C-242)

61

25. REMOVING ENGINE HOOD 1. Remove 3 caps and bolts and 2 caps and nuts.

Remove hood.

62

26. INSTALLING RIGHT-HAND PLATFORM HANDRAIL 1. Install guards , mirrors etc.

(Parts without parts number mean accessories.)

63

27. INSTALLING RIGHT-HAND PLATFORM 1. Remove mounts attached on right-hand platform. (4 places) 2. Set upper half of mount in support mounting.

3. Install right-hand platform on machine.

4. Set lower half of mount on bolts and tighten nuts.

Apply LT-2.

Tightening torque: 490 to 608 Nm {50 to 62 kgm}, desired value 549 Nm {56 kgm}

à ½

5. Remove bolt attached temporarily on front supports and connect ground cable.

64

65

28. FIXING OF AIR CLEANER PIPING (LARGE-CAPACITY AIR CLEANER SPECIFICATION) 1. Install the brackets to the right stay. (Upper and lower ones) 2. Fix the tubes with the band.

3. Take the indicator hoses out of the through holes of the right front support and fix them with the temporary clips.

4. Install the indicator hoses to the right platform assembly as fixed in No. 20 and connect them.

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

66

Part No. 561-84-68240 01024-81225 565-44-12142 01582-11008 01643-31032 561-84-68251 01024-81225 565-44-12142 01582-11008 01643-31032

Part Name BRACKET BOLT BAND NUT WASHER BRACKET BOLT BAND NUT WASHER

Q’ty 1 4 2 4 4 1 4 4 8 8

Condition Packed separately (H7-C-245) Packed separately (H7-C-245) Packed separately (H7-C-245) Packed separately (H7-C-245) Packed separately (H7-C-245) Packed separately (H7-C-245) Packed separately (H7-C-245) Packed separately (H7-C-245) Packed separately (H7-C-245) Packed separately (H7-C-245)

67

29. WIRING ALONG RIGHT-HAND PLATFORM SIDE 1. Clamp 3 cables and a harness from machine body with clamping devices attached on platform and draw them in battery box.

Four clamps for harness Two clamps for cable 2. Connect machine harness to right-hand platform harness with connector (CN-30 and CN31)

68

69

30. WIRING IN BATTERY BOX 1. Remove cover.

2. Connect total 7 harnesses, cables, and connectors of cab J07 terminal, engine starter B terminal, alternator B terminal, emergency steering motor M terminal, and cab J03 terminal.

Numbers are marked on related connecting areas.

1. 73 for alternator B 2. 1 and 2 for engine starter B 3. 3 for emergency steering motor M 4. 70 for J07 in cab 5. FU and 69 for J03 in cab 3. Install cover.

70

31. INSTALLATION OF DIAGONAL LADDER (1/3) (DIAGONAL LADDER + LARGE-CAPACITY AIR CLEANER SPECIFICATION) 1. Install the ladder mount bracket to the right front support.

2. Install the upper step.

3. Install the lower step to the left side of the bumper.

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19)

72

Part No. 561-84-68450 01010-81635 01643-31645 561-84-68440 01010-81635 01643-31645 566-54-12212 566-54-21910 566-54-21920 01011-82010 01580-12016 01643-32060 09415-03614 561-84-68410 561-84-68430 01024-81230 561-89-64820 561-54-6A151 01024-81230

Part Name BRACKET BOLT WASHER BRACKET BOLT WASHER CUSHION BUSHING PLATE BOLT NUT WASHER CAP STEP BRACKET BOLT BRACKET BOLT BOLT

Q’ty 1 4 4 1 4 4 4 2 4 2 2 2 4 1 1 4 1 10 10

Condition Packed separately (H7-C-206) Packed separately (H7-C-206) Packed separately (H7-C-206) Packed separately (H7-C-205) Packed separately (H7-C-205) Packed separately (H7-C-205) Packed separately (H7-C-205) Packed separately (H7-C-205) Packed separately (H7-C-205) Packed separately (H7-C-205) Packed separately (H7-C-205) Packed separately (H7-C-205) Packed separately (H7-C-205) Packed separately (H7-C-205) Packed separately (H7-C-205) Packed separately (H7-C-205) Packed separately (H7-C-205) Packed separately (H7-C-205) Packed separately (H7-C-205/206)

73

32. INSTALLATION OF DIAGONAL LADDER (2/3) (DIAGONAL LADDER + LARGE-CAPACITY AIR CLEANER SPECIFICATION) 1. Install the ladder between the right and left steps.

2. Install the rod to under the step.

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17)

74

Part No. 561-84-68930 01024-81230 566-54-12212 566-54-21910 566-54-21920 01011-82010 01580-12016 01643-32060 566-54-21931 09415-03614 562-89-16161 566-54-12212 566-54-21910 566-54-21920 01597-02016 01583-12012 01643-32060

Part Name STEP BOLT CUSHION BUSHING PLATE BOLT NUT WASHER PLATE CAP ROD CUSHION BUSHING PLATE NUT NUT WASHER

Q’ty 1 4 4 2 4 2 2 2 2 2 2 8 4 8 4 8 8

Condition Packed separately (H7-C-206) Packed separately (H7-C-206) Packed separately (H7-C-206) Packed separately (H7-C-205) Packed separately (H7-C-205) Packed separately (H7-C-205) Packed separately (H7-C-205) Packed separately (H7-C-205) Packed separately (H7-C-205) Packed separately (H7-C-205) Packed separately (H7-C-206) Packed separately (H7-C-206) Packed separately (H7-C-206) Packed separately (H7-C-206) Packed separately (H7-C-206) Packed separately (H7-C-206) Packed separately (H7-C-206)

75

33. INSTALLATION OF DIAGONAL LADDER (3/3) (DIAGONAL LADDER + LARGE-CAPACITY AIR CLEANER SPECIFICATION) 1. Install the covers to the clearance between the radiator guard and ladder.

2. Install the handrail to the front ladder.

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)

76

Part No. 561-84-68470 01024-81020 561-84-68480 01024-81020 561-84-68420 561-54-61910 01010-81635 01643-31645 568-06-15910 569-54-61831 07283-32236 07283-52232 01597-01009 01643-31032

Part Name COVER BOLT COVER BOLT GUARD CLAMP BOLT WASHER UNDER MIRROR U. STAY CLIP SEAT NUT WASHER

Q’ty 1 2 2 12 1 5 10 10 2 1 2 2 4 4

Condition Packed separately (H7-C-206) Packed separately (H7-C-206) Packed separately (H7-C-206) Packed separately (H7-C-206) Packed separately (H7-C-206) Packed separately (H7-C-206) Packed separately (H7-C-206) Packed separately (H7-C-206) Packed separately (H7-C-206) Packed separately (H7-C-206) Packed separately (H7-C-206) Packed separately (H7-C-206) Packed separately (H7-C-206) Packed separately (H7-C-206)

77

34. REPLACING SIDE BRACKET OF CABIN 1. Remove bracket (see photo) from rear right side of cabin once and install bracket in direction as shown in figure. ÃŽ Carry out bracket removal before cabin installation.

78

35. INSTALLING HANDRAIL OF CABIN 1. Install guard and mirrors (Parts without parts number mean accessories.)

79

36. INSTALLING CABIN 1. Remove 4 mounts from cabin floor.

2. Set upper half of mount in support mounting.

Do not use shims. Î During this time, place steering column on floor.

3. Install cabin on machine body.

4. Measure dimension L while not tightening nut.

5. If dimension L exceeds specified value, add shims so that difference among 4 dimensions L is within 0.5 mm.

6. Set lower half of mount in support mounting and tighten nut.

torque: ½ Tightening 343 to 426 Nm {35 to 43.5 kgm}, desired value 382 Nm {39.0 kgm}

7. Seal doors as before.

8. Connect ground cables to front support on front side, and hood mounting bracket on rear side. Î Remove coating on zone to be soldered as ground.

80

81

37. CONNECTING STEERING COLUMN 1. Remove cover from front support.

2. After removing cover from cabin column, connect steering column to steering valve.

3. Mount cover on cabin column as before.

4. Place rubber cover.

Tightening torque: 20 to 39 Nm {2.0 to 4.0 kgm}, desired value 29 Nm {3.0 kgm}

½

5. Mount cover on front support as before.

82

83

38. CLAMPING DRAIN HOSE OF AIR CONDITIONER 1. Remove rear cover from left-hand front support.

2. Clamp drain hose of air conditioner with two clips attached on support.

3. Mount cover as before.

84

39. INSTALLING ROPS AND PAYLOAD LAMP 1. Install ROPS on rear support with bolts attached on support.

2. Install external indicator lamp of payload meter with bolts attached on ROPS. 3. Connect connector CN-14 to external indicator lamp.

85

40. CONNECTING DUMP CONTROL 1. Install dump control bracket assembly with bolts attached on lower side of cabin.

2. Connect cable from hydraulic tank to dump control and clamp cable. (For dimensions see figure.)

3. Connect rod to lever.

4. Make sure that dump lever in cabin can be set on neutral stopper when holding dump.

86

87

41. INSTALLING AIR INTAKE (1/2) 1. Install air cleaner and air cleaner box.

(Parts without parts number mean accessories.)

88

42. INSTALLING AIR INTAKE (2/2) 2. Install bracket to clamp synflex tubes.

89

43. INSTALLING AIR INTAKE (1/2) (FRONT AIR INTAKE SPECIFICATION) 1. Remove air cleaner assembly and air cleaner box accessories.

2. Install air cleaner A and air cleaner box.

3. Connect air intake tube.

(1) (2) (3) (4) (5)

90

Part No. 561-84-6211A 561-84-6931A 01024-81235 561-02-12150 07289-00170

Part Name AIR BOX assembly AIR CLEANER assembly BOLT ELBOW CLAMP

Q’ty 1 1 4 3 6

Condition Packed separately Packed separately Packed separately Packed separately Packed separately

44. INSTALLING EXHAUST PIPE 1. Remove fire prevention cover from machine body.

2. Install exhaust pipe with bolts, bands and the like attached on machine body.

3. Install cover as before.

Fire prevention cover

91

45. DRAWING HARNESS INTO INSIDE OF CABIN 1. Draw harnesses attached machine body into inside of cabin.

(Number of harnesses varies depending on specification.)

2. Clip them.

92

46. CONNECTING HARNESSES INSIDE CABIN (1/2) 1. Draw harnesses into cabin and carry out wiring.

93

47. CONNECTING HARNESSES INSIDE CABIN (2/2)

Engine controller wiring harness (To be brought from chassis) Fix with clips installed temporarily (4 places marked with ✊)

Connection

Engine controller View Z Interruption wiring harness for EC regulation

Engine controller wiring (Electronic governor specification model)

Connection

View Y

Connection of chassis wiring harness

No. 1

94

Connect each wiring harness.

Check connector No. and terminal No.

Connect the engine controller wiring harness according to Fig. 1 - 4.

95

48. CONNECTING AIR CONDITIONER HOSES 1. Remove cover and clamp from side face of cabin.

2. Pass hoses 1 to 4 through cover and clamp.

Replace hoses as before.

3. Loosen 4 bolts and remove cover from air conditioner unit located on lower right side of dashboard.

4. Replace cover as before.

96

49. INSTALLING WASHER TANK 1. Install washer tank with bolts attached on side face of cabin.

2. Connect connector CN-12.

3. Connect hose. ÃŽ Hose may be cut to suitable length if it is too long.

97

50. INSTALLING AND CONNECTING AIR HORN 1. Install air horn with bolts attached on left-hand front support.

2. Connect harness of left-hand front support to air horn. (CN-04 and CN-D5-2) 3. Connect harness to air conditioner receiver.

(CN-04 for machine with air conditioner) 4. Clamp harness with clips. (one place) Clamp synflex tube with clip. (two places)

Clamp harnesses with clips.

CN-04 (for machine with air conditioner.)

CN-D5-1 CN-D5-2

561-35 62900

98

51. WIRING AROUND CABIN (1/2) 1. Connect connectors.

2. Connect harnesses with related clips.

99

52. WIRING AROUND CABIN (2/2)

Machine with auto-suspension or pay load meter

Side view of cabin

Rear lower portion of cabin

100

53. INSTALLATION AND CONNECTION OF FUEL FILTER (-40 °C SPECIFICATION FOR POLYUS) 1. Remove the fuel filter hose clips. Î Discard removed parts.

2. Install the fuel filter and connect and fix the piping.

2-1. Remove bracket 5 installed temporarily to the right stay. Î Do not discard clips, cushions and bolt installed temporarily to bracket 5 since they will be used in Assembly manual No. 0430.

2-2. Install fuel filter mounting bracket 1 to the right stay with bolts 2.

2-3. Install fuel filter assembly 3 to bracket 1 with bolts 4.

2-4. Install right hose clamp bracket 5 to the right stay with bolts 6.

2-5. Direct the 2 hose joint elbows of fuel filter assembly 3 down.

2-6. Check Nos. "15" and "16" of the fuel hoses and the O-ring of the connection-end elbow and connect the hoses.

2-7. Fix the fuel hoses to bracket 5 with clips 7, cushions 8 and bolt 9.

(1) (2) (3) (4) (5) (6) (7) (8) (9)

102

Part No. 561-84-67481 01024-81230 6215-71-620A 01024-81240 561-84-67520 01024-81225 20Y-977-1160 07095-00523 01024-81020

Part Name BRACKET BOLT, SEMS FUEL FILTER A. BOLT, SEMS BRACKET BOLT, SEMS CLIP CUSHION BOLT, SEMS

Q’ty 1 4 1 3 1 2 2 2 1

Condition (Parts list No.) Packed separately (H7-C-145) Packed separately (H7-C-145) Packed separately (H7-C-145) Packed separately (H7-C-145) Install temporarily to right stay Install temporarily to right stay Packed separately (H7-C-145) Packed separately (H7-C-145) Packed separately (H7-C-145)

54. CONNECTING RIGHT-HAND FRONT BRAKE AND RADIATOR SURGE TANK 1. Connect hose from reservoir tank to radiator.

Clamp hose at two points with clips and insulator attached on radiator.

2. Clamp drain hose and front brake hose respectively at two points enclosed by circle as shown in photo.

3. Connect brake hose and tighten it together with filter line hose.

Tightening torque of hose: 29 to 69 Nm {3.0 to 7.0 kgm}, desired value 49 Nm {5.0 kgm}

½

4. Clamp drain hose with clips and insulator attached on U-bolt of transmission cooling tube.

104

Tighten brake hose together with filter line hose

105

55. WIRING FOR HEAD LAMP 1. Remove head lamp. Draw in right-hand ??platform?? harness and carry out wiring.

2. Install head lamp as before.

Clamp wire with clip.

106

56. CONNECTING AIR CHARGE LINE 1. Connect tube to hose from air compressor and clamp hose with clips. Connect hose to hose of right-hand platform side.

Tightening torque: 108 to 167 Nm {11.0 to 17.0 Kgm}, desired value 137 Nm {14.0 kgm}

½

2. Connect synflex tube from air governor to synflex tube of wet reservoir.

Tightening torque: 7 to 10 Nm {0.7 to 1.0 kgm}, desired value 8 Nm {0.85 kgm}

½

108

109

57. AIR PIPING 1. Connect synflex tubes after making sure tube their number. ĂŽ Cut tube to suitable length.

Tightening torque: 3 to 5 Nm {0.32 to 0.50 kgm}, desired value 4 Nm {0.4 kgm} for nominal diameter 04 7 to 10 Nm {0.70 to 1.00 kgm}, desired value 8 Nm {0.85 kgm} for nominal diameter 06 7 to 14 Nm {0.70 to 1.4o kgm}, desired value 10 Nm {1.05 kgm} for nominal diameter 08 and 10

½

2. Remove cover from right-hand platform once.

3. After connection is completed, bundle tubes with band etc.

110

Beside cabin

Behind right-hand platform

111

58. CONNECTING LEFT-HAND FRONT BRAKE 1. Clamp and connect hoses of right-hand platform one after the other. of hose: ½ Tightening29torque to 69 Nm {3.0 to 7.0 kgm}, desired value 49 Nm {5.0 kgm}

112

59. INSTALLING PARTS AROUND HOOD 1. Replace hood as before.

2. Install guard and cover of air joint assembly with attached bolts.

3. Seal gaps between cabin and hood and between cabin and radiator guard.

113

60. CHECKING FOR OIL AND COOLING WATER Î Check oil and cooling water according to Operation and Maintenance Manual.

1. Fill cooling water to H level in radiator sub-tank.

2. Fill cooling water into radiator to water filler port.

3. Check for oil level in all units by indication on gauge.

4. Supply fuel up to required volume.

5. Start engine. Î Do not raise engine speed abruptly. Otherwise, floating seal oil of rear axle will drain excessively.

6. Stop engine. Check for all units again. Î Check for water level at sub-tank side. (unnecessary for radiator side)

114

61. FILLING GAS INTO AIR CONDITIONER 1. Fill gas after connecting gas charger of air conditioner (at engine idling). Î Gas: R 134a (6 cylinders of 20Y-979-3310) 2. Adjust gas in weight properly while observing gas through sight glass on receiver. Î Gas weight: Approx. 1.1 kg

115

62. BLEEDING AIR FROM BRAKE Î Connect vinyl tube to air bleeding plug. Drain oil from brake and discard oil. Î First, bleed air from rear brake.

116

117

63. REMOVING PARTS FROM HOST CYLINDER AFTER TRANSPORTATION 1. Right-hand hoist cylinder: Using lever block, support right-hand hoist cylinder once removed when installing fuel tank.

Left-hand hoist cylinder: Remove brackets etc. and support left-hand hoist cylinder in the same way of right-hand hoist cylinder.

At this time, replace mounting bolts of hydraulic tank and tighten new bolts.

Tightening torque: 490 to 608 Nm {50 to 62 kgm}, desired value 549 Nm {56 kgm}

½

2. Place oil sump.

3. After making sure that dump lever in cabin locates at neutral position, uncap hydraulic tank to release internal pressure.

4. Remove 4 blind parts on both sides.

Replace bolts and tighten new bolts. Î Replace O-ring of loose-supply item with new O-ring.

Use previous washers.

5. Cap hydraulic tank. Î After removing blind parts, do not rise engine speed until hydraulic tank is installed.

(Otherwise, cylinder will extend regardless of lever operation.)

118

119

64. EQUIPPING MACHINE BODY 1. Insert 4 pins A of special sling for body into holes from outer side of body.

Æ

Body weight: 15 tons (standard) Î Select flat ground for this work.

2. Hook chain of body sling at pins A with shackles.

Use two short chains out of 4 chains at front left and front right of body.

3. After checking for balance, lift body. Î Use rope etc. to prevent swing.

4. Move machine near body mounting portion. Î Never access under lifted load.

5. By controlling crane, align mounting holes on chassis with those on body.

6. Adjust shims to mount body in place and then insert pins. Î In this time, make sure that gap between chassis and body does not exceed 25 mm.

(If gap exceeds 25 mm, re-adjust shim thickness.

7. Carry out this work on both sides in the same way.

8. Install lock bolt as shown in Fig. 2.

Tightening torque: 245 to 309 Nm {25 to 31.5 kgm}, desired value 275 Nm {28 kgm}

½

9. Controlling crane and lever block, align upper pin on hoist cylinder with pin hole on body and insert pin. Î If cylinder hole is located under hole on body, operate lever through emergency steering switch to lift cylinder.

10. Install lock bolt as shown in Fig. 3.

Tightening torque: 157 to 196 Nm {16.0 to 20.0 kgm}, desired value 177 Nm {18.0 kgm}

½

11. Place stopper of approx. 50 mm to keep space between body and chassis.

12. Remove lever block from both sides.

13. Lower crane and remove chains and pins.

14. Supply grease to lubrication points.

120

121

65. INSTALLING GREASE TUBES ON HOIST CYLINDER 1. Carry out grease lubrication tubing as shown in figure. ÃŽ Insert tube firmly into bottom of upper nipple.

2. Fill grease.

122

66. ADJUSTMENT OF BODY BOTTOM MOUNT 1. Raise body and tighten left- and right-hand pads on most front side of body. ĂŽ When carrying out body bottom work, set dump lever at neutral stop position in cabin.

Place square timber etc. as chock between frame and body.

2. Lower body near frame once. Then, while lowering body gradually, check that pad seats uniformly on frame. If either side of pad seats later than another, add shims to such side and adjust pads on both side can seat on frame at the same time.

3. Measure space at 6 points between center of pad mounting position and frame while holding frame at seating posture. ĂŽ If gap is under 35 mm, increase same number of shims on both side of most front portion in order to keep 35 mm.

4. Mount pads by using shims to thickness of measurement minus 35 mm (pad thickness). If necessary, use cut shims so that no gap occurs between pad and frame.

5. After mounting all pads, check that no lateral runout and no gap between pad and frame are found.

124

125

67. ADJUSTMENT OF BODY POSITIONER 1. Loosen two bolts A and remove cover B. 2. Operate dump lever to raise body (at position 1, UP). Î Lock lever at body UP position and loose your hold.

3. Adjust lever with nut C so that it is automatically set to position 2, HOLD, 50 to 100 mm before cylinder stroke end, i.e. position 1.

4. After adjustment, tighten lock nut C firmly.

Tightening torque: 8 to 15 Nm {0.9 to 1.5 kgm} In this case, plate to be free from skew during installation.

½

5. Mount cover B with bolts A. 6. Check following items.

(1) Positions 1, 2, 3, and 4 can function properly.

(2) Position 2 can hold or stop body at any position.

(3) Lever is automatically set to position 2 when lever is loosened from HOLD at position 1. (EC regulation) (4) Safety stop works correctly without interference.

(5) Lever is automatically set to position 3 when lever is loosened from EC HI-IDLE at position 4.

(6) ”Pressure adjustment” can be carried out at position 4.

126

68. WELDING BY DETERMINING DIMENSIONS WITH ACTUAL PARTS (BODY FRONT MOUNT) 1. Mount bracket on upper face of rear support.

Adjust bracket to locate at center of mount of body. Î Before welding, protect overall machine body with refractory cloth etc.

2. Raise body and weld bracket permanently.

3. After welding, set pad and shims and tighten bolts. Make tightening force uniform with shims. Î If force is not uniform, then cut shims.

4. Check for gap between pads and body. Î If gap is found, re-adjust gap with shims 5. Install cable clamp onto right-hand mount portion with bolts attached around mount.

128

129

69. WELDING BY DETERMINING DIMENSIONS WITH ACTUAL PARTS (SWING PREVENTION OF BODY) 1. Paste shims of 1 mm onto bracket. Align shims with center of contact face of frame and adjust bracket to contact to both of body and frame.

2. Tack-weld them.

3. Raise body and remove shims and then weld bracket permanently.

130

70. WELDING BY DETERMINING DIMENSIONS WITH ACTUAL PARTS (EXHAUST FLANGE) 1. Tighten lock nut at position matching dimension A (221 mm) shown in figure.

2. Place 3 spacers, 20 mm, ATH-465-027, between tube and nut.

3. Insert plate into flange and mount plate and tube in exhaust inlet on body.

4. Fix plate and tube with C clamp at center of exhaust tube flange. ÃŽ Runout of center to be within 3 mm.

5. Lift plate toward body side and tack-weld plate and tube.

6. Lift body and weld plate and tube permanently.

7. Remove spacers.

131

71. INSTALLING BODY SEATING SWITCH 1. Install bracket assembly on body side to match dimension (99.5 mm) shown in figure.

2. Check that switch can move down 3 to 4 mm.

3. If switch does not move down 3 to 4 mm, keep specified switch depth by adjusting mounting bracket or spring force.

132

72. INSTALLING BODY ACCESSORIES 1. Install mud guard and roke ejector.

133

73. PAINTING 1. Coat weld zones with coatings listed below. Î Wear mask, goggles, and gloves for protection from spray 2. Use coating mixed base and hardner at specified rate (5:1).

3. In addition to body, apply coating to area defected when assembling. Î In addition to body, repair defective coating when assembling.

Primer coating  Urethane GP Primer  Urethane GP Hardener  Urethane GP Thinner Top coating  NAX Mightyracq GIIKB type natural yellow  NAX Mightyracq GIIKB type hardener  NAX Mightyracq GIIKB type thinner Exhaust pipe Heat resistance silver

134

135

74. BODY STOPPER PINS 1. Stow body stopper pins into axle housing.

136

75. ADJUSTMENT OF SUSPENSION Nitrogen gas filler valve

Air bleeder valve Air bleeder

Nitrogen gas cylinder

Location of air bleeder valve of front suspension

Suspension gas filler unit (7826-10-1000)

Adjustment value 250 ± 10 mm Reference

Front

Rear

When cylinder is fully retracted: 108 ± 1 mm When charged with oil of specified quantity: 175 ± 3 mm When truck is empty: 250 ± 10 mm When cylinder is fully extracted: 302 ± 1 mm

1. 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 – 49 Nm {4 – 5 kgm})) 2. Check that the valves are closed and install the suspension gas filler unit to the suspension cylinders.

3. 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.)

4. Open the valve of the suspension gas filler unit gradually.

5. 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.)

6. 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.)

7. Apply the parking brake and check the length of the suspension cylinders.

8. 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

1.

2.

3.

4.

5.

Necessary tools Name Q'ty Bleed air from the cylinders.

Suspension gas filler unit 1 Fill both suspension cylinders simultaneously.

(7926-10-1000) Do not extract the suspension cylinders to the stroke end.

After moving the truck forward and in reverse, stop it without applying the brake.

Do not steer the truck before finishing this adjust- Other remarks ment. (If it is steered, the piping may be broken.)

Necessary equipment Name Q'ty

137

76. SMOOTHING OF FLOATING SEAL 1. Before traveling ĂŽ Travel completed machine to make floating seal smooth inside rear axle.

2. Traveling Conditions Shift Traveling distance (approximately) F1 500 m F2 500 m F3 1000 m F4 1000 m F5 1000 m F6 1500 m F7 1500 m Travel not less than total 7000 m.

3. Checking After traveling, check visually that amount of drain oil is very small.

(Standard: not more than 30 cc per 7 km)

138

PROCEDURE FOR WELDING AND ASSEMBLING THREE SEPARATED BODY PARTS

CONTENTS Preparatory work for assembling three separated body parts ................................................................. 140 Welding process for three separated body parts ....................................................................................... 144 Welding of the body assembly .................................................................................................................... 152 Work procedures for turning over the body ............................................................................................... 154

139

PREPARATORY WORK FOR ASSEMBLING THREE SEPARATED BODY PARTS Process drawing

Welding machine

Genetator

Lowering separated body

140

CO2 welding machine

Order of work

Work procedure

1. Select the place for welding work.

•

The total of floor or ground area moust be at least 169 m2 (13 m x 13 mm).

2. Prepare the welding machine, ganerator, and tools.

•

The flatness of the floor or ground must be less than 0.05 m over 10 m.

3. Unload the body. (Unload in the specified condition.)

•

Set the separated body on suitable wooden blocks.

•

If there is a plate holding the protector, remove it with a gass cutter.

•

A range of 15 mm along the whole line for the body mating portion.

•

Burn off with a gas heater, or grind off the primer and paint with a grinder.

4. Remove the protector stored in the body.

5. Place to remove primer and paint.

6. Turn over the separated body.

7. Set supports on the ground where the separated body is to be assembled as shown in the deagram below.

141

Process drawing

142

Order of work

Work procedure

1. Set one part of the separated body on the support stand.

2. Set the opposite side of the separated body on the suopprt stand so that the clearance is constant.

•

If the two pieces do not match properly, use a hydraulic cylinder to adjust them.

•

After tack welding, remove the bolt, washer, nut, and tube.

•

If the separated parts do not match properly, correct with a hydraulic cylinder.

•

When correcting, check that the tighening bolts are loosened.

3. Use brackets 568-74-11610 (front) and 56183-69430 (bottom), and join the set pieces of the body with the following parts.      

01011-52000 01643-32060 01580-12016 581-74-11630

 Bolt  Washer   Nut  Tube 

4. Pass the alignment pin through the bottom hinge brackets (561-74-61183, 561-74-61193), check the height and position, then remove the pin.

5. Tack weld the body.

6. Position the brakets (561-74-68111), then tack weld.

143

WELDING PROCESS FOR THREE SEPARATED BODY PARTS Process drawing

144

Order of work

Work procedure

1. Weld the front (X portion).

(Large sheet connection portion and channel connection poortion)

•

Use arc welding for the front with vertical welding.

(Follow the vertical welding conditions in Table 1.)

2. Next, position one plate each (561-83-69440, 561-83-69450, 561-83-69471) on the channel, and weld in position.

•

Weld the inside of the channel also.

•

Insert backup material in the joints between channel and channel.(Only joint of bottom plates) (For backup material, use SS41B 9.)

3. Set the cottom (Y portion) horizontal and weld.

(Large sheet connection portion, channel connection portion and two brackets 561-866H110).

•

Insert a support under bottom rear.

•

Perform backstep weldign for bead joint and start of the arc.

4. Use gas to make a hole in the position shown in below in one of the five plates 561-8369462.

5. Next, position 5 plates (561-83-69462), 2 plates (561-83-69521), and 1 plate (561-7462B70) on the channel, and weld in position.

(Note: The one plate of the five plates 56183-69462 that has a hole made by gas is welded to the 7th rib from the front on the bottom.)

6. Next, position 1 plate (561-83-69411), 1 plate (561-83-69481), and 1 tube (561-74-62B20) (12), and weld in position.

7. When the welding is finished, remove the spatter with a grinder and finish the bead.

145

Process drawing

146

Process drawing

147

Process drawing

148

Order of work

Work procedure

8. Check for any welding defects.

(1) Depositive metal check (2) Undercuts, overlaps, adhesion of spatter (3) Lack of welding leg (Minus leg length is rejectde) 9. Turn over Prepare to turn the body over.

•

Turn over the body according to the attached work procedures.

10. After turning over the body, arc-weld the joints of the front part in a vertical position.

(Apply the welding condition in Table 1.)

•

11. Weld the mating portion of the bottom.

•

Carry out arc welding at vertical position. (For welding conditions see Chart 1.)

Place timber under front and back portions of bottom.

Connect ground for welding securely with main body.

Normally use CO2 gas shield welding. If CO2 gas shield welding is difficult, arc welding may be used.

Drying time for arc welding electrode (1) Temperature: 150 to 200°C (2) Time: 120 minutes

Carry out reversing work by using sling holes on both sides.

Reversing work procedures (Turning procedure)

Table 1. Welding conditions Method CO2 gas chield welding

Arc welding

Welding posture

Flat position (F)

Welding current

320 – 350 A 380 – 420 A

220 – 260 A 130 – 160 A

Preheating, Unnecessary postheating

Unnecessary

•

Remarks

(1) Do not use Flat position CO2 gas vertical position (V) welding if the wind Welding rod d1.2, d1.6 speed is d5.0,d 4.0 JIS Z3312 YGW11 JIS Z3212 D5016  more than 2 or equivalent  – 3 m/sec. or equivalent

Gasshield amount

CO2 25 – 35 l/ min.

—

•

•

(2) Remove all moisture, dirt, and paint from the locations to be welded.

12. Finish Use a grinder to remove the spatter and finich the head.

149

Process drawing

150

Order of work

Work procedure

13. Welding the protector (1) Place the protector on the top of the side plate and front plate with a crane.

Weight of protector : Approx. 1,585 kg Crane : Must have capacity of 2 tons and lift of 7m or higher.

Wire rope, chain, chain block : Must have breaking strength of 2.1 tons or higher.

•

Area of the floor or ground must be at least 126m2 (9m x 14m).

•

Level difference of the floor or ground must be 0.05m maximum in 10m.

•

Place wood blocks around the bottom plate so that both side plates will be almost parallel with each other.

(2) Position the protector side plate in parallel with end of the body side plate.

•

If the protector is secured with any plate, cut it with gas.

(3) When positioning, gas-cut the front and side of the protector so that the top of the body side plate will be parallel with the top of the protector.

•

Remove by heating with gas or cut with a grinder.

•

When welding the side plate of the protector, hang with a crane so that the front of the protector will be raised about 1° (Check visually) after welded as shown above.

Note : The protector and front plate are deformed by welding as shown below.

Accordingly, the front and side plates of the protector must be cut with gas to minimize the gap that may be made by welding. (Gap must be 3mm maximum.)

(4) After positioning, secure the front of the protector by tack-welding.

(5) Weld the protector.

Welding order : Weld side plates (on both sides) first.

Welding symbol : Shown at right.

Welding condition : Shown in Table 1.

151

WELDING OF THE BODY ASSEMBLY Process drawing

152

Order of work

Work procedure

1. Install the body to the frame, set in the dumping position, and adjust.

(When installing, see the assembly pocedure.)

2. Adjust the dimension between the body and frame with shims beforehand.

3. Welding of front body mount (561-46-61861, 61871 brakets) • Set the brackets (561-46-61861, 61871) on top of the frame, and weld so that the clearance from the body brackets (56183-61563, 61573 ) is 57 mm.

•

Move the body to the dump position while doing this.

4. Welding of stopper bracket (561-74-6A810) • Weld so that the clearance between the body and frame is 1 – 2 mm.

•

Reduce misalignment of exhaust flange to 3 mm or less.

5. Welding of exhaust (flange 561-02-61150, plate 582-02-11230) • Insert the plate (562-02-11230) into the tube assembly (561-02-61150), then set on the body exhaust inlet port.

• Align the center at the flange mating surface, then weld the tube and plate to the body.

153

WORK PROCEDURES FOR TURNING OVER THE BODY

1.

2.

3.

4.

154

Work procedure

Points of work

1. Prepare a 50-ton crane and a 25-ton crane.

Weight of body STD

2. Insert hanging pins 1 in the body from inside (All four pins).

Other options : Side extension (300mm) 1,100 kg Steel liner 6,000 kg

3. Install 2-piece chains 3 to pins 1 with shackles 2 (Four places on both sides).

Bring the crane trucks as near to the body as possible.

4. Wind both 50-ton and 25-ton cranes simultaneously.

Take care of the center of gravity.

5. Wind the 50-ton crane and unwind the 25-ton crane to place the body on its side.

Only one man shall make signs clearly.

Remarks

15,510 kg

6. Remove the sling from the 25ton crane, but keep the sling of the 50-ton crane installed.

7. Move the 25-ton crane to the opposite side.

8. Install the sling to the 25-ton crane.

9. Wind the 25-ton crane and unwind the 50-ton crane.

10. When the body becomes horizontal, unwind both cranes to lower the body to the ground, then remove the slings.

155

2900 mm transportation posture (If equipped)

CONTENTS

1. Necessary tools and equipment .................................................................................................... 157 2. Field assembly procedure A-1

Removed components list ............................................................................................. 161

A-2

Installation and connection of fuel filter ......................................................................... 162

A-3

Installation and connection of bypass filter ................................................................... 163

A-4

Installation of hydraulic tank .......................................................................................... 164

A-5

Connection of piping around hydraulic tank .................................................................. 165

A-6

Installation of hydraulic tank and connection of piping (1)............................................. 166

A-7

Installation of hydraulic tank and connection of piping (2)............................................. 167

A-8

Assembly of radiator guard ........................................................................................... 168

A-9

Installation of front stay ................................................................................................. 169

A-10 Installation of right hoist cylinder ................................................................................... 170 A-11 Installation of right combination lamp ............................................................................ 171 3. Field welding work on frame divided for transportation Welding procedure Preparation for welding .................................................................................................................. 172 Temporary assembly process of vertical (1) .................................................................................. 174 Welding process of vertical (1) ....................................................................................................... 176 Temporary assembly process of vertical (2) .................................................................................. 178 Welding process of vertical (2) ....................................................................................................... 180 Temporary assembly process of bumper ....................................................................................... 182 Welding process of bumper ........................................................................................................... 184

157

2900 mm transportation posture Necessary tools and equipment 1) Necessary tools No.

Tool name

1

Ring wrench

Specification

2

Impact wrench

GT-S12M or equivalent

1

3

Impact wrench

GT-S22M or equivalent

1

4

Impact wrench

RSP220Nx22 or equivalent

1

5

Impact wrench

RSP310Nx24 or equivalent

1

6

Impact wrench

GTP-800P or equivalent

1

7

Socket

36 (Insertion angle: 25.4)/46 mm

1

8

Socket

14/17/19/22/24/30

1 each

9

Spanner

14/17/19/24/30/36

1 each

10

Torque wrench

For measurement of 28 Nm {2.9 kgm}

1

11

Torque wrench

For measurement of 94 Nm {9.6 kgm}

1

14/17/19/24/30/36

Q'ty

Remarks

1 each

12 13 14 15 16 17 18 19

2) Necessary equipment No.

Equipment name

1

Mobile crane

Min. 441 kN {45 ton}

1

For raising front side

2

Mobile crane

Min. 245 kN {25 ton}

1

For raising rear side

3

Compressor

Min. capacity of 32 l

1

For impact wrench

4 5

Specification

Stepladder (Work stand) 4 steps (About 1.5 m) Wood block

350 Ă— 350 Ă— 350

Q'ty

Remarks

1

For work

4

For positioning workpiece

6 7 8 9

For the other tools and equipment, see the standard model.

159

3) Necessary slings No.

Sling name

1

Nylon sling

Specification

Q'ty

For 147 kN {15 ton} Ă— L4000

4

2 3

Using load: Min. 147 kN {15 ton}

160

4,000

1 : Nylon sling

Remarks

Assembly process No.

Removed components list

A-1 The components of this specification are removed as shown below.

Components in boxes are the same as those of the standard model.

H/T

Bare machine

F/T

R-A/X

Radiator guard

F-A/X(Right and left) Right platform

CAB

Right bumper Hood

Body

Stay 2

Tail lamp

Fuel filter

Filter tube

Hoist cylinder (Right)

Stay 1

Block

Bracket 1

Bypass filter

Bracket 2

161

Assembly process No.

Installation and connection of fuel filter

A-2 1. Install the fuel filter and connect the piping.

Z

Hose numbers

FWD

View Z Precautions When connecting the hoses, check their Nos.

Necessary tools Name • Spanner (24 mm)

Other remarks

162

Q'ty 1

Necessary equipment Name Q'ty

Assembly process No.

Installation and connection of bypass filter

A-3 1. Install the bypass filter and connect the piping.

Z Using bolts installed to frame temporarily, install bypass filter.

Y

View Z

View Y

Matching the Nos., connect the hoses.

Precautions When connecting the hoses, check their Nos.

Necessary tools Name • Spanner (24 mm)

Q'ty 1

Necessary equipment Name Q'ty

Other remarks

163

Assembly process No.

Installation of hydraulic tank

A-4 1. Install the hydraulic tank.

Use bolts installed to frame temporarily.

Hydraulic tank assembly 798 kg

Precautions

Necessary tools Name

Other remarks

164

Q'ty

Necessary equipment Name Q'ty Crane 1

Assembly process No.

Connection of piping around hydraulic tank

A-5

a Nos. in this page correspond to the item Nos. in the following pages.

Connect wiring harnesses.

165

Assembly process No.

Installation of hydraulic tank and connection of piping (1)

A-6

1. Connect rear brake oil line.

Installation of hydraulic tank and connection of piping 2. Connection of steering valve line

3. Connection of oil cooler line

4. Connection of high-pressure filter and transmission filter line

5. Hoist line

6. Hoist line and brake cooling

brake cooling

a The circled Nos. are the Nos. printed on the hoses.

Precautions When connecting the hoses, check their Nos.

Necessary tools Name

Other remarks

166

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

Installation of hydraulic tank and connection of piping (2)

A-7 7. Hoist suction line and brake cooling line

9. Assembly of transmission filler tube

Fix piping as shown in photo.

8. Brake cooling valve line

10. Cable

a The circled Nos. are the Nos. printed on the hoses.

Precautions When connecting the hoses, check their Nos.

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks

167

Assembly process No.

Assembly of radiator guard

A-8 1. Install radiator guard

Bolt tightened to frame temporarily

Main Frame

Precautions

Necessary tools Name • Spanner (24 mm)

Other remarks

168

Q'ty 1

Necessary equipment Name Q'ty

Assembly process No.

Installation of front stay

A-9 1. Assembly of front stay

Tightened to support temporarily

• Insert shims to eliminate the clearance between the support and stay.

• Insert the shims evenly to the right and left sides.

(1) (2) (3)

Part No. 561-54-6133A 561-54-61160 561-54-61170

Precautions

Part name Stay assy Shim Shim

Q’ty 1 8 8

Condition of part Single part Single part Single part

Necessary tools Name • Spanner (24 mm)

Q'ty 1

Necessary equipment Name Q'ty

Other remarks

169

Assembly process No.

Installation of right hoist cylinder

A-10 1. Installation of hoist cylinder • Install the hoist cylinder and fix it with the jig.

• Connect the hoist piping.

Hoist Sylinder

Thick

Thin

Fix cylinder with bracket attached to hoist cylinder.

Fix cylinder with lock plate installed temporarily.

(1) (2) (3) (4)

Part No. 561-63-62103 561-61-63510 01024-81085 07000-F3035

Precautions

Part name Cylinder assy Block assy Bolt O-ring

Q’ty 1 1 4 1

Necessary tools Name

Other remarks

170

Condition of part Single part Single part Single part Single part

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

Installation of right combination lamp

A-11 1. Installation of rear combination lamp

X

• Install the rear combination lamp.

• Connect each wire.

56 Connection Connection 565-06-12280

57

Connection

67 Connection

Z

Payload meter

63

DB1

L.H

Connection

62 Backup alarm

CN 62

08036-01414

56 CN 60

57 Backup lamp

DB1 Seating switch

59 Tail lamp CN 59 60 Tail lamp

59 Connection 60 08193-01512

CN 63

Connection

67 Ground

R.H 561-06-63730

62 Payload meter

(1) (2) (3)

Part No. 561-06-X1180 01010-81420 01643-31445

Precautions

63 Connection Part name Tail lamp assy Bolt Washer

Q’ty 1 4 4

View Z

01643-31032 01010-81016

Condition of part Single part Fixed to frame temporarily Fixed to frame temporarily

Necessary tools Name • Spanner (24 mm)

Q'ty 1

Necessary equipment Name Q'ty

Other remarks

171

Preparation for welding Process drawing

(Welding machine)

172

(Generator)

(CO2 welding machine)

Order of work 1. Select a place for welding work.

2. Position the welding machine, generator, and tools.

Work procedure a The area of the work floor or ground must be at least 144 m² (12 m × 12 m).

(HD785-5 frame measurements 3.3 m × 8 m) a The gradient of the work floor or ground must not exceed 0.05 m in 10 m.

3. Unload the frame.

At this time, place the supports on the ground as shown below (4 places).

a This drawing shows only the main frame.

4. Removal of primer and paint Burn the primer and paint on the area about 15 mm around the welding lines with a gas burner or cut them off with a grinder.

173

Temporary assembly process of vertical (1) Process drawing

(However,1 piece of 561-40-61541 PIN, 2 pieces of 569-52-11130 PIN, 1 piece of 01010-81425 PIN, 1 piece of 569-40-61710 PIN have been installed.)

174

Order of work

Work procedure

1. Sling 561-46-61581 (right bracket) and set it to the frame installing position.

2. Match the temporary mounting plates (3 places) installed to 561-46-61581 (right bracket) and 561-46-61106 (frame), and fix them temporarily with 01010-81260 (bolts), 01580-11210 (nuts), and 01643-31232 (washers).

3. Matching to the scribed (punched) lines on the front, rear, and top of the bracket and frame, tighten the bolts securely (Fig. 1).

4. Install the bracket and frame temporarily

a Take care that the weight of the bracket will not be applied to the temporary mounting plate.

a Check the pitch of the A-frame mounting part of the vertical (Fig. 2). a Insulate the crane hook. a Install temporarily so that the bracket will not move by its weight when the sling is removed.

a Before starting welding, cover the engine exhaust pipe and air intake pipe with heat-resistant cloths, etc. (to prevent dirt, spatters, etc. from entering).

175

Welding process of vertical (1) Process drawing

(Note) Take care that spatters will not stick to the pin which is installed in advance. If the patters may stick to the pin, remove the pin. In this case, the spatters must not stock to the inside wall of the bracket boss. If spatters stick, remove them with an inside grinder (hub).

176

Order of work

Work procedure

1. Weld the frame and bracket. Do not weld the front and rear of the temporary mounting plate, however.

a Apply arc welding in vertical position to the front and rear parts of the bracket.

Apply arc welding in overhead position to lower part of the bracket.

(Observe the welding condition in Table 1.) a When connecting a welding bead, check that there is not an overlap. If there is an overlap, remove the bead from the toe of weld by gouging or with a grinder.

2. After finishing welding, remove the temporary mounting plate.

3. Weld the mounting part of the temporary mounting plate.

4. After finishing welding, remove spatters and finish the beads with a grinder. Finish the bead of part P flatly, in particular.

(Finish the mounting part of the temporary mounting similarly.)

5. Check the welded parts for a welding defect.

(1) Check the deposited metal (appearance of the bead).

(2) Check for an undercut, overlap, and spatter.

(3) Check the welding leg length for insufficiency (Leg length less than the specified value is not permitted).

a Connect the ground cable as near to the welded part as possible. a When connecting a bead and when starting welding, apply return welding.

Table 1 Welding condition CO2 gas-shielded welding Welding position Welding rod Wire/Rod diameter (mm)

Arc welding

Flat

Flat

JIS Z3312 YGW11 or equivalent

JIS Z3312 D5016 or equivalent

(1) When wind velocity is 2 – 3 JIS Z3312 D5016 or m/sec, do not equivalent apply CO2 gas welding. ø4.0 ø5.0 (2) Remove moisture, dust, and 110 – 150 130 – 170 paint from the surface to be Unneces- Unneceswelded. sary sary

ø1.6

ø4.0

ø5.0

Welding current (A) 200 – 350

300 – 500

150 – 190

190 – 240

Preheating/ Post-heating

Unnecessary

Unnecessary

Unnecessary

Unnecessary

CO2

---

---

---

---

---

25 – 35

---

---

---

---

---

Seal guard Gas shielding rate (l/min)

ø1.2

Vertical/Overhead

1) Apply CO2 gas welding as standard. If it is difficult to apply CO2 gas welding, however, apply arc welding.

2) Drying condition of arc welding rod: (1) Temperature: 300 – 350 °C, (2) Time: 60 minutes

177

Temporary assembly process of vertical (2) Process drawing

178

Order of work

Work procedure

1. Set 561-46-62741 bracket to the frame mounting part.

2. Set the bracket so that there will not be clearance in the positioning plates which have been installed (3 places). Install it along the frame in the longitudinal direction and check the parallelism with the right bracket (561-46-62731) and check the pitch of the tap holes. Adjust, if necessary.

a There must not be spatters on the positioning plate and bracket contact face.

3. Install the bracket and frame by tack welding.

a Prevent floating of the workpiece caused by tack welding.

4. Remove the positioning plates.

179

Welding process of vertical (2) Process drawing

180

Order of work 1. Weld the frame and bracket.

2. After finishing welding, remove spatters and finish the beads with a grinder.

3. Check the welded parts for a welding defect.

(1) Check the deposited metal (appearance of the bead).

(2) Check for an undercut, overlap, and spatter.

(3) Check the welding leg length for insufficiency (Leg length less than the specified value is not permitted).

Work procedure a Apply arc welding in vertical position to the sides of the bracket. a Apply arc welding in overhead position to lower part of the bracket.

(Observe the welding condition in Table 1 in page 155.) a Take care that spatters will not enter the tap holes of the bracket (20 Ă— 2.5, 6 places). If any spatter enters a tap hole, chip it or cut the screw with the tap again. a For other precautions for welding, see "Welding process of vertical (1)".

181

Temporary assembly process of bumper Process drawing

182

Order of work

Work procedure

1. Sling 561-46-61211 (bumper: removed part) and set it to the frame installing position.

2. Match the temporary mounting plates (3 places) installed to 561-46-61581 (bumper) and 561-46-61106 (frame), and fix them temporarily with 01010-81260 (bolts), 01580-11210 (nuts), and 01643-31232 (washers).

a Take care that the weight of the bumper will not be applied to the temporary mounting plate. a Place a stand under the bumper.

3. Matching to the scribed (punched) lines on the front, rear, and top of the bumper and frame, tighten the bolts securely (Fig. 1).

4. Checking the pitch of the tap holes of 561-4662720 plates (right and left) at the top of the bumper, install the plates by tack welding. (Fig. 2)

a Insulate the crane hook. a Install temporarily so that the bumper will not move by its weight when the crane hook is removed.

183

Welding process of bumper Process drawing

184

Order of work

Work procedure

1. Weld the frame and bumper. Do not weld the front and area of the temporarily mounting plates, however.

a Apply arc welding in vertical position to the front and rear of the bumper. a Apply arc welding in overhead position to lower part of the bumper.

(Observe the welding condition in Table 1 in page 155.)

2. After finishing welding, remove the temporarily mounting plates.

3. Weld the mounting part of the mounting plate.

4. After finishing welding, remove spatters and finish the beads with a grinder. In particular, finish the joints of the beads and ribs smoothly on the front side of the bumper.

a Take care that spatters will not enter the tap holes of 561-46-62720 plate (20 Ă— 2.5, 6 places).

If any spatter enters a tap hole, chip it or cut the screw with the tap again.

a For other precautions for welding, see "Welding process of vertical (1)".

5. Check the welded parts for a welding defect.

(1) Check the deposited metal (appearance of the bead).

(2) Check for an undercut, overlap, and spatter.

(3) Check the welding leg length for insufficiency (Leg length less than the specified value is not permitted).

185

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

SA12V140-1

HD785-5 Service Meter Reading

Engine Serial No.

Date of Inspection Attachment 1

Location of Machine at Inspection

2

Manufacture

Model Distributor’s Name Serial No.

Customer’s Name

Address:

Signature:

Delivery Report No. attached

Date: Inspector’s Comments:

Inspector’s Name:

KOMATSU USE ONLY : C. Sheet Receiving Date:

Title

By

Signature:

:

Remark:

Check sheets filling instructions:

1. Use following indexes for entry of judgement ..... Normal

!

..... Correction made on abnormal point

..... Abnormal

2. Enter actually measured values in parenthese, [

..... Not applied

].

Notes: (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

No.

Inspection item

Judgment procedure and standards

Check

Check electronic devices in operator’s cab.

Write down part No. and serial No. of controller.

Part No. ( ), Serial No. ( 1

Engine controller No.

Write down version No. of software.

Version of software of engine controller: ( ( )

)(

) )(

Write down part No. and serial No. of controller.

Part No. ( ), Serial No. ( 2

Transmission controller No.

Write down version No. of software.

Version of software of transmission controller: ( ( )( )

)

) )(

)

3

Installation of fuse terminals

Fuses in rear box of operator’s cab must be free from looseness. (Check by touching with hand.)

4

Installation of relays

Relays in rear box of operator’s cab must be free from looseness. (Check by touching with hand.)

5

Connectors of PMC6 (for S-NET monitor) and PMCD (for Installation of PMC6 and PMCD power supply to off-board PMC) must be so installed that connectors operator can handle them.

Check oil and water levels.

6

Level must be between (H) and (H - 10 mm).

Engine oil level Check with engine stopped.

Any water and fuel must not be mixed in oil. (Filler cap (Marking: ENGINE STOPPED) must be free from water drop.)

7

Hydraulic oil level

Level must be within inspection window range.

8

Transmission oil level

Level must be between (H) and (center between H and L). * Check with engine at low idling.

9

Front brake oil level

Level must be between Full and Low. Level must be at center between Full and Low or higher.

Oil or fuel must not be mixed in coolant.

10 Coolant level Oil or fuel must not be mixed in coolant.

Turn switch ON. 11 Function of horn

Sound must be proper in volume and must not have beat noise. (Sensory check)

12 Function of back buzzer

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)

Engine must not start when transmission lever is set to any position other than N position. At this time, transmission mechatronic caution lamp must flash, centralized warning lamp must light up, and centralized alarm buzzer must sound. * User code and error code must not be displayed.

Maintenance Remarks

3/8

No.

Inspection item

Judgment procedure and standards

15 Safety function (2)

When parking lever is set to ON and transmission lever is set to any position other than N position, centralize warning lamp must light up and centralized alarm buzzer must sound.

16 Starting of engine

Engine must start smoothly.

17 Abnormal noise from engine

No abnormal noise must be generated. (Sensory check)

18 Safety function (3)

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. * Check with engine started and parking brake turned off.

19 Safety function (4)

When dump lever is set to any position other than FLOAT and transmission lever is set to any position of D to L, gear can be shifted but cannot be shifted in R. * Check with engine started and parking brake turned off.

20 Safety function (5)

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”. * Check with engine started and parking brake turned off.

21 Function of clearance lamp

When light switch is turned ON (1st, 2nd stage), front right and left clearance lamps and rear right, center, and left clearance lamps (3 lamps) must light up.

22 Check of headlamps

When light switch is turned ON (2nd stage), 2 headlamps (right and left) must light up.

Check of high beam (Function 23 of dimmer switch)

When dimmer switch is operated with headlamps ON, lamps must change (2 lamps ↔ 4 lamps). (Irradiating direction must change.)

24 Function of turn signal lamps

When turn signal lever is operated, front and rear turn signal lamps must flash on correct side.

25 Function of hazard lamp

When hazard lamp switch is turned to ON, right and left turn signal lamps and pilot (arrow) lamp inside operator’s cab must flash. In this case, if key switch is turned to OFF, pilot lamp must not flash.

26 Function of back-up lamps When brake pedal is depressed, 3 red rear brake lamps (right, center, and left) must light up.

27 Function of brake lamps 28 Check of emergency steering 29 pilot lamp

When retarder lever is pulled, 2 red rear brake lamps (right and left) must light up. Center lamp must not light up at this time.

When emergency (or automatic) steering system operates, emergency stop pilot lamp must light up and centralized warning lamp must flash.

30 Function of room lamp

When switch is ON, lamp must light up.

Check of function of air pres31 sure bar gauge

As air pressure rises while engine is running, bar meter must move toward High side.

Check of function of air gover32 nor

When air charge is performed, bar meter must stop at 2nd or 3rd level from top (814 ± 29 kPa {8.3 ± 0.3 kg/cm2}).

Function of engine cooling 33 water temperature gauge

As cooling water temperature rises while engine is running, bar meter must move toward High side.

Function of torque converter 34 oil temperature gauge

As oil temperature rises while engine is running, bar meter must move toward High side.

Function of brake oil temperature 35 gauge of retarder, bar meter must move toward High side.

When brake oil temperature rises because of operation of retarder, bar meter must move toward High side.

Check of function of body op36 eration caution lamp

When dump lever is set to any position other than FLOAT or body is not seated, This lamp must light up. * Centralized warning lamp must not light up and centralized alarm buzzer must not sound.

Check

Maintenance Remarks

4/8

No.

Inspection item

Judgment procedure and standards

Check

When stroke sensor is projected, this lamp must light up. At this time, cenCheck of function of rear brake tralized warning lamp must light up and centralized alarm buzzer must sound 37 stroke end caution lamp and user code“ E-04” and error code“ b0-F6” must be displayed.

Low idling speed, Measured value: ( / ) rpm Standard value: 1000 ± 30 rpm (LiH), 650 ± 25 rpm (LiL) Engine speed * Engine coolant temperature: In green range Engine oil temperature: 70 – 38 * 80°C * Torque converter oil temperature: 70 – 80°C * Check in service mode.

High idling speed, Measured value: ( / ) rpm • Standard value of HD785: 2350 ± 50 rpm (Power), 2300 ± 50 rpm (Economy) • Standard value of HD985: 2450 ± 50 rpm (Power), 2300 ± 50 rpm (Economy) Torque converter stall speed, Measured value: ( / ) rpm • Standard value of H785: 2040 ± 100 rpm (Power), 1950 ± 100 rpm (Economy) • Standard value of H985: 2067 ± 100 rpm (Power), 1950 ± 100 rpm (Economy)

Engine acceleration time (LiL → Standard value: Max. 3.5 sec, Measured value: ( 39 Hi), in power mode

) sec

Engine acceleration time (LiL → Standard value: Max. 5.4 sec, Measured value: ( 40 Stall), in power mode

) sec

41 Function of AISS

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.

While AISS switch is turned OFF, if engine water temperature is below 50°C, low idling speed of engine must be kept at LiH (1000 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 (1000 rpm).

42 Low idling regulation 43 Exhaust gas color 44 Exhaust gas leakage

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 → Hi). Sensory check.

(Standard value: 6 bosch or less) Exhaust gas must not leak from exhaust pipe joint, exhaust shutter, etc.

When engine emergency stop switch at rear of console box Function of engine emergency is turned ON, engine must stop.

45 stop switch * Check after operating engine for at least 15 minutes.

Drive and check truck.

Abnormal noise from transmisNo abnormal noise must be generated. (Sensory check) 46 sion Abnormal noise from differenNo abnormal noise must be generated. (Sensory check) 47 tial 48 Function of shift limiter

When shift limiter switch is turned ON, transmission lever must not shift to“ F7” in D-range and to“ F2” in L-range.

49 Braking mode function

When shift lever is set to D with brake turned ON (rear brake pilot lamp turned ON), gear speed must not change from F2.

50 Dragging of power train

When engine speed is set to high idling in N-range, truck must not start.

51 Straight travel of truck

While truck is traveling, steering wheel must not turn by itself.

52 Heating of parking brake

After truck travels inside yard, check by touching with hand that parking brake is not heated.

Heating of front brake discs After truck travels inside yard, check by touching with hand 53 (Both sides) that front brake discs are not heated.

54 Heating of differential

After truck travels inside yard, check by touching with hand that differential is not heated.

Maintenance Remarks

5/8

No.

Inspection item

Judgment procedure and standards

Heating of final drives (Both After truck travels inside yard, check by touching with hand 55 sides) that final drive covers are not heated.

Heating of rear axles (Both After truck travels inside yard, check by touching with hand 56 sides)brake that axle housings are not heated.

Check performance of brake.

(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 Function of exhaust brake OFF, exhaust brake must operate (only when exhaust brake 57 (Overseas opt.) switch is ON).

When (1) or (2) occurs, exhaust brake pilot lamp must light up.

Uneven working of service When service brake is applied sharply, truck must not turn 58 brake and steering wheel must not turn by itself.

Uneven working of retarder When retarder brake is applied sharply, truck must not turn 59 brake and steering wheel must not turn by itself.

60 Function of parking brake 61 Function of service brake 62 Function of retarder brake

63

Function of emergency brake

* Check in service mode.

Truck must not move at ”F2” stall (2070 rpm or above).

Measured value (F : rpm) * Check in service mode.

Truck must not move at ”F2” stall (1930 rpm or above).

Measured value (F : rpm) * Check in service mode.

Truck must not move at ”F2” stall (1540 rpm or above).

Measured value (F : rpm) * Check in service mode.

When emergency brake switch is turned ON, service brake and parking brake must be applied. (Check that pilot lamp lights up.) * Centralized warning lamp must light up and centralized alarm buzzer must sound.

Write down limit where truck moves.

Measured value (F : rpm) When air pressure lowers below 216 kPa {2.2 kg/cm2}, emergency brake must operate automatically.

While front brake cut switch is turned ON, front brake must Function of front brake cut not operate even if service brake pedal is pressed. (This 64 switch may be confirmed by checking change of oil level in oil tank.)

Check steering function.

Abnormal noise and vibration No abnormal noise must be generated. (Sensory check) 65 in steering operation 66 Smooth steering operation

There must be no hitch and operating effort must not change.

(Sensory check)

67 Steering effort (When empty)

Steering effort must not be heavy. (Sensory check) Standard: Max. 29 N {3 kg}

68 Play of steering wheel

Standard: Max. 150 mm – With engine stopped, measure peripheral length of steering wheel.

Measured value: ( ) mm

Lock-to-lock turns of steering Standard: 3.2 – 3.7 turns 69 wheel Measured value: Left (

) turns, Right (

) turns

(1) Standard: Max. 4.0 sec (Engine speed: 650 rpm) Turning to left ( ) sec, Turning to right ( ) sec Steering speed (Rock-to-rock 70 time) (2) Standard: Max. 3.6 sec (Engine speed: Constant speed above 1500 rpm) Turning to left ( ) sec, Turning to right ( ) sec When key switch is ON and parking brake is OFF, emergency steering Automatic emergency steering system must operate (for at least 24 seconds). * Do not operate emer71 function gency steering pump for more than 90 seconds continuously.

72 Emergency steering effort

Steering effort must not be heavy. (Sensory check) Reference: Max. 29 N {3 kg}

Emergency steering speed Standard: Max. 12.0 sec (With battery charged fully) 73 (Oil temperature: 80°C Atmo- Turning to left ( ) sec, Turning to right ( ) sec spheric temperature: 25°C)

Check

Maintenance Remarks

6/8

No.

Inspection item

Judgment procedure and standards

Check

Check operating performance.

Check that operation is correct (FLOAT → RAISE: 49 N {5.0 74 Operating effort of dump lever kg}, FLOAT → LOWER: 69N {7.0 kg}). Lever must not be hitched. Evaluate by sensing.

Shock made when dump body When dump body is seated, unpleasant shock must not be 75 is lower to end made. (Sensory check) Operate lever to RAISE position and check that it does not return to HOLD when released.

76 Function of body positioner

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. (Difference in dimension between right and left hoist cylinders: Max. 7 mm)

Alignment of dump body on When dump body is lower fully, it must come in contact 77 right and left 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.

Body lifting speed (Oil tem- Engine speed: 2000rpm 78 perature: 80°C Standard: 13.0 ± 1.5 sec, Measured value: (

) sec

Body lowering speed (Lever at Engine speed: Low idling speed (650 rpm) * Encircle body 79 FLOAT, Oil temperature: 80°C type → (Standard • Lock) Standard: 17.0 ± 1.5 sec, Measured value: ( ) sec Hydraulic drift in 5 minutes must be 85 mm or less. (From 80 Hydraulic drift of dump body point where cylinder No. 2 is extended by 100 mm) Measured value: ( ) mm Function of lifting dump body 81 with emergency starting motor Stop engine and check that dump body can be lifted with emergency steering motor.

Inspect each part.

Length of suspension cylinder 82 (Front) * Measure with dump body empty.

Length of suspension cylinder 83 (Rear) * Measure with dump body empty.

Length must be shorter than dimension A. Dimension A: 262 (Position of label) ± 10 mm Measured value: Left ( ) mm, Right ( ) mm Length must be shorter than dimension A. Dimension A: 239 (Position of label) ± 20 mm Measured value: Left ( ) mm, Right ( ) mm (1): When dump lever is set to any position other than FLOAT, display must change from [Soft] to [Hard].

(2): When service brake or emergency brake is turned ON, Automatic suspension control display must change from [Soft] to [Medium].

84 function Measure with dump body empty. (3): Display must show [Soft] in all cases other than (1) and (2) above.

Operation of pneumatic cylinder installed to front axle must conform to display in operator’s cab.

• Link position of cylinder: [Soft → Upper], [Hard → Middle], [Medium → Lower] Locknut must not be loosened.

Installation of dump control 85 linkage

Installation of drive shaft 86 (Engine → Torque converter)

Boots (Rubber covers) of cable must not be twisted. (At right side of cab, hoist valve, and positioner) All mounting bolts must be free from looseness and abnormal play.

I n s t a l l a t i o n o f d r i v e s h a f t All mounting bolts must be free from looseness and abnor87 (Transmission → Differential) mal play.

88 Engine mount

Mounting bolts must be free from looseness.

Transmission mount

Mounting bolts must be free from looseness.

90 Operator’s cab mount

Mounting bolts must be free from looseness.

89

Maintenance Remarks

7/8

No.

Inspection item

Judgment procedure and standards

91 Front supports (Both sides)

Mounting bolts must be free from looseness.

92 Rear support

Mounting bolts must be free from looseness.

93 Engine undercover

Mounting bolts must be free from looseness, and from beat sounds while engine is running.

94 Transmission undercover

Mounting bolts must be free from looseness, and from beat sounds while engine is running.

95 Hydraulic tank

Mounting bolts must be free from looseness.

96 Fuel tank

Mounting bolts must be free from looseness.

97 Inspection around engine

No oil and water leakage.

98

Inspection around transmisNo oil leakage. sion

99

Installation of transmission Cable must be clamped. output shaft sensor cable

100

Water leakage from cooling No leakage. water system

101 Fuel leakage from fuel system

No leakage. (Check gauges installed to tank for leakage in particular.)

Oil leakage from hydraulic oil 102 system (tank, cylinder, pump, No leakage. piping) 103

Oil leakage from transmission No leakage. system

104

Oil leakage from torque conNo leakage. verter system

105

Oil leakage from differential No leakage and final drive system

106 Oil leakage from brake system

No leakage.

107

Oil leakage from steering sysNo leakage. tem

108

Oil leakage from suspension No leakage (Both sides, front)

109

Oil leakage from suspension No leakage.

(Both sides, rear)

110

Air leakage from pneumatic No leakage. devices (including piping) Impurities must be drained securely.

111 Function of air tank drain valve Valve must not be rusted.

112 Installation of dust indicator

Dust indicator must be installed to air tube (air cleaner → engine).

1 piece/truck

113

Car radio antenna (Front of Antenna must be free from harmful flaw. cab)

114

Rear view mirror, undermirrors Must not be loosened.

(Both sides)

115 Tension of fan belt

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.

Check

Maintenance Remarks

8/8

No. 116

Inspection item

Judgment procedure and standards

When belt is pushed with thumb (approx. 59 N {6 kg}), its Deflection of air conditioner deflection must be 10 – 15 mm. Belt must be free from flaw compressor belt and twist.

Plated surfaces must be free from rust, harmful flaw, spat117 Steering cylinders (Both sides) ter, paint, etc.

118 Hoist cylinders (Both sides)

Plated surfaces must be free from rust, harmful flaw, spatter, paint, etc.

119

Suspension cylinders (Both sides, front)

Plated surfaces must be free from rust, harmful flaw, spatter, paint, etc.

120

Suspension cylinders (Both sides, rear)

Plated surfaces must be free from rust, harmful flaw, spatter, paint, etc.

121 Appearance of cab glass

Glass must be free from flaw, paint, etc.

122 Installation of battery

Double nuts for installation of battery must be tightened.

123 Tightness of battery terminals

Terminals must not move when swing with hand.

124

Rubber caps of battery termi- Must be installed securely. nals and positive cable (+) (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, Function of air conditioner cold air must come out. When former is set to red side, hot 125 Large capacity type: 3250 → 4000 kcal/h 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.

If error code history saved in each controller is recognized, record it below. (Check in error history display mode.)

126 Check of error codes

127 Clearing of error codes

Error code: ( Elapsed time 1: ( of occurrence: ( Error code: ( Elapsed time 1: ( of occurrence: ( Error code: ( Elapsed time 1: ( of occurrence: ( Error code: ( Elapsed time 1: ( of occurrence: ( Error code: ( Elapsed time 1: ( of occurrence: (

) ) h, Elapsed ) times ) ) h, Elapsed ) times ) ) h, Elapsed ) times ) ) h, Elapsed ) times ) ) h, Elapsed ) times

time 2: (

) h, Number

time 2: (

) h, Number

time 2: (

) h, Number

time 2: (

) h, Number

time 2: (

) h, Number

After recording error codes, delete error memory in controller. (Check in error history display mode.)

Check

Maintenance Remarks

HD785-5 DUMP TRUCK Form No. GEN00027-03

©2008 KOMATSU All Rights Reserved Printed In Japan 07-08